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Tight deadlines and heavy loads for new aggregate plant

Mellott Company is a contract crusher and screener for Maryland Materials, a major aggregate supplier in the Mid-Atlantic region of the United States. To meet the increased demand for aggregate, Maryland Materials needed to increase its supply. And Mellott had to increase its production capacity — quickly. The plan was to build a new state-of-the-art aggregate plant in North East Maryland.

The plant project included building a crusher wall and installing two new reclaim tunnels, each with multiple hopper openings. To complete the job, Mellott needed a partner that could provide a turnkey solution in a very short time. They chose Big R Bridge because of our experience designing and manufacturing reclaim tunnels and crusher walls.

Developing a value-added solution

During the preliminary stages of the project, Mellott’s engineers worked closely with Big R’s engineering and fabrication departments. Our team manufactured two 12’ diameter stockpile tunnels using our Bolt-A-Plate structural plate product. One tunnel was 164' long with a 72' tall stockpile, and one was 136' long with a 64' tall stockpile. We also manufactured five reinforced hoppers and two bulkheads.

We provided a 37' tall crusher wall with a total area of approximately 3,700 sf and a 321' corrugated steel pipe escape tube, which included several pre-manufactured fittings for ease of installation in the field.

Quick assembly a key component

Big R pre-assembled many of the components before they were delivered. Those that couldn’t be pre-assembled were put together on site. The assembly of the tunnels with reinforced hopper openings and bulkheads took approximately seven days. The crusher wall was installed and backfilled in less than three weeks.

By choosing Big R, Mellott solved their infrastructure challenge in record time. They’re happy. Their client is happy. And Big R has proven, once again, our ability to provide industry-leading mine site solutions.


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