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Holcim Cement Plant

St. Genevieve, MO

Mammoth Industrial Delivered in Award-Winning Style.

PayneCrest was saluted with an AGC Keystone Award for expertly managing the largest electrical contract ever in the region to power the mammoth Holcim Cement Plant. Sprawling over 2,900 acres, Holcim is the world’s largest single kiln cement plant with a more than one-mile-long production process producing four million metric tons of cement annually. The electrical package was its most complex element. Managing more than 400 electricians at its peak, PayneCrest provided 345,000 volts of power directly from the Ameren Rush Island Power Plant and built its entire electrical infrastructure.

“In size, scope and complexity, no project locally has ever required the intense electrical needs as the Holcim Cement Plant near Ste. Genevieve, Mo.” — Rudy Blum, project manager, Holcim (US) Inc.

4.5 M

Feet of cable

250,000

Feet of cable tray

75

Schedules each aligned with a separate cement manufacturing process

37

Miles of fiber strands

Project Image
Project Image

Project Highlights

  • 100-plus electric motors exceeding 200 horsepower and 50-plus electric motors powered by four kilovolt (KV) or 13.8KV feeds
  • Coordinated 400-plus electricians with 3,000-plus journey workers from 15 different trades to maximize overall project construction efficiencies
  • Power and control circuiting consisted of 24,564 unique cables with 219,000-plus terminations.
  • Intricate process wiring for machinery from multiple international suppliers including rock crushers, bucket elevators, air slides and more
  • Improved design and engineering to reduce overall construction costs by 30%.
  • Precision sequencing of electrical installations to accommodate assembly of 250-plus different types of machinery

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