Project Overview
The Cedar Rapids Papermill in Iowa features two high-performance paper production buildings, designed, cast, and erected to support the extreme demands of industrial paper manufacturing. These facilities have been operating under harsh conditions for 29 years since their completion in 1995, proving the resilience and longevity of precast concrete.
For the first production line building, precast concrete was used for the entire structure except for the elevated paper machine track, which was initially constructed with a traditional cast-in-place (CIP) system. The building featured precast concrete columns and beams for a durable frame, insulated wall panels for enhanced thermal efficiency, double-tee precast concrete roof panels for structural integrity, and an innovative precast concrete "Haunch-Slab" system, providing long-span, high-load platforms with up to 40% penetrations for pipes and ducts.
These Haunch-Slabs were designed with tapered ends to handle high shear forces and heavy industrial loads while maintaining a reasonable weight per piece. The CIP topping and emulative slab-to-beam connections ensured even load distribution along the support beams.
Impressed with the engineering efficiency and performance of the first building, the owner sought to accelerate the second production line’s construction. For the second production line, precast concrete fully replaced the other machine track, an industry-first innovation. The entire structure, including the precast concrete machine track, was designed, cast, and installed in a record 18 months—from contract signing to full-scale paper production. This significantly reduced the construction timeline, generating early production revenue for the owner.
Given the 877-mile distance between the precast concrete production facility in Conley, Georgia, and the job site in Cedar Rapids, Iowa, the entire project was shipped by rail, optimizing efficiency and reducing logistical challenges. Paper mills present one of the harshest environments for concrete structures due to high cyclic loading from 80-ton rollers and 120-ton paper rolls, 24/7 operations with minimal maintenance and unplanned shutdowns, constant exposure to moisture and steam, operating temperatures reaching 150°F, and thermal expansion and contraction due to shutdowns and restarts. Despite these extreme conditions, the precast concrete machine track remained in excellent working condition after 24 years of operation.
During an assessment conducted in 2019, it was discovered that machine speeds had more than doubled from 600 feet per minute in 1995 to 1,300 feet per minute, increasing vibration frequencies beyond the original design. Yet, only minor additional bracing was required—demonstrating the robust nature, resilience, and longevity of the emulative precast concrete frame. By 2024, the precast concrete machine track had endured approximately 5.2 billion loading cycles, a testament to the unmatched durability of precast concrete in industrial applications.
The Cedar Rapids Papermill project set a new standard for industrial construction, proving that precast concrete can outperform traditional methods in the most demanding environments. The success of the emulative precast concrete machine track not only enhanced performance but also paved the way for future industrial applications of precast concrete technology. Nearly three decades later, the project continues to serve as a testament to the strength, innovation, and longevity of precast concrete solutions. |