Grain Store Canterbury, Kent

We were very pleased when Shufflebottom’s asked us to erect ‘one of the largest tonnage grain stores Shufflebottom has supplied in its history’. This one was an exceptional feet for us, being one thebiggest stores we have ever erected too and throughout the duration it all ran relatively smoothly. There were so many different elements to it, each section facing its only challenge but we planned and overcame these everytime, making it an exciting erection project for us.

The farm itself it was being erected on, is a large third generation family owned business that farms more than 3500 ha. It grows a mix of energy crops (maize, whole crop rye/triticale and grass silage) that supports their AD plant, as well as combinable crops (milling wheat, OSR, spring oats and peas). All grain from its contract-farmed business is stored centrally in modern grain stores, which is where this Shufflebottom and we come into their story.

Shufflebottom designed and supplied a store that could support the weight and pressure of 12000 tonnes of grain, which encompassed 9.2m high grain walls; along with adjoining lean to extensionsalong the rear and side of the building.

The main 12,000 tonne grain store was 46m long x 33.16m wide x 10.36m to the eaves with a 12.5 degree pitch with 9.2m high concrete walls. The adjoining lean to was 17.25m long x 9m wide and incorporates 4 bays at 5.75m.The rear extension, the fan house lean to, measures 33.18m long x 2.5m wide x 3.5m to the eaves with a 12.5 degree pitch incorporating 6 bays at 5.35m each. The erection went fairly seamlessly, we hired in a 32m Roto Telehandler for the help of the erection which made life a lot easier, the steels were heavy some weighing in a 6T and so precision was key when craning these in to get them spot on. In total there was 50 columns to be erected and then all the roof bracing and purlins to go on.

Before the roof went on, it was time to get all the concrete panels in place. We needed the lifting height to get them up and in. 6 concrete panels in each bay to reach our desired height.

Shufflebottom had pre drilled our handrail system into the steel so this made it quicker to get the nets and handrail system netted prior to roofing. The roof used fibre cement roof sheets with no roof lightswhich made things simpler so the roofing for this was done within 2 weeks. 1972.81 sq metres of roof plus 46 ridge caps!! A tad windy at times but that was due to being that close to the sea we could see the cargo ships on the horizon!.

With the concrete walls being so high, meant there was a smaller amount of cladding needed along the top and sides, this was all done in single skin pastisol tin cladding in a box profile. The fan house to the rear of the store was a little more intrigate with the cladding; cladded first with a perforated tin and then overlaid with 100mm rockwool insulation and then cladded externally with plastic coated tin to help sound proof the fan house.

With the store’s final use being a grain store it meant that there was ventilation, drying systems, and ultimately conveyor beams needed to get the crop out to store. With all of this it meant that the client needed walkways, catwalks and ladders erected.  

We installed a stair tower at the front of the building and an external walkway along the front outside of the building. This proved to be testing as it was incredibly close to the existing building and there was a diesel fuel tank underneath were we were working. We ended up using an small electric scissor lift which could fit into the metre gap and then a 17m reach telehandler to boom out the materials needed to us in a 20m cherry picker. It was certainly tricky but we love a challenge and to see the finished piece was very rewarding.

Also installed was the internal catwalk along the entire length of the building to provide access to the machinery inside. We also installed the conveyor beams to this so the grain equipment could later be supplied and installed. Finally installed where the 3 escape ladders – 2 internally and 1 externally to the ladder tower at the rear of the building.

To finish off we went around and put all the spill boards on and sealed everywhere so they are ready for this years harvest, once the grain equipment has been installed after us.

Overall this job did have some challenges with were inevitable on a project of this scale but Shufflebottom helped when needed and we managed to think outside the box on certain aspects of the job. We thoroughly enjoyed erecting a project of this scale and are proud of the erection quality we have delivered.