CASE STUDY: Asphalt Silos & Conveyors
Posted: January 2025
ABOUT THE CLIENT
Ammann Group, a world-leading supplier of mixing plants, machines, and services, was looking to scale their North American operations and expand their product offerings. Facing tight deadlines, they needed a large-scale fabrication partner for the manufacturing of asphalt equipment for a new plant in Texas. They started their search for a partner who could handle complex requirements and evolving project requirements, while matching the standard of excellence that they are known for.
Ammann was drawn to SWF’s proximity, capabilities, and reputation for handling sizable industrial projects. Seeing that SWF could potentially be the right fit, they submitted the project details and started a conversation with SWFs’ Business Development team. In short order, the two companies kicked off one of the largest fabrication projects in SWF history, and the start of a long-term relationship between Ammann and SWF.
The Problem
Ammann Group required the fabrication and assembly of 100-foot drag conveyors, and large asphalt silos—a massive undertaking requiring creativity and precision. Due to the size and scale of the project, SWF was tasked with navigating the challenges of custom material handling for oversized components and managing long-lead materials like 100-foot single-piece I-beams.
The silos themselves were impressive in scale, measuring 61 feet high, 12 feet 6 inches in diameter, and weighing 49,000 pounds (24.5 tons). Initial plans were for basic supply fabrication, but as the project evolved, Ammann’s needs grew along with it. Those changes provided SWF the opportunity to create turnkey units finished with ceramic tile lining, electrical assembly, and piping.
With deadlines looming, Ammann relied on SWF Industrial to deliver quality results while remaining adaptable to the project’s growing scope. Always up to the challenge, SWF’s creativity and commitment shined through the planning, execution, and delivery.
Several challenges prevented simple, off-the-shelf solutions:
- Product Scale: The size of the asphalt equipment fabrication and manufacturing fully utilized SWF’s high-capacity facilities, requiring significant creativity to optimize crane space, manage material logistics, and accommodate assembly.
- Evolving Project Requirements: The original fabrication expanded to include intricate tasks such as ceramic tile lining—uncommon in SWF’s scope—electrical integration and complex chain motor assembly for the conveyors.
- Supply Chain Hurdles: Securing mill-run materials with long lead times added pressure to meet shifting delivery dates, which SWF navigated with Ammann to keep the project on track.
As challenges and deadlines approached, SWF maintained transparent collaboration with Ammann, resolving each potential roadblock with character, commitment, and creativity.
The Solution
SWF approached the project and each challenge with creative, results-driven project management and a commitment to excellence:
- Material Handling Innovation: SWF’s team restructured shop workflows to accommodate the massive silos and conveyors, optimizing crane space and resource allocation.
- Turnkey Fabrication & Assembly: Beyond fabrication, SWF took on tasks traditionally handled by field teams, including:
Installation of a 25,000-pound conveyor chain and motors. - Precision ceramic tile lining and integrated electrical work.
- Collaborative Change Management: Evolving needs were addressed through tracked time-and-materials solutions, ensuring Ammann’s additional requirements were met efficiently without disrupting the original scope.
- Reliable Delivery Despite Delays: When unavoidable supply chain issues arose, SWF communicated proactively, agreed on revised timelines, and shipped both silos and drag conveyors to the Texas site—fully assembled and ready for installation.
The Result
SWF Industrial delivered one of the largest fabrication projects in its history, exceeding Ammann’s expectations and strengthening a growing partnership:
- Turnkey Delivery: The complete asphalt silos and drag conveyors were delivered ready to use, streamlining site installation for Ammann.
- Relationship Expansion: Midway through the project, Ammann trusted SWF to hold time for a second system—now underway—for a plant in Georgia.
- Time & Cost Savings: By handling the manufacturing and assembly for the asphalt plant equipment in a single location, SWF minimized logistics, saved Ammann time and resources, and ensured consistent communication and quality across all deliverables.
This project was a true demonstration of SWF Industrial’s unique ability to handle highly complex industrial fabrication projects with creativity and precision. With transparency and innovative problem-solving, SWF expanded its boundaries and delivered turnkey results. After a successful delivery and installation, SWF’s work with Ammann is just beginning.
SWF Industrial’s ability to combine their craft, mature project management, and technical expertise allowed them to deliver a complete, high-quality solution under complex circumstances. By meeting Ammann Group’s needs and exceeding expectations, SWF forged a relationship built on trust and reliability—one that promises continued success in future projects.
If you are looking for the kind of partner who builds relationships that last while delivering the results you need for your next project, reach out to our Business Development team today to start a conversation.