Client:
Polysius Corp.

Owner:
Florida Rock Industries

Project Duration:
24 Months

Delivery Office:
Tallahassee

Services:

  • Contractor bid package and schedule
  • Site development
  • Detail engineering
  • Civil, structural, utility systems, piping and electrical design engineering
  • On site electrical engineering support
  • Construction management
  • Threshold inspection

Key Project Issues:

  • Fast-track schedule
  • Karst topography
  • Existing aboveground and underground structures
  • Space limitations
  • Process line integration
  • Tie-in to existing materials sytems
  • Work around ongoing operations

Project Features:

  • Four-stage 235 ft. preheater tower with calciner
  • Process line improvements
Florida Rock - Newberry, Florida

florida rock.jpg
To meet growing market demand, Florida Rock Industries, Inc. began developing specifications in 2005 for a second production line at its cement manufacturing facility in Newberry, Florida. Completed in 1999, the plant was operating at capacity and a new line based on the original Polysius Corp. processing technology would double production to 4,800 short tons per day (stpd). The plant expansion requirements were clear - improve plant operating efficiencies and parts reliability, ensure minimal environmental impact and tie into the existing plant without disrupting ongoing operations.

As the plant detail engineer, BIS Frucon's scope of work was comprehensive. Generate the contractor bid package and schedule. Provide site development, as well as civil, structural, utility systems, piping and electrical design engineering. Additionally, BIS Frucon was charged with construction support and threshold inspection services to accommodate Florida state requirements for large structures more than 50 feet in height.

The Newberry facility is located in central Florida on more than 100 years of quality limestone reserves. The new process line would run parallel to the existing plant and draw materials from old and new storage facilities. Modifications would be necessary for all plant utility and raw/additive material support facilities, including lowering the 135 foot wide by 800 foot long materials storage building foundation and modifying, as well as expanding, the plant's raw and additive material structures. Additional raw materials, including mill scale, fly ash and feldspar, would be housed in a new 120 foot wide by 300 foot long building equipped with a portal reclaimer for fly ash and reclaim hoppers for mill scale and feldspar. A new raw feed proportioning system would be added for the existing line, along with pet coke capability for kiln fuel. Modifications would be required for the coal, coke and clinker handling systems, and both the new and existing process lines would be integrated. The plant also would feature the latest emissions technology to reduce greenhouse gas emissions.

Fru-Con chose a collaborative project approach - drawing upon engineering expertise in its Florida offices and Missouri headquarters. Fitting the new process line into the existing plant, however, presented several engineering challenges. In addition to extreme space limitations, karst topography and poorly documented aboveground and underground structures and utilities complicated the effort. In response, Fru-Con used deep foundations based on auger cast piles for major structures and equipment, and drawings were revised to accommodate existing conditions encountered during construction.

Newberry's second process line currently is under construction. When complete, it will offer Florida Rock added flexibility. All clinker may be ground o site, or it can be shipped via truck or rail to other company facilities for finish grinding and subsequent distribution to markets through the southeastern United States.