overview

Major order: thyssenkrupp Polysius commissioned SGS with the mechanical and electrical installation of a complete cement clinker production line

Industry

Stone/Earth/Cement

Status

In progress

Country

Airvault, France

Services

Construction management & supervision, Electrical installation, Mechanical assembly, Project management

An exciting environmental project is underway for the #SGSteam in Airvault, France. Thyssenkrupp Polysius commissioned SGS Industrial Services with the mechanical and electrical assembly and piping installation of a new 4,000-ton-per-day cement clinker production line. The cement plant is being modernized at Heidelberg Materials France Ciments in Airvault, France. Once completed, the new state-of-the-art production line will replace two existing production lines. The goal is to nearly double clinker production while significantly reducing CO₂ emissions. To carry out the assembly work safely and efficiently, SGS will have up to 500 employees on site during peak periods. Completion is scheduled for spring 2026.

500

Employees in action

3 years

months of construction

7000

tons of steelwork

8000

tons of Equipment

800

km cable

500

tons piping

Project data

Commissioner: thyssenkrupp Polysius France S.A.S.
Customer: Heidelberg Materials France Ciments
Industry: Stone/Earth/Cement
Construction location: Airvault, France
Contruction period: 3 years
Contributors: 500 at peak times

Scope of delivery & service

Mechanical and electrical installation, including piping installation, of a complete cement clinker production line with a capacity of 4,000 tons per day.

Mechanical assembly:

7,000 tons of steel construction
8,000 tons of mechanical equipment
350 tons of piping
Double-shaft hammer crusher with a throughput of 1,200 t/h
Longitudinal mixing bed
quadropol® QMR² 45/23 roller mill with a throughput of 370 t/h
Tangential mixing silo with a storage capacity of 10,000 t
Single-strand, 5-stage dopol® cyclone preheater with integrated calciner
3-support rotary kiln
polytrack® clinker cooler
Processing plant for solid substitute fuels
Dust extraction systems

Electrical installation:

800 km of cable installation
15,000 cable connections
28 km of cable support systems

Project overview

Our contract comprises approx. 7,000 tons of steel structures, approx. 8,000 tons of equipment, 500 tons of piping, and 800 km of cable.

Main components for raw material processing:

Double shaft hammer crusher with a throughput of 1,200 t/h
One longitudinal mixing bed
One quadropol® QMR² 45/23 roller mill with a throughput of 370 t/h
One tangential mixing silo with a storage capacity of 10,000 t for raw meal

Kiln line consisting of:

dopol® cyclone preheater with integrated calciner
3-support rotary kiln
Polytrack® clinker cooler

The plant also includes:

A processing plant for solid recovered fuels (SRF)
Dust extraction systems

Challenges & special features

The cement plant will remain in full operation throughout the entire construction period and commissioning of the new kiln line. In addition, the size and complexity of the project require good coordination and specific expertise in plant construction. Heights of up to 120 m and heavy lifts pose a challenge for our experienced SGS team.

New assembly method worldwide

The 120 m high dopol® preheater tower is being assembled for the first time using a new “upside down” concept (polfast®). Here, the preheater stages, including refractory lining and electrical systems, are prefabricated in parallel on a ground-level assembly platform. These individual segments are lifted and positioned from the inside. This process requires precise and safe work combined with good coordination.

State-of-the-art technology

The cement plant sets new standards in terms of safety and sustainability. The plant guarantees future-proof cement production with significantly reduced emissions.

About our customer thyssenkrupp Polysius GmbH

thyssenkrupp Polysius provides technologies, services, and modernization solutions for cement plants, focusing on optimizing performance and sustainability across the entire plant lifecycle. Leveraging deep process expertise, long-standing industry experience, and technology-driven optimization approaches, Polysius supports plant operators worldwide in improving operational efficiency and sustainably reducing emissions in existing assets.