Aggregate Material Handling & Processing Facility

Location: San Antonio, TX

Type: Aggregate

Yards of concrete: 2,990

Pounds of rebar: 481,844

Completion: 2025

Description

This project focused on expanding an aggregate material handling and processing facility to increase production capacity through the construction of a new secondary plant dedicated to base material production. As one of Superior’s largest aggregate projects, it demonstrated our ability to execute complex concrete construction in a demanding, high‑pressure environment.

Scope of Work: Superior’s scope included the construction of reinforced concrete foundations for major plant infrastructure, including hoppers, electrical houses, dual log washers, dual screens, secondary screens, crushers, stationary stackers, and radial stackers.

Execution & Coordination: The project required detailed planning and precise coordination, particularly during a scheduled shutdown of the main conveyor system supplying the active plant. To minimize downtime, the team conducted a full dry run to verify that all new equipment would operate seamlessly once the system was restarted. During the shutdown, which coincided with a planned power outage, our crews safely and efficiently completed the concrete work, allowing plant operations to resume the following week.

Planning & Performance: The success of this fast‑paced project was driven by thorough pre‑planning and strong on‑site leadership. Ahead of the shutdown, the team pre‑tied rebar cages, pre‑cut formwork, and staged all required materials. This preparation enabled uninterrupted excavation, steel placement, and monolithic concrete pours, ensuring the project stayed on schedule.

Project Impact: This project stands as a strong example of Superior Construction Services’ commitment to quality craftsmanship, jobsite safety, and reliable performance under pressure.

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