Located in the harsh environment of a limestone quarry, the structure of the Romeoville Aggregate Screening Plant must withstand constant bombardment of small and large pieces of limestone rocks. This constant abrasion can only be fought off by the powerful barrier and cathodic protection of hot-dip galvanized steel.  The zinc-iron alloy layers created during the galvanizing process become harder than the steel itself, reaching a hardness of 250 DPN.  Also challenging, the structure is situated in a wet screen environment, as well as a water marine due to the adjacent river. The metallurgically bonded zinc iron alloy will protect the structure for decades from nicks and chips and the harsh Illinois winters.

The manufacturer was impressed by the AGA life cycle cost calculator, which reveals the savings of hot-dip galvanized steel over the life of a project. While the initial cost was competitive with paint, the life cycle cost was miniscule in comparison to what the maintenance would be on a painted structure in this harsh environment. Hands down, HDG was the most cost effective solution.  Additionally, the manufacturer had used HDG on previous projects that required superior corrosion protection, made the choice to galvanize this structure with the greatest confidence.

Since HDG steel is the most recycled product in  the world and this plant will probably outlast the quarry, it is good to know that this project site can be reclaimed and be part of the sustainable development of the area. The galvanizer offered a customized turnaround time that allowed extra time to install auxiliary motors, liners and belts. In turn the manufacturer was able to deliver the finished product on time.

The cathodic protection of the zinc coating  makes a strong visual statement of durability and superior protection, and more than 200 tons of screen tower, splitter feed chutes, gathering conveyors, stockpile conveyors, and walkway platforms were galvanized.  The screening plant is in constant state of vibration, requiring  precision for all bolt together assemblies. The galvanizer provided uniformity for all ladders, stairs and platforms ensuring solid connections that will remain corrosion free.

In an industrial marine development, the Romeoville plant blends perfectly with the surrounding  environment making it a community friendly  operation providing employment to local people. 

This system processes limestone in a very harsh, wet environment. The system is subject to constant moisture, being hit by limestone material, and nicked by small grains of limestone. The abrasion resistance  of the HDG coating will mean little or no maintenance for decades. The customer had required a coating that would provide a long usable life with minimal maintenance. They also wanted an environmentally friendly coating. With HDG all their requirements were accomplished for durability, sustainability, and environmentally friendliness. The Romeoville plant has the capability to produce 1800 tons per hour of crushed limestone in various sizes used in highway construction, building products and other manufacturing processes.