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Cheyenne Wohlford, CEOThese structures, which range from large terminal facilities strategically positioned along rail lines and waterways to grain elevators scattered throughout the U.S., all face a common adversary—the need for timely repairs.
CCS Group is the leader in structural inspection services and engineered concrete repair solutions, aiming to minimize operational delays and reduce unforeseen costs while adhering to project timelines.
CCS Group does more than patch up old silos—they enhance them. In every repair and assessment, CCS Group’s motto is ‘Repairing yesterday’s structure with tomorrow’s technology.’
Commenting on this, CEO Cheyenne Wohlford states, “It’s not all about just fixing what’s broken. It’s about completing full inspections before emergencies to reduce cost and construction downtime. By using our ground penetrating radar (GPR) scanner and confined space drone, we can provide the client with an in-depth report showing all the possible deficiencies and issues and pricing for each scope of work.”
Unveiling the Unseen
The first step in any inspection or repair process is identifying the goal. Depending on the desire or need, the approach may vary. If the inspection resembles a health checkup, with no predetermined areas of concern, the process might be more extended. This is because the objective is to uncover the unknown. On the other hand, when an engineer or client reaches out with a specific demand for exact measurements or video data of a structural issue such as a failing roof beam or an interior wall collapse, the inspection can be swift, often on an emergency response basis. In both cases, the gathered data serves a singular purpose: key repair decisions.
Grain storage facilities make it difficult to detect hidden flaws that, if left unaddressed, could lead to catastrophic failures.
CCS Group’s advanced inspection tools, including GPR and drones, allow it to unveil issues that could compromise the silo’s stability.
The GPR scan from top to bottom exposes the state of the rebar structure. This critical element maintains the silo’s cylindrical shape and overall structural integrity, unlike relying solely on blueprints, which may not accurately represent the condition of the construction.
Complementing the GPR scans is drone technology, which is useful for assessing hard-to-reach areas like roof beams or trusses.
The drones, designed for confined spaces, capture high-resolution video and photos and use light detection and ranging (LIDAR) technology to create detailed 3D models of the structures. The combined power of GPR, drones and LIDAR tech offers a precise snapshot of the existing rebar structure, laying a solid foundation for CCS Group to determine the necessary repair strategies accurately.
A testament to this approach can be found in the story of a client from the Upper Midwest whose facility faced an intimidating challenge. An initial assessment called for 20 shotcrete liners, an extensive repair estimated to cost around $2.5 million. Seeking a second opinion, the client engaged CCS Group to determine if every silo required lining. CCS Group proposed a solution that included engaging a third-party engineer for an unbiased review and conducting their advanced inspections using GPR scans to evaluate the condition of the silo reinforcements. Their findings showed that only five silos needed repairs, substantially reducing the scope of work. This targeted approach cut the repair costs to approximately $625,000, saving the client an impressive $1.9 million compared to the initial estimate.
Ensuring Silo Longevity
Once the necessary repairs are determined, the process can encompass a variety of solutions. Sometimes, this involves external concrete crack and spalling repairs to protect the rebar from moisture migration, which inevitably leads to oxidation and rusting—the primary cause of rebar deterioration and loss of tensile strength.
CCS Group employs carbon fiber for areas with localized damage that lack sufficient reinforcement but do not require a full liner. This material is used externally to reinforce structures, allowing for precise, localized repairs that maintain the structure’s integrity.
Roof coatings are another critical service for a silo’s external maintenance. In facilities storing large quantities of grain—potentially worth millions—the roof’s integrity is vital. Water infiltration through the roof can cause the stored grain to spoil, rendering it unsellable and necessitating its disposal. Thus, effective roof coatings are vital for preserving the condition of the grain.
When it comes to internal structure repairs, CCS Group installs shotcrete liners. This technique includes installing a new rebar structure within the old one and adhering to current building design standards and codes. In this approach, the existing structure is given zero structural capacity, with the new internal reinforcing steel structure fully assuming the silo’s required strength, tailored to its current loads and usage.
CCS Group also addresses the functional aspects of silo operation with its hopper installation and repair services. Hoppers, located at the lower portion of the silo, are crucial for the efficient flow of grain. They are designed with slopes ranging from 25 to 40 degrees to facilitate movement toward the discharge areas. CCS Group’s expertise includes repairing existing hoppers and installing new, fully sloped, steel reinforced shotcrete hoppers, enhancing the functionality and durability of the silo. Success Built on Team Integrity and Expertise
Clients recognize CCS Group for their outstanding work, integrity and exceptional staff. The team includes an experienced operations director who oversees project scheduling and client interactions, a highly skilled project engineer, and a project director who acts as a vital link between operations and on-site execution.
In every repair and assessment, CCS Group’s motto is ‘Repairing yesterday’s structure with tomorrow’s technology
CCS ensures that its team comprises individuals who grasp the company’s mission, are deeply committed to its success, and are equipped with the necessary skills and capabilities to effectively meet and exceed clients’ expectations.
Charting the Course for the Next Market Innovation
As CCS Group looks to expand its market reach, the ethanol and bulk liquid storage sector emerges as a key area of focus. Clients in this sector require precise information about the steel thickness of their storage tanks. CCS Group is integrating innovative technology with its existing drone fleet to meet this need. This new addition involves an ultrasonic thickness (UT) testing device that mounts directly onto the drone. Once equipped, the drone can magnetically attach itself to the interior walls of the steel tank, enabling the UT testing arm to conduct thorough thickness measurements at multiple points. The data collected from these tests will empower CCS Group to make well informed decisions regarding the maintenance, repair, or replacement of storage tanks, preventing costly operational downtime and mitigating potential environmental or safety risks.
Through these advancements, CCS Group reinforces its dedication to enhancing the resilience and operational efficiency associated with silo infrastructure, demonstrating that the future of industrial maintenance isn’t just about preservation—it’s about evolution.
