Lehigh Portland Cement Plant Modernization

Union Bridge, MD

“The end product is among the finest cement plants in the world. The quality is of a very high standard and this was only attainable because people cared and paid attention to detail. We worked as a team that wanted to win.”

Al Barzoloski Project Manager Lehigh Portland Cement

Scope of Work

Cianbro constructed a state-of-the-art cement plant. With the highest capacity kiln, this project is the largest of Lehigh’s 12 plants and the most modern cement plant in North America.

Project Details

  • Placed 55,000 cubic yards of concrete foundations
  • Erected 14,000 tons of structural steel
  • Erected 12,000 tons of ductwork and piping
  • Erected and welded a raw mill grinding plant with a 6-meter table
  • Erected and welded a pressurized coal mill with a 2.8-meter table
  • Erected and welded a 475 feet high preheater tower—one the world’s largest—with six, 32 feet diameter cyclones
  • Aligned and welded a 630 ton rotary kiln with eight, 17 feet diameter, 2 inch thick, steel sections—230 feet total length
  • Erected and aligned a two-stage clinker cooler system
  • Installed over 10,000 I/O electrical connections and over 800 electrical drives ranging from fractional to 8,500 horsepower
  • Moved over 600,000 cubic yards of earth
  • Employed a 700 ton crane with a total hook height of 528 ft

Lean, Innovative, and Unique Project Solutions

The Cianbro team, peaking with over 1,350 team members, self-performed all core competencies—concrete forming and placement, steel erection, rigging, welding, millwright work, electrical and instrumentation, and pipefitting. Cianbro also completed several heavy rigging challenges, which included lifting the 230 feet, 630 ton kiln in six sections weighing up to 158 tons each.


2002 AGC Build America Award