In 2024, Flynn Bros. was contracted by Louis Dreyfus Company (LDC) to design and construct three large-capacity Brock grain bins at their active facility in Yorkton, Saskatchewan. This project aimed to significantly increase LDC's grain storage capacity at this key location. Flynn Bros.' extensive experience in agricultural construction, particularly with large-diameter grain bins, made them the ideal partner for this critical expansion.

Project Timeline:

• May 2024: Project mobilization and site preparation commenced. This included surveying, layout, in preparation for foundation construction.
• May - July 2024: Foundation construction was the primary focus. Each bin foundation required substantial concrete work: 
  • Footings: 94 cubic yards of concrete per bin.
  • Stem Walls: 144 cubic yards of concrete per bin.
  • Bin Slab: 218 cubic yards of concrete per bin.
  • Under the Bin Slab: 2500 cubic yards of granular fill were placed and compacted to provide a stable base.
• July - September 2024: Erection of the three Brock grain bins took place. This involved the meticulous assembly of the steel bin sheets, utilizing specialized equipment. A total of 26 bin jacks were strategically installed around the perimeter of each bin to facilitate the controlled lifting and construction process. Each completed bin weighed an impressive 267,000 lbs. 
• September 2024: Project completion, this would normally include the final inspections and handover to LDC operations, however we are set to return to the site in August 2025 for commissioning and final handover.

Challenges and Solutions:

One of the significant challenges encountered during this project was working within an active operational facility. The site experienced considerable truck traffic related to ongoing LDC operations, as well as the presence of operations staff. Flynn Bros. implemented strict safety protocols, including clearly defined work zones, constant communication with LDC personnel, and careful coordination of construction activities to minimize disruption and ensure the safety of all individuals on site.

Interesting Project Facts:

• Massive Foundations: The sheer volume of concrete required for each bin foundation highlights the scale and stability engineered into these structures. Each foundation incorporated a total of 456 cubic yards of concrete and 2500 cubic yards of granular fill.
• Heavy-Duty Construction: Each of the three completed grain bins weighed 267,000 lbs, underscoring the robust steel construction necessary for storing large volumes of grain.
• Grain Handling: Each bin was equipped with a 12-inch diameter, single-pass Springland sweep system boasting a capacity of 6000 bushels per hour (BPH), allowing operations to efficiently clean out the bin.
• Specialized Aeration: The aeration systems in each bin were specifically designed for canola storage, featuring customized planking to ensure optimal airflow and maintain grain quality. Each bin was equipped with four powerful 22-inch, 575-volt fans to facilitate this crucial aeration process.
• Innovative Lifting: The use of 26 bin jacks per bin demonstrates the sophisticated engineering and construction techniques employed by Flynn Bros. to safely and efficiently erect these large-scale structures.

Conclusion:

The successful completion of the three 105 ft diameter Brock grain bins for LDC in Yorkton in the face of operational constraints and challenging weather conditions underscores Flynn Bros.' expertise, adaptability, and commitment to delivering high-quality agricultural infrastructure. The project significantly enhanced LDC's storage capacity with robust, grain bins tailored to their specific needs, further solidifying Flynn Bros.' reputation as a trusted partner in the agricultural sector.