Graymont (CLM Corporation) Kiln #5

The $36 Million CLM Corporation Kiln #5 project is designed to process 650 tons of lime per day and was comprised of two main construction contracts.
The first contract was a fast track design-build package between Lakehead Constructors and CLM Corporation (now owned by Graymont). The design-build balance of plant was designed by Krech-Ojard & Associates and entailed:

• 52,000 feet of pipe piling
• 4,500 cubic yards of concrete foundations
• 800 tons of structural steel (including the 176′ tall product transfer tower)
• 1,100 feet of materials handling conveyors for stone, lime and coal
• 235 feet of Precast tunnel and feeders for stone handling
• Crushing and Screening equipment
• Three lime storage silos rated at 100, 500 and 1,500 tons of storage
• A new rail spur and combination rail/truck scale for product delivery
• New plant control room

The second contract for Lakehead Constructors entailed erection of the 185′ long, 13′ diameter kiln, supplied by A-C Equipment, and the 110′ tall lime stone preheater tower and firing building, designed and supplied by Metso Minerals. The new kiln provides an approximate 50% increase in capacity over the plant’s four existing kilns.

The fast track design build nature of the project presented the team with its biggest challenge. Design began in June of 2006, the project was permitted in August of 2006 and construction began immediately afterwards. The just in time nature of final construction document completion required extensive coordination between the owner, multiple designers and contractors. Foundation construction was required throughout the winter in order to ensure that structural and kiln erection could begin in April 2007 and that the December 31, 2007 completion deadline could be met. At its peak, the project employed over 100 workers.

Accomplishments:

The project was completed on budget and three weeks ahead of schedule, enabling the owner to begin manufacture and sale of lime sooner that expected.