Case Study

Upgrading flour storage silos for international manufacturer of baked goods

CLIENT OVERVIEW

International baked goods manufacturer in Portland Metro Area with continuous production operations dependent on bulk ingredient delivery by railcar.

THE CHALLENGE

Aging Infrastructure Meets Modern Standards

Several 200,000-lb capacity flour silos from the 1950s needed replacement:

  • Safety Gap: Existing silos didn’t meet current NFPA combustible dust regulations
  • Structural Concerns: 70-year-old mild steel structures couldn’t meet current building codes and Oregon seismic standards
  • Zero Downtime Required: Full storage capacity had to be maintained throughout construction and commissioning

Brownfield Complexity:

  • Active railroad tracks with daily flour deliveries adjacent to construction zone
  • Waste compactor operations requiring multiple weekly exchanges
  • Critical roadways for finished product distribution
  • Multiple stakeholders requiring continuous coordination

Aerial view of industrial storage silos and processing equipment at a manufacturing facility, showcasing T&M Design’s expertise in industrial engineering and construction management.
Aerial view of the three old silos with railroad tracks in the background.

THE SOLUTION

T&M Design’s Role: Project manager, construction manager, lead engineering firm, and commissioning lead

Strategic Phasing:
  • Positioned three new silos to keep all five original silos operational during construction
  • Installed divert valve on existing discharge piping for flexible commissioning
  • Commissioned each new silo individually with ability to revert if needed
  • Completed full commissioning before demolishing existing structures
Multi-Disciplinary Coordination:
  • Partnered across electrical, mechanical, structural, civil, combustible dust, and controls engineering
  • Developed comprehensive Dust Hazard Analysis (DHA) and Technical Opinion Report for permitting
  • Designed foundations following geotechnical testing
  • Managed daily logistics with rail company, bakery personnel, and waste vendors
Execution:
  • Two of Oregon’s largest cranes required for vertical silo installation
  • Maximized pre-fabrication to minimize crane time and operational disruption
  • Pre-assembled platform assemblies, catwalks, and spiral stairs
  • Integrated new NFPA-compliant safety systems: deflagration panels, fast-acting isolation valves, automated shutdown controls

THE RESULTS

  • Zero operational disruptions throughout the entire construction, commissioning, and transition period
  • Full NFPA compliance with modern combustible dust hazard management systems, including deflagration protection and automated isolation
  • Enhanced structural integrity meeting current building codes and Oregon seismic standards
  • Improved equipment reliability with new systems designed for decades of service
  • Better maintenance access with spiral staircases replacing bucket ladders, providing safe access to all five silos
  • "Instantaneous Start Up" recognition—the client's first U.S. project to receive this designation, reflecting exemplary safety records, zero construction disruptions, and seamless process transition

KEY TAKEAWAYS

Complex brownfield projects require more than engineering expertise—they demand embedded support and daily coordination across multiple stakeholders. T&M’s approach kept production running, workers safe, and the project on schedule and budget.

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