Kaluga 8500 TPD Cement Plant – Silos & Process Structures

Under the Kaluga 8500 TPD Cement Plant project, SİBA built numerous silo and auxiliary structures with high-volume slipform applications, while the process buildings were executed with conventional formwork. This case study addresses the roughly 110,000 m² of slipform, execution under harsh winter conditions, and the variety of silos.

Project facts

• Location: Kaluga, Russia
• Capacity: 8500 TPD cement plant
• Methods: Vertical slipform (silos) + conventional formwork (process structures)
• Slipform quantity: Approximately 110,000 m²
• Scope: Construction of silo and process structures

High-volume slipform

Approximately 110,000 m² of slipform construction was performed within the project. An application of this scale requires equipment planning, workforce organisation and concrete supply to be managed in harmony with the requirement for continuous placement.

Execution under harsh winter conditions

The works were carried out under harsh winter conditions dropping below −20°C. Because low temperatures directly affect the setting and strength gain of concrete, the concrete mix, placement and curing processes had to be carefully managed according to the climatic conditions in order to sustain the continuous advance of the slipform.

In a continuous slipform pour, winter is not merely a matter of comfort; it is an engineering variable that governs the behaviour of the concrete.

Variety of silos

All silo structures were built using the vertical slipform method. The scope includes four cement silos (Ø24 m, h=70 m), one raw meal silo, eight clinker distribution silos, a multi-chamber cement silo and a rectangular elevator tower. The triangular columns inside the raw meal silo were also executed by slipform.

Scope

• Reinforced concrete silo structures (vertical slipform)
• Four cement silos (Ø24 m, h=70 m)
• One raw meal silo and eight clinker distribution silos
• Multi-chamber cement silo
• Rectangular elevator tower (vertical slipform)
• Triangular internal columns in the raw meal silo (slipform)
• Process structures (conventional formwork)

Outcome

The Kaluga project is an example of engineering and site organisation that carries out high-volume slipform application under harsh climatic conditions, taking its place among SİBA's international cement references.