SILO BUILDUP REMOVAL & AIR PAD RESTORATION

IA Mechanical performed a full cleanout and aeration system rehabilitation in a reinforced concrete blending silo experiencing material buildup and airflow obstruction issues. The accumulated raw mix was removed to expose the silo floor and the clogged air pads. IA Mechanical restored the functionality of the silo by performing the required air pad maintenance to re-establish proper material flow within the silo.

A cement facility operating a four-pack of reinforced concrete blending silos experienced significant flow issues in two units, with one silo showing severe restrictions in raw mix movement that disrupted production. The facility engaged IA Mechanical (IAM) to assess interior conditions, remove hardened material, and restore proper aeration performance. Because air pads are essential for maintaining material fluidity and preventing compacted buildup, restoring airflow and eliminating obstructions was critical to returning the silo to reliable operation.

Industrial Access’ Rope Access Division performed the initial entry into the silo to evaluate overhead hazards, including loose material, roof-structure deterioration, and moisture-driven instability. After completing the inspection and formally clearing the space for safe access, the IAM division entered the silo through the existing wall door and utilized the internal scaffold system to conduct their work. No simultaneous entry occurred, ensuring full compliance with confined space procedures while providing a verified-safe environment for the mechanical team to perform the cleanout and air pad rehabilitation.

Once the space was cleared for mechanical entry, IAM technicians began removing the compacted raw mix using mechanical breakup methods and vacuum extraction to fully expose the silo floor and aeration components. The crew cleaned all air pathways, including pad boxes and supply lines, and replaced clogged air pad filters with new units to restore proper airflow. Sealant was applied to secure all seating surfaces, and IAM verified system performance and airflow distribution after reinstallation to ensure the silo was operating as designed before demobilization.

All cleanout and aeration rehabilitation work was completed safely and effectively, resulting in the removal of approximately 1,360 tons of compacted raw mix from the silo. Clearing this buildup restored uniform airflow, improved discharge consistency, and significantly reduced the likelihood of future blockages. The silo returned to full operational functionality, and the corrective work enhanced overall performance while underscoring the importance of proactive inspection and routine maintenance to prevent similar issues from recurring.