Successful construction projects are built on strong partnerships. In Circleville, Ohio, a commercial grain facility expansion is taking shape thanks to a collaborative effort between Graber Construction as the lead contractor and APEX Industrial as the steel solutions provider. APEX Industrial worked closely with Graber’s on-site teams to ensure each steel component fit perfectly into the build plan. This united approach – combining Graber’s construction leadership and APEX’s structural design expertise and fabrication excellence – is driving the project’s success and setting a high standard for teamwork in the industry.

Custom-Engineered Steel Solutions for the Circleville Project

At the core of this expansion are APEX Industrial’s custom-engineered steel structures, which form the backbone of the upgraded grain facility. Every element was tailored to the project’s needs, ensuring robust performance and seamless integration with the grain handling equipment. Some of the key structural components provided by APEX include:

• 18′ x 24′ x 172′ Freestanding Tower:
  This towering structure is the centerpiece of the expansion, rising 172 feet to support new grain handling equipment. The tower provides a stable framework for high-capacity bucket elevators and a large grain distributor at its summit. Designed as a freestanding unit, it can bear enormous loads while standing independent of other buildings – a testament to APEX’s structural engineering prowess.
• Cantilevered & Dual-Cantilevered Service Platforms:
  A series of heavy-duty service platforms are attached at various levels of the tower and adjoining structures. Some platforms cantilever outward on one side of the tower, and others are dual-cantilevered, extending on two opposite sides for broader reach. These platforms give maintenance crews safe, convenient access to critical equipment like motors, valves, and the distributor chutes. Each platform is built to accommodate the specific equipment at that elevation, with galvanized steel construction for maximum durability in all weather conditions.
• Custom Catwalks and Support Beams:
  Spanning across and between the new tower and existing silos, APEX fabricated multiple catwalks to connect handling within the facility.     These elevated walkways – some stretching well over a hundred feet in length – allow personnel to traverse safely between the grain elevator, storage bins, and the rail loading area. Sturdy support beams accompany the catwalks wherever extra reinforcement is needed, such as over wide spans or under heavy conveyor equipment. The catwalks feature slip-resistant  grating and integrated guardrails, all engineered to meet strict safety standards while streamlining the grain flow between process areas.
• Switchback Stairs for Tower Access:
  To ensure workers can reach the top of the 172′ tower efficiently, APEX installed a switchback stair system along the tower’s height. This     staircase zig-zags upward with intermediate landings, making the long ascent safer and less strenuous. The switchback stairs, complete with handrails and rest platforms, provide an OSHA-compliant alternative to ladders and enable operators to inspect or service equipment at any level of the tower without specialized lifts. This access point is also suited with a stair security door, securing safe and warranted entry.
• Bulk Weigher Rail Loadout Structure:
  An important addition is the new bulk weigher rail loadout system, housed in a custom steel support structure manufactured by APEX. This structure elevates a high-capacity bulk weigh scale and its associated hopper and spouts directly above the rail line. Engineered by VAA, the frame is precisely designed to bear the heavy weight of grain as it’s rapidly loaded into railcars. The bulk weigher structure not only supports the scale equipment but also aligns perfectly with the railcar loading position, ensuring that grain can be loaded quickly and accurately. With this APEX-built support in place, the facility can fill outbound railcars at an impressive rate, dramatically improving throughput for grain shipments.

Each of these components was fabricated by APEX Industrial to meet the project’s specific requirements. From massive towers to intricate platforms,APEX’s ability to deliver turnkey steel solutions has been crucial in bringing the Circleville expansion from concept to reality.

Quality Craftsmanship and Innovation in Action

APEX Industrial’s contributions go beyond supplying steel – it’s about delivering quality and innovation at every step. All structures for the Circleville project have been crafted with high-grade, galvanized steel,protecting them against corrosion and ensuring they withstand decades of heavy use in outdoor agricultural environments. APEX’s fabrication team employed advanced manufacturing techniques to maintain tight tolerances on every beam,bolt-hole, and weld. This precision means that when the steel arrived on site,Graber Construction’s crews could bolt everything together efficiently without delays or rework, keeping the project on schedule.

Innovation is a hallmark of APEX Industrial’s approach. For this facility, many steel components were custom-engineered in unique configurations to solve site-specific challenges. For example, designing dual-cantilevered platforms required creative engineering to balance weight and support on the tower without excessive additional bracing. APEX’s engineers developed an innovative bracket system to mount these platforms securely, providing the needed access space while maintaining structural integrity. Similarly, the long-span catwalks were designed as modular sections that could be lifted and connected in the air, an innovative approach that minimized disruption to ongoing plant operations during installation. By thinking outside the box and working shoulder to shoulder with our partners, APEX delivered solutions that improved both the safety and functionality of the grain terminal.

Boosting Efficiency and Supporting Circleville

The enhancements to this grain facility are more than just a construction achievement; they bring tangible benefits to Circleville’s agricultural community and economy. With modernized equipment and the robust infrastructure,the facility’s efficiency is soaring. Grain can now be received, processed, and loaded out faster than ever before. In fact, the upgraded rail load out system can handle significantly higher volumes in less time – enabling the elevator to load unit trains (long strings of rail cars) in a fraction of the time it used to take. This increase in throughput means farmers and suppliers experience quicker turnarounds when delivering grain, reducing wait times during the busy harvest season and preserving the quality of their crop through faster handling.

By expanding and updating the grain terminal, the project is directly supporting local agriculture. Circleville and the surrounding region are home to many corn and soybean producers who rely on efficient storage and marketing of their grain. The new platforms, towers, and handling systems allow the facility to scale up its capacity, so it can serve more farmers or larger harvests without bottlenecks. Additionally, the improved equipment ensures that grain is handled gently and accurately, which can lead to better overall grain quality and fewer losses. Farmers benefit from a facility that can keep up with modern demands, helping them stay competitive and confident that their product will get to market quickly and safely.

Strengthening Circleville’s Future in Grain Handling

This project highlights what’s possible when collaboration, quality, and innovation come together. Graber Construction’s hands-on experience, VAA’s engineering insights, and APEX Industrial’s steel craftsmanship have collectively transformed the Circleville grain elevator into a state-of-the-art facility. The new freestanding tower and network of platforms and catwalks not only look impressive against the skyline but also function seamlessly to expedite grain handling operations. APEX Industrial is proud to have contributed its expertise to a venture that improves safety, efficiency, and capacity for everyone involved.

As the expanded facility comes online, its benefits will be felt throughout the region – from local farmers enjoying quicker service to grain buyers receiving shipments on schedule. The Circleville community can be confident that this modern grain terminal will support the agricultural economy for decades to come, solidifying the area’s reputation as a vital hub in the grain industry. Through strategic partnership and superior engineering, the Circleville project stands as a model of success – demonstrating how upgrading infrastructure can fuel growth and prosperity in local agriculture. 

APEX Industrial is proud to announce its involvement in the Utah Flour Milling (UFM) expansion, located in Richmond, Utah. This facility is part of a major expansion for UFM, which will support a major international snack food bakery in Richmond. Bratney, a trusted partner for turnkey plant design, engineering, and construction services, selected APEX Industrial for its expertise in custom tower, support structure, and catwalk engineering and manufacturing for the project.

A Strategic Partnership for Growth

The Utah Flour Milling expansion is expected to generate 31 new high-paying jobs and bolster the agricultural industry in Cache County, Utah.The new grain elevator will enhance supply reliability and plant efficiency,serving as a critical hub for the production of flour for industrial bulk and pack customers.

Bratney, the lead for this project, chose APEX Industrial to deliver high-performance infrastructure for UFM. Bratney’s expertise in turnkey projects and APEX’s custom manufacturing solutions delivered quality, easy to assemble solutions for the growing demand of this high-quality flour mill.

APEX’s Role in the Project

APEX Industrial supported the grain handling infrastructure for this state-of-the-art flour milling facility. Our contribution was focused on the design, engineering, and manufacturing of custom towers, catwalks, platforms,and support beams. Below are the key specifications of the structural components we provided for the project:

• Custom Structural Towers: Designed and manufactured to support the grain handling systems, ensuring safe and efficient operation.
   
  • 4' x 17' 2-legged Tower
   
  • 4' x 4' x 16' Freestanding Tower
   
  • 6' x 28'-5.5" 2-legged Tower
   
  • 6' x 6' x 29'-9" Freestanding Tower
   
  • 8' x 8' x 27'-9.5" Freestanding Tower
   
  • 4' x 6' x 20' Freestanding Tower
   
  • 6' x 6' x 20' Freestanding Tower
 
• Catwalks and Support Beams: Providing safe access to all areas of the facility, these components are critical for ensuring maintenance crews can easily access equipment at all heights.
   
  • 4' Catwalk Support Beam
   
  • 6' Catwalk Support Beam
   
  • 3' x 38' Catwalk
   
  • 2'-6" x 65' HT Catwalk
   
  • 3' x 90' Catwalk
   
  • 4' x 6' Catwalk Support Beam
   
  • 3' x 165' Catwalk
 
• Platforms and Safety Accessories: APEX’s custom platforms provide stable, convenient access for operators, enabling them to maintain and monitor equipment effectively.
   
  • Ladder & Cage
   
  • Ladder Sidestep
   
  • Ladder Rest Form
   
  • Ladder Security Door
   
  • 6' x 6' Service Platforms
   
  • 8' x 8' Top Service Platform

These components are crucial to the grain handling operations and ensure safe access, efficient grain movement, and long-term reliability of the facility.

Enhancing Supply Reliability and Sustainability

This expansion will help Utah Flour Milling meet increasing demand for flour, focusing primarily on producing flour for industrial bulk and pack customers. In addition to its operational benefits, the facility will contribute to sustainability goals by eliminating the need for over 2,200 truck loads of flour transportation annually, reducing green house gas emissions in the process.

A Beautiful Location with a Bright Future

Situated in the picturesque landscape of Richmond, Utah, the UFM facility is set against the backdrop of snow-capped mountains. This expansion will foster economic growth in the area while enhancing Utah’s position as a leader in agricultural innovation and sustainability.

APEX Industrial is honored to have been chosen by Bratney to contribute to the UFM expansion project. This collaboration highlights the strength of strategic partnerships in driving agricultural growth and innovation. Completion of this project will not only support Utah Flour Milling’s operational needs but also play a significant role in strengthening the region’s economy and its agricultural capabilities.

For more information on APEX Industrial’s involvement in this project or to learn how we can support your next infrastructure project, reach out to us today.

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APEX Industrial is proud to be part of the groundbreaking development of ALCIVIA’s new state-of-the-art grain terminal in Hager City, Wisconsin. This project, in collaboration with J&D Construction Inc., highlights APEX’s expertise in delivering custom-engineered solutions to enhance grain handling efficiency and market access for agricultural producers.

A Towering Infrastructure

At the heart of this advanced grain terminal is the 20'x24'x151’ Support Tower,which plays a crucial role in the grain handling system. Designed and manufactured by APEX Industrial, the tower supports the key equipment needed to move grain quickly and efficiently throughout the facility. The tower includes:

• Four Bucket Elevators (151’ OAH): Essential for transporting grain across the facility at optimal speeds.
• Enclosed Manlift (152’ OAH): Providing safe access to elevated sections of the facility for maintenance and monitoring.
• Three Duct Distributors (142') and Three Inlet x 8 Duct Distributors (133'): Ensuring the precise and efficient movement of grain throughout the terminal.
• 12,000 BPH Drag Scalper (133'): Effectively cleaning and separating grain as part of the material handling process.

Custom-Engineered Platforms and Catwalks

To ensure operational efficiency and worker safety, APEX Industrial designed a series of custom platforms and catwalks.These structures provide safe access to different areas of the grain terminal,ensuring smooth day-to-day operations. Key components include:

• 24'x49' Top Platform: Providing ample space for operators and equipment at the highest point of the tower.
• 24'x32' Platform at 124': Offering convenient access to critical areas of the grain handling system.
• Three 20'x24' Platforms at 142', 133', and 114': Supporting maintenance and inspections at different levels of the facility.
• 12'x24' Cantilevered Platform at 110': Allowing for safe movement around the tower’s exterior.
• 29'x32' Platform at 91': A spacious platform that supports operators in maintaining high operational standards.
• 8'x24' Platform at 51': Ensuring accessibility at mid-level areas.
• 7'x14' Platform at 10': Providing easy access to the lower levels of the terminal.

Additionally, APEX designed a custom stair system to support access from 110' to the top of the tower,ensuring safety and operational efficiency.

A Strategic Location for Market Access

This grain terminal will significantly enhance ALCIVIA’s ability to serve farmers in west-central Wisconsin and southeast Minnesota. The facility will feature 3.9 million bushels of upright grain storage, serviced by two 4,700-bushel per hour dryers and three 1,500-bushel capacity dump pits,providing an impressive combined grain handling speed of 60,000 bushels per hour. These features will ensure quick and efficient loading and unloading of grain, benefiting local producers and enhancing market access.

Located on 40 acres with Class I BNSF rail access, this facility can reach the markets within the BNSF network. In addition, ALCIVIA can load shuttles on the UP and CPKC railroads which provides significant advantages to both domestic and export markets. It also boasts access to the Mississippi and Illinois Rivers, positioning ALCIVIA for optimal logistical and arbitrage opportunities.

The Role of J&D Construction Inc.

As the contractor responsible for the erection of the facility, J&D Construction Inc. has played a vital role in bringing APEX’s design to life. Their expertise ensured the seamless installation of APEX’s components, setting the stage for the successful operation of the new grain terminal. Their collaboration with APEX Industrial emphasizes the importance of teamwork in the delivery of high-performance agricultural infrastructure.

Commitment to Quality and Safety

APEX Industrial’s commitment to excellence in design,engineering, and manufacturing ensures that this terminal will meet the highest standards for safety and reliability. Each component has been carefully crafted to withstand the demands of grain handling, supporting the long-term success of ALCIVIA’s operations.

The ALCIVIA grain terminal in Hager City is more than just a facility; it’s a state-of-the-art infrastructure project that reflects APEX Industrial's dedication to advancing the agricultural industry. This collaboration with J&D Construction is an example of how custom-engineered solutions can meet the evolving needs of the grain industry, providing high-quality grain storage, handling, and loading capabilities that enhance operational efficiency.

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