Hot Gas Duct & Valve Replacement

Irish Cement Ltd

Tusker delivered a complete engineering solution for Irish Cement — fabricating, delivering, and installing a replacement Hot Gas Duct and Valve for Coal Mill 3 entirely in-house, completed safely and on schedule within a tightly controlled annual shutdown window.

Client:

Irish Cement Ltd

Service:

Service

Location:

Drogheda, Louth

The Project

During Irish Cement's annual plant shutdown, Tusker was tasked with replacing the Coal Mill 3 Hot Gas Duct and Valve — a large, complex ducting system critical to plant operations. The project called for detailed planning, precision fabrication, specialist lifting, and efficient installation, all delivered within a fixed shutdown schedule.

The Challenge

Coordinating fabrication, delivery, removal, and installation within a fixed shutdown window
Managing large-scale lifting and site access requirements
Meeting Irish Cement's stringent safety procedures throughout
Achieving precise alignment of the new duct and valve assembly with existing plant infrastructure
Minimising risk while maximising efficiency during a time-critical shutdown period

The Solution

Tusker carried out a detailed site assessment and engineering review before fabrication began, then manufactured the entire replacement ducting and support structure in-house — including forming, rolling, and bending duct sections, welding heavy-gauge steel ranging from 5mm to 10mm thick, and producing bespoke supports and connection points. 3D scanning technology was used throughout to verify dimensions and ensure accurate integration with the existing plant, giving the fabrication team a high degree of precision before anything reached site.

On site, the scope covered the full lifecycle of the works: establishing exclusion zones, dismantling and removing the existing assembly, installing a new single vane damper, and managing all access and lifting requirements using cranes, teleporters, MEWPs, and scaffolding. Keeping fabrication in-house gave Tusker full control over quality and programme risk, and allowed close coordination between the workshop and the site team throughout.

The Result

The new duct and valve assembly was fabricated, delivered, installed, and commissioned safely within the shutdown period, allowing Irish Cement's plant to return to operation as scheduled. The project delivered a durable, precisely aligned solution built to integrate seamlessly with existing infrastructure — a result of close collaboration across Tusker's fabrication, mechanical, lifting, and site management teams.