US Gypsum Kiln Rebuild Project: A Testament to Precision and Efficiency

The US Gypsum Kiln Rebuild Project, which began in 2023, was a meticulously planned and executed effort to ensure the continued reliability andefficiency of the kiln system. Spanning two years, the project involved a dedicated crew working on-site every week, along with seven scheduled outages, each lasting one week and running 24-hour shifts. With over 10,000 man-hours and more than 100 skilled craft workers contributing throughout the project’s duration, the rebuild was successfully completed on time and within the expected schedule.

The project required mobilizing and demobilizing all necessary manpower, materials, tools, and equipment to safely execute the work. A superintendent and a team of millwrights were deployed to handle the mechanical work. Over the course of two years, a rotating workforce of skilled craft workers, including millwrights, welders, and riggers, played a crucial role in maintaining efficiency and safety throughout the rebuild.

The project was executed with precision, efficiency, and a commitment to safety, with the team working in a 24-hour shift structure during scheduled outages to minimize production downtime. Over two years, a dedicated crew remained on-site every week, ensuring that all aspects of the kiln rebuild were carried out effectively.

Key factors contributing to the project’s success included meticulous scheduling of seven planned outages to minimize disruption, efficient workforce management, and proactive maintenance efforts to improve kiln reliability and prevent unexpected failures.

By maintaining a structured approach and adhering to the planned timeline, the US Gypsum Kiln Rebuild Project was completed successfully. The project resulted in enhanced kiln performance and longevity, reduced downtime through well-coordinated execution, and a safer, more reliable operation. The expertise and dedication of the team ensured that the project met all expectations while upholding the highest standards of quality and safety.