Specialty Gypsum Products Plant Expansion


Southwest United States


2019 / 2020


Outstanding market conditions and sales justified our client's exploration of a next phase growth plan for their Southwest plant following the completion of the Industrial Ally designed Alpha Hemihydrate Production Line expansion. Utilizing the scan data obtained from site, Industrial Ally developed various concepts to increase production in all areas of the plant. Multiple concepts were considered in these areas and evaluated based on the following criteria: capital cost, operating costs and logistics, future expansion, and functionality within the existing plant operations. Upgrades throughout the facility included: additional raw material storage, new 30 tph Raymond Roller Mill Circuit, new batch calcining kettle circuit for Beta Hemihydrate Production, new Steam Autoclave system with pan dryers and grinding/reheat circuit for Alpha Hemihydrate Production, and a new product mixing tower. Strategic tie-ins to the existing semi-finished product storage silos allowed for use of existing storage while minimizing capital impact. Additionally, concepts for increased warehouse storage, an additional bagging line, new bulk rail loadout system, and automated super sack filling stations modernized their product distribution system, while supporting increased capacity. Upon completion of the conceptual design a capital cost estimate was prepared to justify the business case for the project. The project then progressed into preliminary engineering and development of Design Build Bid Packages, of which Industrial Ally solicited and evaluated bids for the Design Build project execution strategy.



  • 5-ton Steam Autoclaves – Melco Steel
  • 300 psig Steam Generation System – Clayton Industries ▪ 60-inch Raymond Roller Mill – Raymond Bartlett Snow
  • Batch Calcining Kettle – Truflow Systems
  • Over 1,400 cubic yards concrete
  • Over 275 tons structural steel
  • Over 5,000 LF of Piping


  • 3D Scan of entire facility
  • Process Flow Diagrams
  • Preparation of Mechanical Specification and RFP Packages for 291 pieces of Mechanical Equipment
  • Solicit and Review Supply Proposal for Mechanical Equipment
  • Preliminary General Arrangements
  • Piping, Chute work, and Ducting Quantification
  • Conceptual Structural Engineering for Materials Quantification
  • Preparation of Capital Cost Estimate
  • Preparation of Design-Build RFP Packages
  • Solicitation and Review of Design-Build Proposals

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