Silo Construction Blogs

There are numerous considerations at the start of any silo construction project. While silos can seem like a relatively straightforward structure, a lot goes into silo engineering and construction. The many factors of silo construction and engineering, in addition to fluctuating material costs, make it impossible to set a standard cost of silo construction.

 

Working with an experienced silo engineering company can take the guesswork out of the project and make sure you start off on the right foot. Once you have determined the most appropriate quantity and size for your silo, it's natural to begin considering the silo construction costs and looking for ways to maximize your spend.

 

Steel and concrete are the most frequently utilized material for silo construction. Both steel and concrete silos are used in various industrial settings for bulk material storage of ash, coal, lime, aggregate and more. When comparing the two construction materials, concrete is the clear winner.

 

Not only are concrete silos far more durable than their steel counterparts, concrete silos are generally less expensive than metal silos, particularly when you consider the total cost of ownership. Steel silos suffer from expensive corrosion issues and are highly susceptible to structural failure from high winds and excessive internal pressure. Compared to steel, concrete has many benefits when it comes to designing and building silos, leading to less upkeep required to maintain their overall functionality and safety.

 

 

A well-maintained silo can and should last decades. When looking at silo construction cost, it's important to look beyond the upfront expense alone. Though concrete silos withstand more than steel silos, all silos require routine maintenance and inspection. A proactive inspection program can safeguard your team members and ensure your structures' safety and continued operation. Regular examinations can identify potential problems and avoid wall collapse, fractures, and deterioration of the structure, which may result in accidents or fatalities in the workplace.

 

 

Stave silos are constructed using staves, precast concrete blocks, that interlock. For added durability, Marietta Silos produces staves that are 5 ¾", versus the standard 2" thickness.

 

Slipform silos are constructed using a custom-built form system and a continuous pour that necessates silo completion before construction can be halted. Slipform silos have a smoother, joint-free, exterior. It is typically used for silos that are larger and 65' in diameter or when several concrete silos need to be constructed at once.

 

Jumpform silo construction is typically the most economical silo construction method thanks to the reusable silo framework that can be set up quickly. Jumpform silo construction is also one of the strongest silo construction types available as the controlled process makes it easy to check the quality of the reinforcement steel placement and equipment before pouring.

 

Ready to move forward with the construction of a new silo? Learn how to choose a silo contractor or schedule an inspection of your existing structure.

 

Begin Your Silo Project

Our silo services are as expansive as the industries we serve. From the most difficult silo cleaning, silo maintenance, and silo repair challenges to the most basic - Marietta Silos can handle it all.

 

We have an extensive background in silo engineering, construction, inspection, and restoration of concrete silos used in a wide variety of industries. We perform services for facilities storing bulk materials such as carbon, black cement, clay, clinker coal, fly ash, foundry sand, grain products, gypsum, lime, bottom ash, salt, soda ash, and more. No matter what type of structure you have or the material stored, consider Marietta Silos to service your silos or bulk storage structures.

 

Marietta Silos has more experience in silo restoration than any other company in the United States. If you have known or suspected problems, contact us for efficient, cost-effective solutions.

 

Whether you store clay, lime, limestone, sand, gypsum, cement, salt, or any other aggregate, our in-house experts can help walk you through all the design, engineering, and construction options we offer to those in the cement and manufacturing industry. We ensure your concrete silo is built safely, economically and will last for years to come. We also have a vast amount of experience restoring and rehooping concrete stave silos, including former agricultural silos that have been adapted for industrial use.

 

Bulk material used in the agricultural industry and the food and beverage industry typically requires a sealed silo interior to prevent material storage. Like other bulk material storage containers, agricultural silos are also susceptible to material buildup and require regular, professional cleaning and other silo maintenance services.

 

Within the power industry, Marietta Silos is the leading constructor of concrete fly ash silos in the country. We have built more fly ash silos than all our competitors combined. Marietta Silos is experienced in design and construction methods that can help increase equipment longevity and operating efficiency by constructing fly ash roof enclosures that provide protection from the environment.

 

We have earned an unparalleled reputation for excellence through extensive experience with concrete fly ash silos with numerous leading power utilities and contractors throughout the United States. Marietta Silos is also highly experienced in silo building and design for bottom ash and fly ash storage silos.

 

In addition to the construction, repair, and inspection of fly ash silos for the power industry, Marietta Silos is also experienced in maintenance and repair services for bottom ash clarifying tanks. Bottom ash is a by-product of a coal-burning power generation facility. After the coal has been consumed, bottom ash remains and must be removed from the bottom of the boilers which typically consists of various metals, slate, and rock.

 

Looking for silo cleaning and maintenance services for your industry? Our sister company USA Silo Service serves numerous industries with silo cleaning, inspection, and maintenance services. Read the latest USA Silo Service blog to learn more about the industries they serve.

What is silo engineering?

 

Silo engineering takes into consideration numerous elements to ensure the structural integrity of a silo design. The storage capacity you need helps determine the correct silo size, though other factors, including the seismic probability of your location, are also considered.

 

When designing concrete silos, Marietta Silos follows the silo design codes outlined in the American Concrete Institute (ACI) 313-16: Design for Concrete Silos and Stacking Tubes for Storing Granular Materials. As a member of the ACI Committee, we stay on the cutting edge of the latest industry standards and updates. We also often work with an experienced silo engineer to help ensure the structures are designed to withstand external forces and the static pressures exerted by the type of stored material at rest and during flow.

 

What are some important considerations when designing a storage silo?

 

Cement silo construction and concrete silo design consider the stored material, flow patterns, size, and more when creating a custom storage solution. All stored materials flow at different rates and via different flow patterns through a silo. Understanding how a stored material flows through a silo determines whether the silo should be designed with a flat bottom, funnel flow, mass flow, or expanded flow.

 

In addition to considering static pressures of the intended bulk storage material, silo engineers also determine reinforcement arrangements necessary for the silo size and silo construction type, Jumpform, Slipform, or Stave. Loading and unloading needs are also important considerations, as the most critical portions of this design involve the lower part of the silo. This is where large loads from the stored material are channeled. An efficient flow pattern allows for the effective unloading of the silo.

 

Marietta Silos' knowledge and experience mean that our designs will be the best possible designs to fit your needs. Our engineering practices conform with the method that our construction crews utilize for our Jumpform and Slipform systems, so it's important to use Marietta Silos for your silo engineering as well as the silo construction.

 

How much does it cost to build a silo?

 

On average, concrete silos are typically lower in cost than metal silos. However, because so many factors must be considered during silo engineering, setting one standard or fixed price is impossible. When determining the cost to build a silo, it’s best to start with a consultation with a professional silo engineering and construction company, like Marietta Silos, which uses a silo engineer to ensure your silo is designed to be structurally sound and economical for your unique application.

 

What is the difference between a tank, a silo, and a stacking tube?

 

While tanks are used to store liquids, silos are used to store bulk solids for a variety of industries. Stacking tube are much smaller than traditional storage silos. They are often used in coal plants, mines and storage facilities, shipping terminals, and limestone storage. The stacking tube format facilitates an even distribution of coal or limestone into neat piles. While stacking tubes can be constructed using the same Jumpform technology as much larger storage silos, their comparatively small size makes them a less expensive option for industries that do not have as much material to store.

 

What are the advantages of using a silo for bulk material storage?

 

Storage silos let you store materials in a smaller footprint when compared to a horizontal warehouse. When compared to piles, they also provide better protection from the elements.

 

What construction material is better for silos concrete or steel?

 

Concrete offers numerous advantages and provides better structural stability than steel or aluminum in constructing storage silos. Concrete better resists internal pressure that causes buckling, splitting, and other failures of steel silos, like abrasive inner wear from stored materials and corrosion. Using concrete instead of steel to construct storage silos eliminates these risks when combined with proper maintenance and inspection.

 

Concrete silos require minimal maintenance as they are not typically weakened by abrasive or corrosive materials or moist environments that lead to rusting in steel. However, when steel silos experience wall thinning from abrasive storage materials, corrosion from internal or external moisture compounds the risks of silo failure.

 

Ready to start your next silo design project?

 

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