Texas Lehigh Material Reclaimer Analysis
| Owner | Texas Lehigh Cement Company |
|---|---|
| Client | Reinhart & Associates |
| Project Location | Buda, Texas |
Key Features:
- Forensic Investigation and Analysis
- Steel Box-Beams
This existing 140ft clear-span structure moves along rails either side of a continuous pile of varying types of raw product that is mixed on the basis of chemical composition, ground to a fine powder, and sent to the kiln in the process of producing portland cement. The operation of this mechanized structure is vibration intensive. The owner had been plagued with problems including the structure spreading at its base and derailing, cracks propagating in the 8 foot deep x 5 foot wide steel box-beam structure, and bolted connections failing in the trusswork at the operator-side of the reclaimer.
Starting with a random stack of original fabrication drawings, PESC replicated the geometry and developed a three dimensional structural model that we used to analyze this complex system. This modeling and analytical effort yielded results that correlated remarkably well with observed behavior. Calculated elastic deformations quickly explained the repeated derailing of the support cars. Connections that were predicted by analysis to fail had in fact failed. High stress zones revealed by analysis correlated well with areas at which fractures had repeatedly required repair; stress levels at these areas were such that fatigue fractures would be expected under the cyclic loading that resulted from the operation of the reclaimer.
PESC developed a detailed report of findings and recommendations that provided the owner the basis for making the decision to repair or replace this equipment (which was ultimately replaced).