For storage projects where construction typically demands warmer temperatures, there’s another option: A DomeSilo can be built any time of year, with work marching right through the calendar.
The industry norm is for new grain-storage projects to wrap up right before harvest. In contrast, a dome can be finished early in the calendar year, providing plenty of time for commissioning before product shows up, said Dome Technology sales manager Heath Harrison. “With a winter-build schedule, it can allow for several months of utilizing the new structure, getting staff used to it, finding the efficiencies, (and) fixing any potential issues before farmers start rolling in from the field,” he said.
Making the most of the off season starts with proper planning in the warmer months. Dome Technology then completes foundational concrete work before harvest while temps are pleasant. If new storage is being built in an area that is not impacted by the harvest, construction continues until completed, regardless of the weather. But if the site must be sensitive to the harvest, construction crews leave during harvest, then come back and complete the project during the winter.
The all-weather schedule works because a dome is built from the inside out. Once the outer membrane is inflated to create the dome shape, rebar and concrete are applied to the inside; once rigid, construction continues within the structure. Because of this method, “customers hardly know we’re there because the only impact is concrete trucks coming in and out; other than that, all the construction is inside the inflated airform,” or membrane, Harrison said.
Questions to guide your project
Once you’ve decided on a dome, asking the right questions is key to securing the ideal handling system. Companies can use these questions to get the planning process started:
What are our throughput goals? In discussions with engineers, companies should identify the desired type of throughput, whether the product will be stored long term or processed quickly, what type of transportation will move grain to customers, and more. If a dome is selected, those topics will be addressed during the preliminary phase to ensure the facility is optimal for the customer.
Different reclaim systems will be discussed early on, and multiple options are available. Desired throughput rate will inform the handling system and its size, but the type of equipment selected might largely be determined by cost. Grain is most commonly reclaimed via clean-sweep screw or auger that pulls material into a hopper. But some types of reclaim can’t move 100,000 bushels an hour out of a dome — that’s best achieved by a front-end loader or a Vibrafloor. However, the cost difference between those two options is substantial — the former might cost $150,000 to $250,000 versus $1 million for the latter. Since grain is a tight-margin industry, the more product a company pushes through, the more money they make, and many seek the least expensive system that can move the most volume.
With throughput shaping the entire process, engineers can identify the costs of various types of systems, and based on the speed and volume of reclaim, customers can choose the best system to meet their needs.
What foundation system is best? Traditional bulk storage often requires expensive deep-foundation systems based on the amount of weight the structure will hold. Dome Technology engineers have developed diverse and economical foundation solutions that can be chosen based on site geology.
A dome’s strength provides high tolerance for total and differential settlement. That quality combined with geotechnical engineering and site analysis ensures substantial foundational strength. The combination of the ring foundation and the concrete shell distributes loading uniformly, even over irregular surface conditions. Customers can save millions as the need for deep foundations is reduced or eliminated.
How do we combat flow issues? Oily grains are prone to caking or bridging in storage, especially when product is stacked especially deep. When the problem is severe, grains fail to free-flow.
Breaking down a compacted pile within a dome is possible, and companies can choose from multiple methods to tackle the problem. A front-end loader can knock down product, but this approach is sometimes avoided because of safety concerns. Safer alternatives include a whip-chain system to break product, air cannons that blast grains loose or a screw reclaimer capable of working under pile load.
What are we forgetting? An expert team that understands product qualities and reclaim options will guide customers in analyzing all aspects of the reclaim process. Dome Technology relies on two types of scope questionnaires, one for a fixed budget and another for a quick budget. So whether a project is imminent or simply hypothetical, companies can get a good idea of what’s available and how to reach their storage and handling goals.
Another advantage of front-end engineering is potential cost savings at every stage of the project. For instance, companies often ask what kind of civil work Dome Technology can complete. Depending on what’s most cost effective, Dome Technology’s team can either perform the excavation and backfilling on a project or hire a local contractor, whichever is most economical.
Editor’s note: This article was published in the Sept. 2025 issue of Dry Cargo Magazine.