Tusker was commissioned by Irish Cement to replace an ageing Electrostatic Precipitator (ESP) Inlet Wall filter system, essential for emissions control and environmental compliance. The project required a complete end-to-end solution, which Tusker delivered entirely in-house — covering design, fabrication, transport, and installation.

The existing ESP system had become inefficient and difficult to maintain. Tusker’s objective was to deliver a high-performance replacement that would improve particulate capture, integrate with existing infrastructure, reduce maintenance, and provide long-term durability.

A bespoke modular system was developed to suit the site’s spatial constraints. Key innovations included optimised airflow, improved electrode configuration, and a modular design for off-site fabrication and easier on-site assembly.

Fabrication took place at Tusker’s facility, incorporating 150mm-thick specialist insulation rated to 650°C, and custom-rolled aluminium cladding for durability and thermal performance. Precision welding ensured all internal joints were airtight.

The structure was transported as abnormal loads, assembled on-site, and lifted into position using in-house designed and tested lifting beams — minimising crane time and installation risk. During the same shutdown window, Tusker also replaced drag chains, bearings, and serviced mechanical systems.

The completed system significantly improved efficiency, reliability, and compliance, and was delivered safely, on time, and within budget.

This project exemplifies engineering excellence, innovation, and quality. Tusker’s ability to deliver a complex, high-performance system entirely in-house, from design to installation, demonstrates unmatched capability and coordination. The use of specialist materials, custom lifting solutions, and seamless execution make this a benchmark project in industrial engineering.

Tusker recently achieved a significant milestone by successfully completing our full external recertification audits for both ISO 14001 (Environmental Management) and ISO 45001 (Occupational Health & Safety Management) standards, with zero non-conformities raised.

In addition, Tusker holds the following certifications:

EN 1090 Execution Class 4 – the highest level of certification for structural steel fabrication in Europe, demonstrating our capability to deliver complex and safety-critical structures.

ISO 3834 – confirming our compliance with international standards for welding quality, ensuring the integrity and reliability of welded components in demanding applications.

ISO 9001 – reflecting our dedication to consistent quality management and continuous improvement.

These certifications collectively highlight Tusker’s commitment to excellence, compliance, and industry leadership.