POLYGON MACHINE
BOLTED SEGMENT KITSET
CEMENT SILO AND MINERAL SILO
Bolted segment kitset silos are increasingly favored for storing cement, minerals, and other bulk materials. Unlike traditional welded silos formed as single units, these modular silos consist of pre-fabricated steel segments assembled on-site using bolts. This article examines the advantages of bolted kitset silos over welded types, comparing aspects such as cost, transport, installation ease, maintenance, and long-term durability. We also explore key applications and current adoption trends in Europe and the U.S., showing why these systems are gaining popularity across multiple industries.
Why choose Polygon Machine?
Polygon Machine delivers certified quality (TSE & ISO 9001), global expertise, and durable solutions from 30 m³/h to 240+ m³/h. Polygonmachine is a trusted partner in both compact and large-scale projects.
What cement silo types are available?
Stationary, mobile, and horizontal cement silos—plus cement feeders, filters, and safety systems. Every unit is customizable to match your storage, capacity, and operational requirements.
How is long-term support handled?
Polygon Machine ensures fast setup, training, and after-sales service, minimizing downtime. All plants include modern automation and safety features for easy, efficient use.
Overview of Bolted Segment Kitset Cement Silos
Polygon Machine Bolted segment kitset silos have emerged as a popular solution for storing cement, minerals, and other bulk materials. These silos are composed of pre-fabricated steel segments that are bolted together at the installation site, as opposed to traditional welded silos which are fabricated as a single unit. This article provides an in-depth look at bolted kitset cement/mineral silos and compares them with welded silos in terms of cost, transportation, installation, maintenance, and durability. We also explore use cases and current trends in Europe and the U.S., highlighting why bolted silos are gaining traction in various industries.
Overview of Welded Silos
Polygon Machine Welded silos come in a variety of sizes but are often limited by transportation constraints if they are shop-fabricated. A typical shop-welded silo might be up to about 8–12 feet (2.5–3.5 m) in diameter so that it can be transported by road on a truck trailer. Larger diameters (above ~14 feet) become difficult to ship as a single piece and may require special permits or escort vehicles due to oversized load regulations. For this reason, very large capacity welded silos are usually constructed on location (field-welded piece by piece) or replaced by bolted designs. Still, welded silos are favored for permanent installations where the silo will remain in place for decades. They can be custom-built with specific heights, diameters, and features (e.g. integrated foundations or unique shapes) to suit a facility’s layout. The result is a durable, heavy-duty storage solution with minimal seams and exceptional longevity.
What makes bolted segment silos different from welded silos?
Bolted silos consist of pre-fabricated steel segments assembled on-site, making them easier to transport and install compared to one-piece welded silos.
How easy is the installation of bolted silos?
A 100-ton capacity bolted silo can be assembled by a small crew in just a few days without the need for heavy welding equipment.
Are bolted silos cost-effective?
Yes. They offer lower transportation and installation costs, especially for large capacities, while maintaining excellent durability.
What industries use these silos?
They are widely used in construction, agriculture, mining, and bulk material handling across Europe, the U.S., and beyond.
Cost Considerations: Initial Investment and Overall Economics
Cost is a key factor when choosing between bolted and welded silos. Bolted kitset silos are often touted as a cost-effective option for bulk storage, particularly for larger capacities. Their modular construction allows manufacturers to mass-produce standard panels and ship them efficiently, which can lower transportation and fabrication expenses per volume stored. In many cases, bolted silos require a lower upfront investment than an equivalent-capacity welded silo – one industry source notes that bolted silos tend to be the “most cost-effective option,” whereas welded silos may demand a higher initial investment for the same storage volume. This is especially true when considering field-assembled large silos: assembling one large bolted silo can be cheaper than delivering and installing multiple smaller welded silos to get the same capacity.
However, it is important to note the nuance in cost structure. The manufacturing cost of a bolted silo can be slightly higher than that of a similar-sized welded silo due to the additional engineering of flanges, bolts, and seals, as well as the need for on-site assembly labor. In other words, making many bolted panels with precise bolt holes, gaskets, and coatings is a bit more complex than fabricating a plain welded cylinder. On the other hand, transportation and deployment costs for bolted units are usually lower – standard container or truck shipment is possible without special permits, and site assembly can be done without heavy welding equipment. Welded silos, if delivered as one piece, might incur high transport fees (for oversized loads) or require specialized lifting trucks. If built on-site, welded silos need skilled labor and potentially more on-site fabrication time, which adds to cost. Thus, when total cost of ownership is considered (including delivery and installation), bolted silos often come out ahead for large or remote projects. In summary, bolted silos minimize costs through modular production and easier logistics, while welded silos may carry higher initial costs in scenarios where transport and on-site constraints make delivery difficult.
TRANSPORTATION AND LOGISTICS
Optimized Transport Efficiency with Bolted Segment Silos
Transportation requirements sharply differentiate bolted and welded silos. Bolted segment silos are designed with logistics in mind – all the silo components can be broken down into shippable segments or panels.
Typically, these parts can be packed into standard trucks or shipping containers, allowing economical transport by road, rail, or sea. This avoids the need for special oversized load permits in most cases.
Moreover, manufacturers often stock standard bolted panels in inventory, which means orders can be fulfilled and shipped faster, reducing lead times for urgent projects.
Welded Silos and the Challenges of Oversized Transport
Welded silos, in contrast, face more challenges in transport. A fully welded silo is a rigid, bulky unit that must be hauled on a flatbed or special truck. As mentioned earlier, the diameter and height of a shop-welded silo are constrained by what can legally and safely travel on highways (typically under about 12 feet wide without escort).
Larger welded silos (e.g. those needed for high-volume cement storage) might not fit within these limits and thus require special transportation planning – this could involve highway permits, escort vehicles, or moving at off-peak hours, all of which increase cost and complexity. There is also a higher risk of damage to the silo during transport, since any dent or impact to the one-piece structure could compromise its integrity.
In fact, one industry datasheet notes that with bolted silos, individual panels are less likely to be significantly damaged in transit (and can be replaced if needed), whereas a welded tank delivered in one piece has “less chance of individual components being damaged” simply because there are no separate parts – but any damage that does occur to the single unit is harder to fix.
Global Shipping and On-Site Assembly: The Bolted Advantage
For international shipments or long-distance trucking, bolted silos clearly hold an edge. They can be containerized and shipped globally with ease.
A welded silo, if required overseas, might even need to be welded together after shipping (to get around transport size limits), effectively turning the project into a field-weld job. Field-welding on site is possible but typically more labor-intensive and time-consuming than bolted assembly.
In summary, bolted kitset silos offer superior logistics flexibility – they are purpose-built to travel in pieces and be reassembled anywhere, while welded silos are constrained to feasible shipping sizes or else demand on-site fabrication when scales get large.
INSTALLATION AND ASSEMBLY
Step-by-Step Assembly of Bolted Silos On Site
When the silo components arrive at the site, the installation process diverges significantly between bolted and welded designs. Bolted silos require on-site assembly: the steel panels must be lifted and bolted together in sequence, often starting from the bottom rings and working upward (for vertical silos).
This process is somewhat like erecting a giant metallic shell by joining dozens or hundreds of plate segments. The assembly does require a trained crew and equipment (usually a crane or jacks to hoist segments into place, and hand tools or pneumatic wrenches to tighten bolts).
However, it is generally efficient – bolted silos are engineered for relatively quick construction. For example, one manufacturer reports that a 100-ton capacity bolted silo can be fully assembled by a team of just 3 workers in about 3 days.
Rapid Installation Advantage of Pre-Fabricated Welded Silos
Welded silos can take two paths for installation. If a welded silo is delivered as a complete unit, installation simply involves preparing the foundation and then lifting the silo into place. A crane will hoist the entire silo and set it onto its base or supporting legs. This process is very fast – essentially the silo is “stood up” and anchored, which can happen in a matter of hours once the crane is on site.
Indeed, in cases where a suitable crane and clear space are available, a delivered welded silo can be erected with less labor and time than assembling an equivalent bolted silo panel by panel. There are fewer pieces to handle (just one big piece), eliminating the step-by-step bolting work.
This is a benefit on sites where skilled labor is scarce or time is extremely critical. However, a major prerequisite is that the silo could be transported to the site in one piece, which, as discussed, is feasible only for moderate sizes and accessible locations.
Field-Welded Silos vs. Modular Builds: Site Constraints and Labor Considerations
The other scenario is field-welding: when a silo is too large to ship, crews may weld it together on-site from steel plates or sections. Field-welded silo construction is more akin to a typical construction project – it requires certified welders, welding equipment, and often extensive scaffolding or specialized jacking systems to construct the silo vertically.
This process can be time-consuming and must follow strict quality controls (non-destructive testing of weld seams, proper weather conditions for welding, etc.). As a result, field-welding is usually reserved for very large silos or certain materials (it’s more common in liquid storage like fuel tanks). For dry bulk like cement, many operators prefer bolted silos over field-welded because of the simpler assembly.
Moreover, site conditions can influence the choice: if the installation space is tight or indoors, it might be impossible to maneuver a fully welded silo into position, necessitating on-site assembly of a bolted silo that can be built in situ. In summary, welded silos have the advantage of faster setup if delivered fully built, whereas bolted silos require assembly effort but offer more flexibility in where and how they can be erected. Project managers must weigh the availability of installation time, local labor, and equipment when choosing between the two.