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Sugar Transloading Facility Design and Construction

Project Summary

The client needed to build a sugar transloading facility on a greenfield site in the Midwest to reduce their shipping and delivery times in the region. They wanted to receive sugar from bulk rail cars and store the product in a 1.3 million cwt. dome silo. The facility’s sugar loadout rate will fill four trucks per hour from two loadout locations, totaling 200,000 pounds of sugar per hour.


Project Summary

This project was designed in a year-long accelerated timeframe to complete construction for the Fall 2016 sugar beet harvest, with initial design work beginning in Fall 2015. During the course of the project, ADF:


  • Created 33 electrical drawings including: 9 power layouts; 8 lighting layouts; 3 single line diagrams; 2 electrical panel and equipment schedule drawings; 1 site grounding plan; 8 fire alarm plans
  • Provided construction assistance with vendor submittals, approvals and coordination
  • Designed power distribution for 87 motors throughout the facility
  • Coordinated the implementation of 20 panels and MCC’s, plus additional fuse disconnects and transformers
  • Provided site and trans loading building photometrics
  • Used photometric software to provide lighting design to the administrative building and transloading facility
  • Coordinated equipment requirements with 22 vendors and 16 contractors
  • Assisted in the implementation and planning of life safety equipment throughout the facility
  • Provided guidance for equipment installation and use in a Class II, Division 2, Group G environment
  • Programmed entire facility PLC system to control the transloading process from rail to truck
  • Developed displays for operators and processes to allow for multiple transloading possibilities during operations
  • Integrated several third party systems to enable seamless communications, including Allen Bradley, safety suppression systems, weight scales, HVAC units, and facility utilities
  • Designed electrical and control components to allow for future expansion to second transloading facility