Articles & News
Articles & News
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- by Rebecca Pyper
With its list of cement customers increasing, Dome Technology promotes a design-build approach for more and more projects. It’s good […]
With its list of cement customers increasing, Dome Technology promotes a design-build approach for more and more projects. It’s good for cement companies and their timelines, and it’s attractive to quality subcontractors and vendors eager to be part of complex, important projects.
Dome Technology’s design-build services address engineering, construction and all related systems at the design level. The result is greater simplicity, assurance and value from start to finish. When a single party is chosen to provide the entire project, costs go down. When the plan changes, it isn’t taxing to spread the word because everyone who needs to know already does. But sometimes changes aren’t necessary at all; when one team oversees every element, it’s easier to spot gaps. “When it’s confined under one umbrella, it’s much easier to define those missing links,” Dome Technology sales manager Heath Harrison said. The result is a turnkey facility with all components running seamlessly because each was planned with the others in mind.
Turnkey construction is about more than combining individual parts to create a cohesive whole. It’s really about building trust and empowering the customer.
Good for customers
Based on customer must-haves and a firm budget, Dome Technology can execute an entire project from design to completion. After more than 40 years of experience in bulk construction, the company’s network of bulk-storage vendors and subcontractors is wide and deep, allowing the team to partner with the best in the industry. The Dome Technology team works to maximize every dollar and plan components with the others in mind.
To start a project, a customer provides the budget and a list of required features; Dome Technology then identifies what can be included for the set price. The two groups can add or subtract features to achieve the structure a customer needs within budgetary constraints. These questions guide early conversations:
- Capacity requirements: How much cement needs to be stored and transported annually?
- Geographical and geological position: Define the site requirements and determine the site-specific geotechnical information.
- Expansion: Is this a project extending a facility’s original scope? Is future growth likely?
- Product consideration: A turnkey builder can provide counsel on designing unique storage for each specific stored product.
- Operations: What are the company’s plans for filling, reclaim, product management and controlling inventories? If these aren’t known or defined, help is available.
Two major advantages with design-build are that change orders are reduced and schedules are usually met because each phase of the project is built into the plan. These often yield cost savings and a smoother construction experience.
Storage is the largest component in a new facility, and a dome is built with an unlimited lifespan—its concrete shell and geometry boast unrivaled strength. Dome construction methods require no interior trusses, so every square foot can be utilized for storage or reclaim systems.
Besides costing less to build and operate, domes are also cost efficient. Domes are built with locally available concrete and reinforcing steel, and often local crews are hired for construction, a benefit for city economies as it provides jobs and pumps money back into the marketplace. Also, a dome’s double curvature requires fewer construction materials with significantly less waste, and a dome can be built quickly; one the outer weatherproof membrane is in place, construction moves inside where building continues regardless of the weather.
Attracting the best subcontractors and suppliers
With projects all over the world, the most efficient way to execute large cement projects is to rely on relationships with industry experts for product handling and monitoring. Cement companies benefit from the best products on the market and close working relationships between Dome Technology and those providing the storage-structure’s systems. For decades Dome Technology has worked with vendors who provide fluidized floors, geotechnical support, foundation systems, reclaim products, ship unloaders and more.
In addition, subcontractors are safe working on a Dome Technology project. Dome Technology follows strict safety commitments; field employees are OSHA and MSHA trained and receive site-specific training. They are expected to follow safe practices, including wearing personal protective equipment, avoiding shortcuts that compromise safety, hydrating and stretching daily for optimal physical health, employing proper lifting techniques and only operating equipment qualified to operate. In this way, all workers at a Dome Technology site are protected, and the project experiences fewer schedule interruptions.
Simplicity first and last
A design-build approach simplifies a project from start to finish. Cement companies get the most value for their money and benefit from existing partnerships between contractors and vendors. Subcontractors and vendors benefit from working with familiar teams to build quality facilities. It’s the latest method for achieving a cement facility customized to exact specifications.
By Rebecca Long Pyper for Dome Technology
Editor’s note: The preceding article was published in the April 2021 issue of Dry Cargo International.
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Dome Technology has produced a new video highlighting its work for Barrette-Chapais in Port of Saguenay, Quebec, Canada. Click here […]
Dome Technology has produced a new video highlighting its work for Barrette-Chapais in Port of Saguenay, Quebec, Canada. Click here to view.
Dome Technology was contracted to build two DomeSilos, measuring 120 feet (36.5 m) in diameter and 131 feet (39.9 m) tall and each capable of storing 21,000 metric tons. Because of their geometry, DomeSilos are able to store more product in a smaller footprint, stacking pellets deeper and storing them all the way to the structure’s apex.
Flat storage was Plan A for the Port of Saguenay site, but after weighing a reduction in available space against storage requirements, the decision was made to shift to a dome, said Granule 777 general manager Yann Sellin.
According to Dome Technology sales manager Cameron High, one of the customer’s main requests was the ability for truck drivers to pull in, unload product, and return to the pellet plant without interruption and on repeat. “They wanted from start to finish a fully automated system,” he said.
Dome Technology also acted as construction manager, supervising Canadian crews on all equipment installation—load-out system, bucket elevator, and conveyance. The Bruks conveying system is the most exciting feature for the company, Sellin said.
A full project summary is also available, and our industrial video library can be accessed here.
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Bulking up on storage was a way to stay ahead of the curve for Ozinga. “It is our view that […]
Bulking up on storage was a way to stay ahead of the curve for Ozinga.
“It is our view that the country is in the early stages of an expansionary period, creating extra demands on our raw materials,” Ozinga President Marty Ozinga IV said. “Storage helps us manage our supply chain to ensure reliable and economical sources of quality materials.”
As part of their proactive approach, the company contracted with Dome Technology to build a DomeSilo™ in Chicago, Illinois, then turned around and completed a full terminal upgrade two years later.
First things first: A storage dome
The first stage of the Ozinga project was, in a word, enormous. Ozinga needed to beef up cement storage, and that equated to a 50,000-metric-ton DomeSilo built with steel-reinforced concrete and all the monitoring and loading systems to carry operations into the next several decades. Dome Technology was hired to manage the entire scope of the project, from the barge unloader and dome storage to the reclaim system and truck load-out.
Until this point, Ozinga brought in product by barge and was using three 10,000-ton silos to store it, but the company needed to increase efficiency and storage capacity. Ozinga management considered slip-form concrete silos, bolted steel silos and flat storage for the Chicago site, but “we determined that the dome storage was the most economical and efficient form of storage for the amount of material we wanted to store and the amount of annual put-through,” Ozinga said.
According to Ozinga, the company had two main criteria for the new dome. One was a location with ample access to different modes of transportation including the river, rails, the Great Lakes and the highway. The selected Chicago site met these needs and boasted space for further expansion. The other non-negotiable was redundancy, an advantage made possible by custom pneumatic transport and reclaim systems.
These must-haves required a solid plan from the start, including site considerations and infrastructure placement. In addition, a host of mechanical work was required. The custom dome and all its associated systems comprised a Dome Technology design-build project with design support from Engineering System Solutions (ES2).
Completed in 2017, the DomeSilo is 125 feet in diameter and 138 feet tall. Product is loaded into the storage pneumatically via a barge unloader, and dual Fuller-Kinyon pumps convey product from the dome to two day bins. Dust-collection systems are installed, and level monitoring allows site managers to keep constant tabs on the amount of stored product.
The dome can be loaded at a fill rate of 300 metric tons per hour. Cement enters the filter receiver at the apex and is then discharged into the dome or directly to loadout silos. This system was designed with flexibility in mind; Ozinga was bringing in fly ash and slag on barges and wanted to utilize this same system to load these products from barge to trucks.
To comprise the redundancy plan, FLSmidth provided a Docksider Model DS-1 barge unloader, a Ful-Floor fluidized reclaim system and a Fuller-Kinyon transfer system. The double dihedral, fully fluidized floor discharges product on two sides of the dome. A fluidized floor allows companies to aerate different areas of the floor at different times, so fluidization is especially even and does not asymmetrically load the dome structure.
The advantages of this floor system are twofold: A large reclaim tunnel is unnecessary as product is fed to the sides of the dome, and all mechanical equipment is stored outside so maximum interior space can be utilized for storage. Also, an aeration pipe runs under the peak in the floor in a small tunnel, drastically reducing penetrations to the exterior wall where pipe would otherwise run around the perimeter. Reduced access points on the dome’s exterior means fewer possible areas for moisture entrance. And since fluidized floors are operated by multiple valves and blowers, they’re low maintenance, and the risk of breakdown is lower than that associated with mechanical reclaim equipment.
Because the dome was to be built on an existing wood-pile foundation that had once supported silos, action had to be taken to account for the possibility of settlement “as the piles may have lost integrity of 60 years,” ES2 engineer Adam Aagard said. The dome did not experience a concerning amount of settlement, “but they didn’t want to take that gamble, and neither did we,” he said, adding that the dome and its foundation are sufficiently robust to weather extreme weather conditions or natural disasters.
According to Ozinga, the dome will help the company secure reliable and economical sources of raw materials—a capability that will help the company continue to distinguish itself from the competition. “In the long run, this (dome) will help secure the future of Ozinga as an independent, American-owned and operated family business,” he said.
Second stage: Terminal expansion
With the dome complete, the stage was set for the second portion of Ozinga’s project: terminal expansion with a focus on receiving fly ash and slag. Dome Technology acted as construction manager and oversaw the erection of two 4,000-ton silos for storing slag and fly ash, one rail silo, one blower building/electrical room and three operator load-out kiosks. Two new truck loadout lanes and scales and one new rail scale were also added to the site, as well as automation and programming for these systems.
Another key component of the expansion included the ability to transfer from barge to storage. An additional conveyance line was added and buried, and two new 4,000-ton drive-through steel silos were built, one for slag and one for fly ash. Each has its own loadout lane and FK pump that can transfer product to the silos at 50 to 80 tons per hour, depending on the product. These pumps can also transfer to the new rail loadout silo that holds 300 tons.
An existing three-pack of silos used for loading trucks was improved. Ozinga opted to modify their hopper and install a covered structure so operations could proceed regardless of the weather. The FK pump was also upgraded for a higher loading rate, as was the compressed air system.
In April 2019 the fully upgraded terminal was ready for operations with a host of conveyance options. For offloading, product can be conveyed from a barge, railcar or truck; product can also be transferred from the existing 50,000-metric-ton dome. On the loading side, inbound product can be housed in one of the 4,000-ton silos, the rail silo or the existing 10,000-ton tanks, or it can be loaded into trucks or rail cars—“that’s a lot of versatility,” said Dome Technology project manager Brent Toone.
For 40 years Dome Technology has developing innovative ideas and expanding its expertise. The Ozinga terminal expansion is an example of what the team can do for cement companies worldwide. “The projects for Ozinga are a good example of Dome Technology’s capability to take a project from conception all the way through to commissioning,” Dome Technology CEO Bradley Bateman said.
By Rebecca Long Pyper for Dome Technology
Editor’s note: The preceding was published in the February 2021 issue of International Cement Review.
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Not all domes are hulking monoliths. Sometimes commercial domes are chosen specifically for their aesthetics, and here are a few […]
Not all domes are hulking monoliths. Sometimes commercial domes are chosen specifically for their aesthetics, and here are a few of those projects.
LaHaye Student Center Expansion, Liberty University
Lynchberg, Virginia, USA
Project completion: May 2014
Liberty University wanted structures with domed roofs reminiscent of Thomas Jefferson’s Monticello. Concrete shells 30 feet and 61 feet in diameter were built atop steel-structured walls. These shells provided the roof element, and using the shotcrete method, they were more economical than steel or cast-in-place concrete, which would have been too heavy to use. University officials also chose the thin shell because of its insulation value.
The continuous concrete shell protects the interior from external precipitation and provides necessary strength that complements the dome’s double curvature, resulting in a self-supporting structure free of interior supports.
Shotcrete also leant cost efficiency to this project. Because of the shotcrete process, Dome Technology built this architectural dome at a significantly lower cost than steel roofing.
Lumberton Performing Arts Center
Lumberton, Texas, USA
Project completion: 2013
The Lumberton Independent School District Performing Arts Center in Lumberton, Texas, acts as the primary performing arts facility for school events and is also a go-to site for community functions.
Built by Dome Technology, the 1,500-seat dome-shaped building stands 56 feet high and 179 feet in diameter. A connected foyer softens the look of the structure.
But the center’s principal role is serving as command center during natural disasters. From June 2015 to June 2016, Lumberton experienced 173 weather-related events requiring emergency personnel to utilize the center.
“We’re on the Gulf Coast, so we are a hurricane-prone area. Our center becomes the command center (for the) few personnel that must stay until the eleventh hour,” said district coordinator of special programs and communication Gretchen Scoggins. “That’s its primary purpose; we just get to use it the other 99 percent of the time for events.”
The center was finished with the safe-shelter function in mind, and “everything is ready to roll—literally—out of here,” Scoggins said. Removable auditorium seats are carted to storage facilities across the parking lot, freeing up room for the emergency-management team staying during storms. During tornadoes, however, the center is the designated shelter-in-place for students at the adjacent high school and intermediate school.
The Lumberton project is one of Dome Technology’s finest architectural domes, said project manager Daren Wheeler. “The campus that this dome is on is a really sharp-looking campus. This is a big dome, and generally speaking, when you put a dome of this size on a property, it usually dominates it. That’s not the case here; it really complements the campus,” he said.
Faena Hotel restaurant
Miami Beach, Florida, USA
Project completion: 2014
An elliptical dome was built adjacent to the Faena Hotel in Miami Beach, Florida. Dome Technology built the dome, which was then finished by the customer as the Pao by Paul Qui restaurant.
Spaceport Fire Station
Truth or Consequences, New Mexico, USA
Project completion: 2008
When Spaceport America needed a fire station for its campus in Truth or Consequences, New Mexico, a modern aesthetic with a nod to the desert environment was a must.
Dome Technology was contracted to build the fire station with its organic design that captures the sense of space exploration and complements the landscape. For improved function and a futuristic feel, the dome was built with large openings, including a 30-foot cantilevered “eyebrow” shell within the dome structure. The exterior was finished with sand-colored tiles to blend with the surroundings.
“The design of the fire station fits well with the design of the Spaceport and the overall design environment which was trying to be achieved,” said T.J. Allard, who oversees protective services at Spaceport America for Fiore Industries, a company contracted to provide protective services for the campus, including all firefighting services.
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In April 2021 Dome Technology had 17 active projects with several more about to go under contract. In response, the […]
In April 2021 Dome Technology had 17 active projects with several more about to go under contract. In response, the company has been working through a hiring blitz to acquire necessary employees to oversee and complete work.
This number of projects in the bulk-storage industry is the result of decades prioritizing clients, employees, and best building practices. “We ride for the customer’s brand, we do our best to provide a good working environment for our employees, and we try to use technology to innovate and bring the best solutions we can,” Dome Technology Vice President of Operations Dan South said.
To date, Dome Technology employs 125 people who provide services in construction, welding, fabrication, engineering, sales, marketing, accounting, and more. Based on the current project load, the company is actively recruiting employees for field work and fabrication in the on-campus shop.
Dome Technology has also started an internship program where college students seeking engineering or construction experience can work alongside seasoned professionals on real-life projects. Information about these openings and other employment opportunities can always be found on the Careers page.
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Editor’s note: On May 14, Dome Technology celebrated the 80th birthday of founder Barry South, pictured here second from left […]
Editor’s note: On May 14, Dome Technology celebrated the 80th birthday of founder Barry South, pictured here second from left with his sons. Below is a brief history on how Barry and his brothers developed the idea of dome construction and how their experience led to the creation of Dome Technology.
The South brothers grew up in east Idaho. In their early 20s, Barry and Randy operated a sawmill in Island Park, and David left for work in Chicago, where he learned about urethane insulation. Intrigued by its insulative properties, he moved home and enlisted the help of Barry and Randy in working a urethane business. Most of their work comprised of insulating potato storages.
In the first five years, the brothers pursued potato storage because they knew customers and were adept at spraying urethane. They chose a 105-foot diameter dome as their go-to model, reusing an airform—the fabric membrane that gives a dome its shape—and building all 12 domes with a single skin that had to be carefully removed for every new project.
Dome Technology was officially created in 1975 with the three brothers at the helm. David and Barry were awarded a patent for the dome model of construction in 1979.
“At the beginning, we were under the impression this is a brand-new thing and a lot of people are going to want to buy. That didn’t last too long. People are reluctant to be the first to do something new,” Barry said.
It took at least 10 years for Barry to be convinced the dome would have staying power in the marketplace, and that decision was made based on customer feedback.
Today’s domes are sophisticated monoliths that can withstand harsh climates and have an indefinite lifespan. The brothers now own individual businesses—David operates Monolithic.org; Randy runs South Industries in Menan, Idaho; and Barry stayed with Dome Technology. Three of Barry’s sons are part of the executive team today.
For more information on our company’s history, in particular about noteworthy projects, visit our About page.
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When planning or improving a coal storage and handling facility, it’s important to consider first things first. Domes are an […]
When planning or improving a coal storage and handling facility, it’s important to consider first things first. Domes are an ideal option for storage since the apex can easily support large loads from the headhouse and conveyors, and the overall system is efficiently designed for filling, storage, and reclaim systems. But these features all come standard. Customizing the structure and its systems is the key to optimal function. Here are a few important categories to consider for a one-of-a-kind, high-production facility:
The amount of storage and desired throughput
Storage requirements dictate everything else, from the type of storage to how often the facility will be emptied and how many tons will run through it per week or month. This is also the time to discuss anticipated growth and plan for that too.
Coal projects often start with a look at the end and work backwards. For ADM in Clinton, Iowa (pictured above), the size of the dome was driven by their desired burn rate. As a cogeneration power plant, ADM needed to maintain a constant 60,000 short tons of coal on site. So a 298-foot dome was planned and built to accommodate those needs. Later, in Columbus, Ohio, ADM contracted another dome to be built, this one 300 feet in diameter with the same storage capacity to get a similar amount of kilowatts.
The type of coal being stored
With bituminous coal, stacking and reclaim options are expansive. From front-end loader to stacker reclaimer or drag chain, coal producers can be selective, balancing low cost with sophistication. Dome Technology’s team has seen rotary plows with cone-shaped piles as an effective reclaim option, but another effective choice is tall domes with a high percentage of live reclaim.
With subbituminous coal, requirements are stricter. Based on volatility, customers must decide how they’ll maintain access to the pile for putting out potential fires and hot spots.
A doughnut-shaped pile is a good option for storing subbituminous coal. The pile is placed and reclaimed using a stacker reclaimer, a model that allows access to the pile and can work particularly well when the cleanout happens every couple weeks. A monitoring system on the inbound conveyor is necessary so hot coal is rejected before being placed in the storage.
A kidney-shaped pile can also work well. The stacker creates a pile that tapers off on the side, and the filling arm’s swing is 230 to 250 degrees. This shape provides ample access to the pile, so while it might not make the most of a dome’s capacity, it does provide peace of mind and safety when managing a volatile product like coal.
Site restrictions
Although a round dome is predictable and popular, elliptical-shaped domes work well on narrow sites. For one recent project, Dome Technology proposed an elliptical-shaped dome located on a port to reach the desired capacity and fit the available space. The dome would be 300 feet long and 200 feet wide and 80 feet from the ground level to the top of the dome. Three filling points would line the top of the dome shell with a drag chain and front-end loader providing reclaim. Since an elliptical dome like this isn’t perfectly round and therefore won’t distribute loads evenly, engineers design the structure to support anticipated loads.
Dome Technology typically employs a design-build method for the entire project, but companies can also request support in specific portions of projects. With more than 40 years in the dome-building industry and a portfolio of completed projects to match, the team can provide the design and installation of the mechanical systems required for bulk storage, from equipment on the inbound side to reclaim systems and throughput speed. When every element is planned with the others in mind, the result is a seamless, highly efficient system.
By Rebecca Long Pyper for Dome Technology
Editor’s note: The preceding was published in the February 2021 issue of Dry Cargo International.
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On April 28 The Crude Life podcast featured Dome Technology Vice President of Operations Dan South—listen here (the interview starts […]
On April 28 The Crude Life podcast featured Dome Technology Vice President of Operations Dan South—listen here (the interview starts at about the 44-minute mark).
South explains dome construction and the work Dome Technology does within the energy sector, specifically with coal and petcoke storage. “Our engineers specialize in thin-shell concrete design, so it’s very unique. We use a lot of finite-element analysis in the designs, and they’re great buildings,” he said.
South also discusses the energy industry internationally and the challenges of building bulk storage in the United States and abroad. For environmental protection and optimal transport, domes contain fugitive dust and can be designed for compatibility with rail, truck, or barge.
The Crude Life is a podcast dedicated to the oil and gas industries and explores key players and energy innovations in this sector. Listen to the entire interview with South here.
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Many wood-pellet companies are reaping the benefits of two innovative Dome Technology features: the filling tube and round explosion panels. […]
Many wood-pellet companies are reaping the benefits of two innovative Dome Technology features: the filling tube and round explosion panels.
Filling tube
Wood-pellet companies working with Dome Technology have the option of installing a filling tube as an innovative way to load pellets with reduced dust and better product protection.
The filling tube is based on a concept common in coal and mining storages. A belt conveyor moves product into the top of the dome, where pellets enter the filling tube. Openings are incrementally located along the tube’s shaft, and product rolls through the openings and into the pile, resulting in smoother, more even pile creation. Dome Technology sales manager Lane Roberts said he is fielding more calls than ever about installing filling tubes.
Pellets loaded with a filling tube look cleaner and are stacked more uniformly. This mode of filling also reduces the likelihood and/or severity of deflagration. This is possible since the airborne dust concentration is reduced. Most dust is confined within the tube; as a result, the filling tube acts as a crucial part of a dome’s deflagration-mitigation plan.
The tube also protects product integrity, minimizing fines generated during the drawdown process by reducing the pressure head on the product flow line. Although there are no guarantees regarding the reduction of fines, experience shows considerable fine reduction.
Four filling tubes have been installed in four different wood-pellet domes, two for Savannah Bulk Terminal in Georgia, USA, and two for QSL in Quebec, Canada. Customers with a filling tube report lower fine percentages during ship loading than previously experienced.
According to Peeples Industries project manager Brad Orwig, the filling tubes in the Savannah domes have worked very well for the company since installation four years ago. “The pack factor has been reduced or completely eliminated. The stratified dust blanket has been reduced or eliminated, allowing a reduction of degradation during storage as well as improving the breathability of the pile,” he said, adding that on the discharge side, the shear within the pile is reduced.
An existing structure can be retrofitted to accommodate a filling tube, but the less-expensive option is to have the foundation planned and constructed with the filling tube in mind.
Explosion panels
Dome Technology has pioneered proprietary round explosion panels ideal for products prone to deflagration. Until now, square and rectangular explosion venting have been the norm, but Dome Technology’s round model has been and will continue to be installed on bulk-storage domes with significant advantages.
Whether a pre-manufactured rectangular panel or a metal cladding piece, a squared-off panel creates a weak spot. Round panels are preferable because there are no sharp corners for stress concentration.
The proprietary explosion vents are comprised of a circular geodesic steel lattice covered with the same PVC fabric used in the dome construction process. The panel is anchored to the dome with explosion-venting relief screws that remain secure during the design dead, live, and wind loads. But in the event of a deflagration event, the screws release the panel and allow for the release of the excessive internal pressure. The system is watertight and meets the required operational design loads.
In the event of an explosion, the fabric accepts the load and transfers it uniformly around the ring’s circumference. “Because it’s circular we can predict the load going to each of the fasteners really well,” said Jason South, Dome Technology Vice President of Engineering, Research, and Development. “If it were rectangular, the pressure going to each fastener could be different,” and more difficult to estimate.
For more information on these systems and others, contact our sales team.
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As decades pass, the need for larger-scale dome repair work may become more likely. Speedy repairs are a must to […]
As decades pass, the need for larger-scale dome repair work may become more likely. Speedy repairs are a must to protect the concrete dome structure and the material it stores. Dome Technology offers complete renovation options for the fabric membranes.
PVC-coated polyester fabric is durable and can last up to 20 years, but in the event of damage, customers can often make repairs themselves. For small repairs, Dome Technology’s team provides instructions and mailed materials; in many cases, a simple heat-welded patch over the damaged area will be the only mending required.
For serious damage, Dome Technology can patch, coat, or even recover structures on site in the United States and abroad, depending on the circumstances and condition of the dome.
The fabrics Dome Technology uses today are more sophisticated than those in previous decades, so very little maintenance is required. When the surface looks dirty, customers can clean the outer PVC airform with a few simple tools—mild detergents, soft brushes, and low-pressure water are all it takes to restore most membranes to original condition. High-powered pressure washing is discouraged and might remove the membrane’s protective coatings applied to maximize the lifespan.
For more information, contact our sales team.