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Silos are massive engineering feats designed to withstand immense pressure. However, because they are subject to constant loading and unloading cycles, even minor structural compromises can lead to catastrophic failure. At Marietta Silos, we believe understanding the why behind silo collapse is the first step toward prevention.
- Design Errors and Improper Loading
A silo is designed for specific flow patterns, either funnel flow or mass flow. When a silo is repurposed for a different material than originally intended, or when asymmetrical loading occurs, lateral wall pressures can exceed design limits. This imbalance often leads to wall buckling or total structural failure. - Foundation Settlement and Deterioration
The weight of a fully loaded silo is immense. If the foundation settles unevenly (differential settlement), it creates tilting or leaning. This shifts the center of gravity and introduces stresses that the concrete or steel walls were never meant to handle. Regular foundation checks are a critical part of our professional inspections. - Corrosion and Concrete Delamination
For concrete silos, carbonation and chloride intrusion can cause the internal reinforcing steel (rebar) to rust. As the steel expands, it causes the concrete to spall or delaminate, stripping the silo of its structural "skeleton." In steel silos, oxidation and wall thinning from abrasive materials create weak points that can "zipper" open under pressure. - The Domino Effect of Roof Failures
A collapsing roof doesn't just damage the top of the silo; it often compromises the entire structure. Roof failures are frequently caused by excessive vacuum pressure during discharge or over-pressurization during pneumatic filling when venting systems are clogged.
Engineering a Safer Future
At Marietta Silos, we don't just repair silos; we engineer solutions. From Jumpform and Slipform construction to advanced structural restoration, our team ensures your storage assets meet the highest safety standards.
Get started today with a structural evaluation of your silo.
At Marietta Silos, we believe a well-maintained silo is not just a structure; it's a guarantee of safety, longevity, and uninterrupted performance. While trained professionals must perform silo inspections and all structural repairs to prevent silo failure or serious injury, there are still things facility managers can check for regularly.
Use this checklist to empower your facility managers to conduct safe, simple visual checks from the exterior and know exactly when it's time to call our silo experts.
Part 1: Exterior Warning Sign Checklist for Facility Managers
Facility managers should perform these visual checks safely from the ground or a securely guarded platform. Your goal is to spot the warning signs that trigger a professional service call.
Part 2: Structural Inspection & Restoration (Always Call Marietta Silos)
The following tasks require specialized engineering knowledge, non-destructive testing (NDT) tools, or confined space entry training. Marietta Silos professionals must be called for these tasks.
Conclusion
A disciplined approach to silo inspection, repair, and restoration helps avoid costly downtime, extends service life, and ensures safety.
If you've spotted a structural warning sign, don't delay, contact Marietta Silos for support on your next inspection or restoration project today.
For decades, silo inspection has relied on a trained eye, methodical evaluation, and years of experience identifying signs of wear and deterioration. While that expertise remains essential, new technology is helping Marietta Silos take inspection accuracy and efficiency to another level. Our AI Silo Inspection service combines artificial intelligence with drone-based data collection to provide a clearer, more complete picture of your silo's condition.
A Smarter Approach to Structural Health
AI Silo Inspection uses drone capture technology to collect high-resolution images and video of the entire exterior of a silo or bulk storage container. These images are processed using proprietary software that creates a 3D digital twin of the structure. From there, artificial intelligence algorithms analyze the surface to detect cracks, spalling, corrosion, and other types of damage.
Each defect is recorded on the 3D model, identified by type, and ranked by severity. The result is a visual, data-driven record of the silo's condition that can be used for maintenance planning, budgeting, and risk assessment. Because the AI software can detect even very small defects, smaller than 0.1 millimeters, it provides a level of detail that helps identify issues long before they become critical.
Faster, Safer, and More Consistent
Traditional exterior inspections often require scaffolding or rope access, which can limit visibility and increase downtime. Using drones allows our inspectors to safely access every part of a silo's exterior, regardless of height or location. In many cases, images can be collected in a matter of hours, giving facility managers the information they need without interrupting operations.
The AI Silo Inspection report provides detailed analytics, including images, damage mapping, and severity rankings, along with Marietta Silos' professional recommendations. When used annually, this service builds a consistent record of exterior condition over time. Tracking changes year by year helps facility managers identify trends, prioritize repairs, and reduce the likelihood of unexpected failures.
Supporting Comprehensive Silo Care
AI Silo Inspection can be used as a standalone service or as a supplemental inspection between regular professional inspections. It is also available as an add-on to one of Marietta Silos' three inspection levels. By integrating AI-driven analytics into an ongoing maintenance plan, businesses gain a more reliable foundation for asset management and budgeting.
As part of our commitment to advancing silo safety and performance, Marietta Silos continues to invest in tools and techniques that make inspections more precise and efficient. AI Silo Inspection represents an important step in that direction, combining modern data analysis with our long-standing expertise in silo engineering and repair.
To learn more about how AI Silo Inspection can enhance your maintenance strategy, visit mariettasilos.com/ai-inspection.
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