| Metric | Result | Context |
|---|---|---|
| 28 Days | Project Duration | Demolition and installation completed inside a 30-day outage window at an operating cement plant |
| 30 Days | Scheduled Duration | Outage window allotted by the plant for the full scope of work |
| 2 Days | Schedule Savings | Project finished ahead of schedule, returning the plant to production early |
| Ahead | Schedule Performance | Completed 2 days ahead of the planned timeline |
| 0 | Safety Incidents | Project executed incident free |
| 3 | Project Phases | Pre-assembly, demolition, and installation of the new clinker cooler |
| 2 | Companies Involved | Southern Welding as lead, with Elite Refractory in support |
Project Overview
Southern Welding was selected to support a Texas cement plant with the pre-assembly, demolition, and installation of a new clinker cooler at its Midlothian, Texas facility.
The project involved a large-scale installation that had to be completed within a tightly controlled 30-day outage window. With the plant’s ability to resume operations dependent on the completion of the work, maintaining the schedule was critical from day one.
Southern Welding’s scope covered three phases: pre-assembly of components ahead of the outage, demolition of the existing equipment, and installation of the new clinker cooler. Monte Holder led the project as Project Manager, with support from Jack Revey, Logan Shelton, and Sam Gibson.
Through careful project coordination and efficient field execution, the crew completed the demolition and installation portion of the project in 28 days—two days ahead of schedule—allowing the plant to begin running the new cooler two days earlier than planned.
Scope of Work
Clinker Cooler Pre-Assembly
- Preparation and pre-assembly of components for the new clinker cooler
- Work completed ahead of the outage to streamline field operations once installation began
Demolition
- Removal of existing equipment to make way for the new clinker cooler
- Careful coordination to maintain progress and prepare the work area for installation
Installation
- Installation of the new clinker cooler within the scheduled outage window
- Close coordination between project management, field crews, and supporting personnel to keep the work moving efficiently
Execution Under a Tight Schedule
The project was scheduled for 30 days, creating a clear and demanding target for the field team.
Southern Welding’s crew maintained focus on the critical path throughout the project and completed the demolition and installation work in just 28 days. Completing the project two days early gave the plant additional time to prepare for operations and allowed the new cooler to begin running two days ahead of schedule.
For an outage project, where every day can affect plant operations, maintaining momentum from pre-assembly through final installation was critical.
Strong project leadership was central to holding that schedule. Monte Holder led the project with support from Jack Revey, Logan Shelton, and Sam Gibson, coordinating the work from pre-assembly through demolition and final installation and keeping the project focused on the 30-day completion window.
Despite the size of the project and the compressed schedule, the work was completed incident-free, demonstrating Southern Welding’s ability to combine schedule performance with safe field execution on a major cement plant project.
What Made This Project Exceptional
A Large-Scale Installation in a 30-Day Window
The clinker cooler project involved significant demolition and installation work that had to be completed within a strict 30-day window. The size and complexity of the project made schedule management a critical factor in its successful execution.
Pre-Assembly for Efficient Installation
Pre-assembling components ahead of the installation phase helped the team prepare for the outage and maximize productive time once field installation began.
Two Days Ahead of Schedule
Southern Welding completed the demolition and installation in 28 days instead of the allotted 30 days. That two-day gain allowed the plant to begin running the new cooler earlier than originally planned.
Incident-Free Execution
The project was completed without an incident, demonstrating the team’s ability to maintain safe operations while executing a demanding installation on a compressed schedule.
Experienced Project Leadership
The project was led by Monte Holder, with support from Jack Revey, Logan Shelton, and Sam Gibson. Their coordination helped keep the project moving toward its aggressive completion target while maintaining safe and productive operations.
| Metric | Result |
| Project Scope | New clinker cooler |
| Scheduled Duration | 30 days |
| Actual Duration | 28 days |
| Schedule Savings | 2 days |
| Plant Startup | 2 days early |
| Safety | Incident-free |
| Location | Midlothian, Texas |
Southern Welding completed the project two days ahead of schedule, allowing the plant to begin running the new clinker cooler two days earlier than planned. For a cement plant operating within a tightly controlled outage window, completing a major equipment installation ahead of schedule helped minimize downtime and supported an earlier return to operation.
Customer Impact
Southern Welding helped minimize the time required to complete the outage scope and supported an earlier return to production.
Delivered By
Southern Welding
Project Manager: Monte Holder
Key Contributors: Jack Revey, Logan Shelton, Sam Gibson
Supporting Company: Elite Refractory
Services Provided
- Clinker Cooler Pre-Assembly
- Industrial Equipment Demolition
- Clinker Cooler Installation
- Cement Plant Maintenance
- Industrial Equipment Installation
- Outage & Shutdown Services
- Large-Scale Industrial Project Coordination
- Project Management
- Safety Planning & Execution
The Southern Welding Difference
The Texas cement plant clinker cooler project demonstrates Southern Welding’s ability to execute large-scale cement plant work within demanding outage schedules.
With only 30 days available for demolition and installation, the team completed the project in 28 days, finishing two days ahead of schedule and allowing the plant to begin running the new cooler two days early. The project was completed incident-free, combining schedule performance, operational efficiency, and safe execution.
30 days allotted. 28 days delivered. 2 days back to production. Zero incidents.
Have a Project Like This?
Southern Welding self performs demolition, pre-assembly, and installation work at cement and industrial plants across the country. Tell us what is on your outage schedule and we will tell you how we would run it.
[Contact Us] or call (469) 517-0410