Taking down an 850,000-bushel grain bin is not a job for brute force alone.

For Global Bin Builders, an Iowa-based contractor specializing in grain storage construction and repair, dismantling large steel storage bins is a carefully engineered process that relies on experience, planning and the right equipment.

The company recently completed the dismantling of an aging grain storage bin at a poultry feed mill in Rose Hill, N.C., where crews used a Terex TRT 80US rough-terrain crane to remove the structure one section at a time rather than simply pulling it over.

Sound Heavy Machinery photo

"We're basically taking it down piece by piece," said Jim Rothers, vice president of Global Bin Builders. "There are elevators, conveyors, and other material handling equipment around it the customer wants to protect. You can never be certain when you are pulling something over."

The bin, which measured approximately 186 ft. in diameter and held an estimated 850,000 bushels of corn, had reached the end of its service life after years of operation.

"Everything has a lifespan," Rothers said. "Some things that cost more have a longer lifespan and some less expensive designs have a shorter lifespan. This particular design had reached that point."

The facility has replaced the aging steel structure with five slip-formed concrete storage silos, each capable of holding roughly 400,000 bushels. Together, the new structures provide modern storage capacity designed for decades of service.

Specialized Niche

CEG photo

Although Global Bin Builders, led by Stephanie Voxland, president and Rothers' wife, is known today for constructing and repairing grain bins across the United States, the company began much differently.

Rothers originally operated a millwright business repairing conveyors and material handling equipment at grain facilities. As more customers called asking for grain bin work, he shifted the company's focus.

"The phone just kept ringing," he said. "I followed where the demand was."

That decision transformed the business.

"I worked with four people then," Rothers said. "Now we work with about 100 people."

Today, erecting new grain bins remains the company's primary business, but repair work has grown significantly, particularly after severe storms damaged grain storage facilities across the Midwest.

The company also has developed proprietary repair methods that allow damaged bins to be restored without complete disassembly.

"We've developed repairing a bin without taking it completely down and rebuilding it," Rothers said. "It's often about a 50 percent savings."

The technique, which the company calls "repair in the air," allows crews to replace roofs and repair structural components while leaving much of the original bin standing.

Global Bin Builders has completed projects from Connecticut to Oregon, although 70 percent of its work remains concentrated in Iowa, Nebraska, Wisconsin, and the Dakotas.

Careful Demolition

Sound Heavy Machinery photo

At the North Carolina project, the dismantling sequence began at the top of the structure.

Crews first removed roof sections using grinders, impact tools, and the crane before moving to the supporting rafters. Torch cutting was scheduled to begin as demolition progressed, with the sidewalls removed after the roof structure had been dismantled.

The controlled process minimizes the risk of damaging nearby infrastructure while allowing steel components to be safely lowered to the ground.

"It's safer," Rothers said. "There's equipment around it that they don't want damaged."

Crane Fits Job

To complete the dismantling, Global Bin Builders rented a Terex TRT 80US model series rough-terrain crane from Sound Heavy Machinery out of Wilmington, N.C. Rated at 80 tons, the crane features a five-section, full-power boom that extends to 138 ft. and a 35-ft. jib that can be positioned at 0-, 20- or 40-degree offsets to provide additional reach over the grain bin. The four-wheel-drive, four-wheel-steer crane rides on a single-carrier chassis and uses four hydraulic outriggers to provide a stable lifting platform while crews removed roof sections and structural components.

The combination of boom length, jib configuration and lifting capacity allowed operators to safely lower steel sections from the top of the approximately 186-ft.-diameter structure without disturbing surrounding conveyors, elevators, or other equipment.

Rothers said he discovered the crane while searching for equipment available near the project site and rented it with the possibility of purchasing it after the job.

"It's really working well for us."

Sound Heavy Machinery photo

Built in Italy, the crane appealed to Rothers because of its rugged construction and straightforward operation.

"It's stout," he said. "It doesn't get pushed around by the wind so much."

Rather than choosing a crane loaded with electronic features, Rothers said he values reliability and simplicity.

"I like simple. There are cranes you can spend a lot more money on with more bells and whistles, but there is also a lot more to maintain."

For the type of work Global Bin Builders performs, he believes uncomplicated equipment is often the better investment.

"I want to turn the key and go to work. If I step away for 15 minutes, I want my number two guy to be able to get in the crane and run it without having to figure out a complicated computer system."

He acknowledged that sophisticated crane technology has its place, particularly on congested urban job sites where advanced load monitoring systems and automated safety features are required.

"If you're in lower Manhattan, that's a different situation," he said. "Those cranes have a place."

For grain storage projects, however, he said the TRT 80US crane's conventional load charts and straightforward controls are exactly what his crews need.

"I'm just going to put my outriggers all the way out and go to work," Rothers said. "I don't need to spend another $100,000 on features we aren't going to use."

After consistently exceeding job site expectations, the crane proved its value, leading Rothers to purchase it from Sound Heavy Equipment.

Nationwide Reputation

Despite working in a specialized segment of the construction industry, Global Bin Builders has steadily expanded through referrals and relationship building.

Rothers credits the company's growth to hiring a dedicated salesperson who attends industry conferences, meets with insurance adjusters, and maintains customer relationships.

"It's a small industry. Word of mouth goes a long way."

That reputation has helped the company build and repair grain storage facilities throughout the country while tackling increasingly complex projects, including replacing roofs on 100-ft.-diameter grain bins without dismantling the entire structure.

Whether erecting new storage facilities, restoring storm-damaged bins or carefully dismantling aging structures like the one in Rose Hill, Rothers said the company's focus remains the same: completing challenging work safely, efficiently and with equipment that matches the job.