Hot Gas Duct and Valve Replacement – Irish Cement

The Hot Gas Duct and Valve Replacement for Irish Cement showcases Tusker Steelworks' ability to deliver a complete engineering solution, combining in-house fabrication expertise, specialist lifting capability, and exemplary project management within a critical annual shutdown period.

What sets this project apart is the fact that Tusker delivered the entire package from start to finish. The project involved the fabrication, supply, delivery, removal, lifting, installation, and commissioning of a new hot gas duct and valve assembly, while maintaining the highest standards of safety, quality, and efficiency. Every aspect of the works was carefully planned and executed, including the establishment of exclusion zones, dismantling and removal of the existing assembly, installation of a new single vane damper, provision of all fixings and materials, and the management of all access and lifting requirements using cranes, teleporters, MEWPs, and scaffolding.

A key differentiator was Tusker's ability to fabricate all ducting and support steelwork entirely in-house. Using advanced fabrication techniques, including forming, rolling, bending, and welding of 5mm–10mm plate steel, the team produced a high-quality, bespoke solution tailored to Irish Cement's operational requirements. Maintaining full control of fabrication ensured exceptional quality standards, reduced programme risk, and enabled seamless coordination between workshop production and site installation.

The project also demonstrated outstanding teamwork and integration across Tusker's fabrication, mechanical, lifting, and site management teams. This collaborative approach allowed the duct and valve replacement to be completed safely and efficiently within the shutdown window, ensuring the plant was ready to return to operation as scheduled.

The successful outcome delivered long-term value to Irish Cement through a durable and precisely installed solution that aligned accurately with existing infrastructure. Beyond the technical achievement, the project highlights Tusker's commitment to safety, innovation, quality workmanship, and customer-focused delivery.

This project deserves recognition because it exemplifies the very best of engineering excellence, an end-to-end solution delivered safely, on schedule, and to the highest standards of fabrication and installation. It is a testament to Tusker Steelworks' capability to undertake complex industrial projects and successfully transform engineering challenges into practical, high-quality results.