Design and Build of Raw Meal Silo

Case Study

Design and Build of Raw Meal Silo, Philippines

CEMEX Philippines demonstrated its commitment to a better future by expanding its Solid Cement Plant in Antipolo City, Rizal, with the addition of a new integrated cement production line. This expansion increased Solid Cement’s annual capacity by 1.5 million tons, bringing the total output to 3.4 million tons, positioning CEMEX to better meet the growing demands for the nation’s infrastructure programs and building needs. BEC was awarded the contract for the construction of the Raw Meal Silo, a critical component in the cement production process.

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Challenges

The project presented several complex challenges that required innovative solutions and meticulous planning:

Restricted Site Space: Limited working areas complicated logistics, material handling, and construction sequencing.

Aggressive Schedule: Meeting tight deadlines required meticulous planning and execution.

Concrete Transportation: The significant distance from the batching plant raised concerns over premature concrete setting, especially in hot weather conditions.

Slipform Operation Complexity: Managing slipforming during tower crane mast extensions and tie-back installations without disrupting structural alignment or safety.

BEC's approach

BEC undertook the slipform construction of the silo walls, installation of inner columns, construction of the silo slab and sloping concrete slab, and installation of post-tensioning ducts and buttresses. Advanced slipform construction techniques were employed to maintain continuous operations while effectively managing the complexities of tower crane mast extensions and tie-back installations. Careful planning and proactive resource management minimised potential disruptions, ensuring project timelines were met. To address concrete quality concerns, BEC introduced a special retarder into the mix. This additive slowed the setting time of concrete, ensuring that it maintained its quality and workability upon arrival, ultimately delivering a superior finish.

The BEC Advantage

The Raw Meal Silo project was delivered successfully, meeting all quality and safety standards while staying within the project timeline. BEC’s innovative solutions and effective project management significantly contributed to CEMEX’s increased production capacity, reinforcing their role in supporting the Philippines’ infrastructure development. The project was completed with zero lost-time incidents, demonstrating BEC’s unwavering commitment to health, safety, and environmental standards.