CHS Worthing rail project

Welcome to the new CHS Worthing rail project update! The project started September 14, 2023. Since then, the majority of the work has been underground. Going forward, we will see more above-ground changes start to take shape. Exciting times ahead!

Current statistics:

Around 4,000 yards of concrete and 1.2 million lbs. of rebar.
100% of deep foundation in the ground – over 3,500 yards of concrete in 467 auger cast piles

Rendering of complete project — **Figure 1:** 3D Rendering of completed project.

**Figure 2:** Aerial Photo taken 07/08/24 of current project site

Week of July 1, 2024 Highlights

The lumber brigade continues at the Worthing project! The team has completed the inside portion of the slip form. With wall thickness ranging from 8” to 16”, the team has started moving the inside forms to begin work on the outside forms. As shown in the pictures, the slip form is constructed from 2×6 framing along with tongue and groove fencing to create a nice clean circle.

The dryer foundation and scale foundation have been poured, completing all the major foundations for our project. The dryer foundation will support our new 7500-bushel-per-hour dryer, allowing us to dry grain 24/7 if needed. The scale foundation will hold our new 120’ inbound scale, which, combined with our existing scale, will speed up truck traffic and help our customers get back to the field quicker.

The Federal Grade Inspection building was erected throughout the week. This building will be used to inspect and grade our shipments. Samples will be taken from our loadout to ensure we are shipping the best quality grain from our facility.

**Figure 3:** Here is a closer look at the inner wall of one of the large grain tanks. You can see the design created using tongue and groove fencing, which ensures a secure and stable structure.

**Figure 4:** Rebar getting tied for the grain dryer foundation.

**Figure 5:** Flying saucers – Inner slip form removed to work on out slipform

**Figure 6:** Here are a couple of inner slip forms for the circle bins and an inner slip form for one of the star bins.

**Figure 7:** Overhead view showing the inner slip form shapes taking place.

**Figure 8:** Here is the beginning of the slip form for a couple of overhead bins and the bulkweigher loadout. This loadout will be used to weigh the grain before it is loaded onto the railcar, ensuring accurate measurements and efficient operations.

**Figure 9:** The foundation for our new scale got poured. Team is working on the truck approaches for the scale.

**Figure 10:** Federal Grain Inspection Building taking shape.

Aerial photo of new terminal to date of June 24 — **Figure 2:** Aerial Photo taken 6/24/24 of current project site

Week of June 24, 2024 Highlights

This week at the Worthing Ag Terminal Project, our theme was all about lumber! The team has started assembling the intricate slip form that will shape our future elevator. Over the next few weeks, this form will gradually rise from ground level to 140 feet in the air.

Last week, we also poured the truck approaches on both sides of the receiving building and laid the foundations for the inspection and scale buildings. Meanwhile, our electricians are busy connecting the electrical systems in the motor control room. It’s exciting to see the progress!

View of concrete slab of floor and forms for elevator bins — **Figure 3:** The start of the slip form is underway! Here, you can see the concrete wall that will be positioned between two of the elevator bin tanks.

View of construction workers working on forms for bins — **Figure 4:** A couple of overhead bins are being formed, along with a star bin located between the large circular bins.

Wide view of entire project showing concrete slab and forms — **Figure 5:** View of the slipform and bin shapes taking place.

Wide view of entire project with concrete slab floor and wooden forms started for bins — **Figure 6:** View from the north of the overhead bins and bulkweigher area of the slip.

Overhead view that shows the shape and forms of entire structure — **Figure 7:** Overhead view of the shape of the elevator when it’s poured.

More concrete is poured for additional structure — **Figure 8:** The team can’t go a week without making a few concrete pours. They poured the truck approaches for the trucks to come in and out of the elevator receiving building.

View of foundation for the scale — **Figure 9:** The foundation for our new scale shack has been poured. It will be situated between our existing outbound scale and the new inbound scale to the south.

**Figure 2:** Aerial Photo taken 6/24/24 of current project site.

Week of June 17, 2024 Highlights

As everyone knows in our area, last week was incredibly wet, with our project receiving over 17 inches of rain. Despite the relentless downpour, our dedicated crew continued to make progress, working tirelessly rain or shine. During the rainy days, the team was busy behind the scenes stripping forms underneath the elevator mat in the tunnel and working in the woodshop, cutting pieces for the slip form. They even navigated through water to reach the project site.

The milestone for the week is the completion of the elevator mat. The final 500+ yards of concrete were poured, finishing the foundation for the silos. This achievement involved tying 340,000 pounds of rebar by hand and completing three large pours totaling over 1,650 yards of concrete. To put it in perspective, that’s enough concrete to pour over six miles of sidewalk. Our civil contractor demonstrated exceptional skill in managing the site’s water drainage. Thanks to the well-designed ground, all the water drained off the project site into our ditches, ensuring no damage despite the heavy rains. There was even some light-hearted discussion about potentially accepting barges through the new facility due to the depth of the water. Thankfully, the water has receded, and the project remains on track without any damage.

Our civil contractor demonstrated exceptional skill in managing the site’s water drainage. Thanks to the well-designed ground, all the water drained off the project site into our ditches, ensuring no damage despite the heavy rains. There was even some light-hearted discussion about potentially accepting barges through the new facility due to the depth of the water. Thankfully, the water has receded, and the project remains on track without any damage.

**Figure 3:** Aerial photo of the elevator mat being poured

**Figure 4:** The final elevator mat pour has commenced, utilizing over 500 yards of concrete and more than 100,000 pounds of rebar.

**Figure 5:** The elevator mat is now complete. The team is currently marking out the silos in preparation for building the forms.

**Figure 6:** The team has stripped off the plywood in the basement below the elevator mat. This area is our reclaim tunnel, which will house an 80,000 bushel per hour conveyor.

Aerial photo of project site as of June 10, 2024 — **Figure 2:** Aerial photo taken 6/10/24 on current project site

Week of June 10, 2024 Highlights

The primary highlights included increased use of rebar and concrete. This focus is essential for completing the elevator mat, which will allow us to progress towards slipping the silos. The team successfully poured an additional 500 yards of concrete, as illustrated in the accompanying photos, demonstrating significant progress on the elevator mat.

In addition to this major pour, the team completed several smaller pours, including the control room floor, which will house the controls for the elevator, and the footings for two of the fall protection towers. Once completed, we will have 600 feet of fall protection, ensuring the safety of our grain operations team when opening or closing railcar lids.

Our electricians have been diligently working in the motor control room, installing electrical panels that will supply power and control the elevator. Additionally, our local electric cooperative activated the electrical transformer, providing us with the necessary 4000-amp power required to operate the elevator efficiently.

Second elevator mat utilzing 500 yards of concrete and over 100,000 lbs rebar — **Figure 3:** The second elevator mat pour has commenced, utilizing 500 yards of concrete and over 100,000 pounds of rebar.

Aerial photo of elevator mat as of June 10, 2024 — **Figure 4:** An aerial photo of the elevator mat shows that over two-thirds of it has been poured, with the remaining portion scheduled for completion next week.

Second elevator mat with rebar as of June 10, 2024 — **Figure 5:** The rebar being installed for the elevator mat, also known as the pile cap. This structure sits atop the auger cast piles and supports the entire elevator.

Motor control room progress as of June 10, 2024 — **Figure 6:** Motor control room progress – panels are being installed.

Image of fall protection flooring — **Figure 7:** Fall protection footing – 600 feet of fall protection will keep our employees safe loading train.

Control room floor as of June 10, 2024 — **Figure 8:** The control room floor has been poured and is ready for the builders, who will be on site after the 4th of July to erect the receiving building and control room office.

**Figure 1:** 3D Rendering of completed project.

**Figure 2:** Aerial Photo taken 6/10/24 of the project site.

Week of June 3, 2024 Highlights

This week was marked by substantial progress in both concrete and rebar work. Over 680 yards of concrete were poured within a seven-hour period, a notable achievement in our construction timeline. The process was impressive to observe, with significant changes unfolding throughout the day. Our team utilized multiple vibrators to ensure the concrete settled well between the rebar, complemented by a large super screed to achieve a level surface. The coordination required among team members for this extensive pour, covering approximately 40% of the elevator mat at a thickness of three feet, was exemplary.

Our rail contractors were also onsite to reassemble the rail system, which had been temporarily out of service due to the installation of tunnels and conveyors beneath. This reassembly is a crucial step towards future train loading operations.

Additionally, plumbing installations were completed for the onsite bathroom, and efforts are underway to connect water to the elevator. These seemingly small but essential steps are preparing us for the construction of the control room building.

This week also saw a peak in workforce presence, with 55 employees onsite, including our general contractor, rail contractor, electrical contractor, plumbers, and electric cooperative. It is impressive to witness the dedicated efforts of everyone involved, each contributing to the successful construction of the elevator.

**Figure 3:** Rebar installed and ready for the big pour.

**Figure 4:** After the first 40 trucks, the team began using the super screed to level the concrete.

**Figure 5:** By the time 65 trucks had delivered their loads, the concrete was starting to reach the end point.

**Figure 6:** 680 yards of concrete delivered by 85 trucks. The shapes of Bins 11 and 12 are now clearly visible

**Figure 7:** The rail system is being reassembled. We are fortunate to be able to shut this down while still utilizing the small loop for offloading fertilizer.

**Figure 8:** Plumbing for our bathroom and utility room in the control room building.

**Figure 2:** Aerial Photo taken 6/3/24 on current project site

Week of May 27, 2024 Highlights

After 8.5 miles of drilling and 3500 yards of concrete in over 450+, the auger cast piles or deep foundation is complete. This is a huge milestone for the project.

The team is now focused on the elevator mat. As mentioned before the heavy lifting continues with putting in rebar for the elevator mat. The team has worked hard over the last week placing and tying rebar by hand. You can see in the picture how much rebar is being installed. They are working from south to north to start pouring the elevator mat in the next week.

The MCC room continues to take shape and is close to being wrapped up for the next phase. The steel roof and walls are being installed.

The new inbound scale dirt work is complete and ready for the forms and foundation to get the new scale placed and ready to be in service for this fall.

**Figure 3:** Steel going up in the MCC Room ceiling and walls, doors being installed.

**Figure 4:** Concrete forms are done for the elevator mat as well as you can see all the auger cast piles are installed. Finishing the forms shows the shape and how the elevator will look as it goes up.

**Figure 5:** Can see some of the 400,000 lbs of rebar getting installed in for the elevator mat.

**Figure 6:** Closer view of how complicated this rebar is to be installed all by hand and tied together.

**Figure 8:** Can’t see a whole lot here but groundwork is complete for the scale and scale building foundation to be set. This new scale foundation will be for the new inbound scale to pair with the existing scale to be the outbound scale speeding up traffic flow.

**Figure 2:** Aerial Photo taken 5/23/24

Week of May 20, 2024 Highlights

We’ve had some exciting developments over the past week! Our first above-ground structure, the Motor Control Room (MCC room), is now taking shape. Additionally, we’ve placed a transformer right next to the MCC room, which will soon be connected by our local power cooperative.

Concrete has been poured for the west and east rail approaches, allowing our rail contractor to return and put our track back in service. The concrete under the rail will help keep things tidy and clean after loading trains.

We’re down to about three working days left on our deep foundation work. With 93% of the deep foundation completed, over 3,300 yards of concrete have been poured into 417 of the 451 auger cast piles that will support the elevator. Once this is finished, the team will focus on installing 400,000 pounds of rebar into the Elevator Mat. This mat will evenly distribute the weight of the elevator across the deep foundation piles. The Elevator Mat will be a three-foot-thick concrete slab, requiring nearly 2,000 yards of concrete or 250 cement trucks.

The foundation for the control room building, which will connect to the receiving building, is also being prepared. Once this is poured, we can proceed with erecting the control room and receiving building.

**Figure 3:** 6 completed silo roofs ready to be placed in the slip form

**Figure 4:** Forms for the Cconcrete mat that will sit on all the auger cast foundations being formed. This mat will have a 3’ thick piece of concrete with over 400,000lbs of rebar in it.

**Figure 5:** The start of the rebar being installed for the elevator mat.

**Figure 6:** MCC Building was built quickly, along with electrical transformer set in place.

**Figure 7:** Floating foundation for control room of the elevator. This is one of three places where the elevator can be controlled from.

**Figure 8:** Concrete rail approaches in place

**Figure 2:** Aerial Photo taken 5/13/24 of the project site

Week of May 13, 2024 highlights

We had two big concrete pours last week. They poured the south receiving floor, where trucks will drive to dump grain. They also poured the north rail and truck pit. The concrete foundation pad for the 4,000 amp transformer that will supply power for the project is ready for the local power company to install. Silo roofs are being put together and two are complete and staged for installation.

The existing scale has been taken down for preparation of the foundation that the new scale building will sit on. Digging has begun for the new inbound scale footings.