Quarry Built as Greenfield Project
The APAC Mid-South Warren County Quarry is a state-of-the-art processing plant and rail load out facility that is constructed on a 1,200 acre site owned by APAC Mid-South in Warren County, Georgia near the town of Camak. Construction of the plant required 250 acres of disturbed area for the plant.
This design-build project is a green field quarry with a granite processing plant and rail load out facility. As the Construction Manager, Brasfield & Gorrie provided a preliminary conceptual design and a civil design. In addition, the development of the bid packages, the bid process and the contracting process were completely managed by Brasfield & Gorrie and all contracts were held by Brasfield & Gorrie.
Brasfield & Gorrie managed all construction activities including the site development, processing equipment, structures, conveyors, a truck scale, paving and railroad construction. The site development consisted of over 1,000,000 cubic yards of structural fill for the construction of the plant, rail bed, and entrance road. Overburden removal for the initial and future pit developments was used for the structural fill material needed for the project. Also, as a part of the site development, roughly 200,000 cubic yards of rock removal through drilling and blasting was crushed and used as the stone required for site development. We were also responsible for implementation of the civil engineer’s erosion control plan, installation of 3,500 linear feet of storm water piping, and the construction of two lakes for capturing runoff water including 80,000 square yards of 40 mil HDPE liner. A rail spur from the CSX mainline track was needed for shipping out material and required the installation of 22,704 linear feet of rail track with steel ties. The steel ties were chosen to minimize routine maintenance of the track. The rail work included all turnouts, crossovers, and installation of a precast concrete crossing for the entrance road. Additionally, asphalt paving and striping was required for the entrance road and office parking lot area, along with a certified truck scale and wheel wash.
The primary portion of this project consisted of the design and construction of a complete granite processing facility. This began with the surge pile stacker and concrete reclaim tunnel, where the granite crushed at APAC’s temporary primary and secondary crushing plant is stockpiled. From the surge pile, the stone is conveyed to the finishing plant or Tertiary/ Quaternary Plant, where the stone is sized for specific product gradations with five vibratory screens and three cone crushers. This finishing plant produces a base material, ballast, 56s, 7s, 89s, or various other aggregate products through blending. Fines that are screened out will produce a M10/Screenings product, along with manufactured sand. The graded products are stockpiled on the ground or onto a corrugated multi-plate reclaim tunnel using fixed conveyors or radial stackers. The continuous conveyor through the three reclaim tunnels sends the products to the two rinse screens to be washed in preparation for load out into rail cars. Once the product has been washed, it is loaded into railcars with a radial stacker feeding two 35-ton bins constructed over the two rail tracks. A very small amount of finished product will be stockpiled on the ground for local truck sales.
The project also included a fines recovery plant, where the rinse water containing fines will be pumped, so the fines can be retained for production of sand products, and the water can be cleaned and re-used. The entire processing and load out facility is automated, and can be controlled from several control booths in the plant.