Holcim cement kiln
Project Spotlight: Emergency Kiln Tyre Replacement at Holcim Westport
Kernohan’s long-standing relationship with Holcim’s Westport cement plant dates back to 1977, and over the decades we’ve supported many critical maintenance and engineering projects on site. One of the most challenging and rewarding of these came when Cement Kiln 2’s number 2 tyre failed, prompting an immediate call to action.
From Emergency Repair to Complex Replacement
What began as an emergency repair quickly evolved into a complex and high-risk replacement operation. With the plant approaching its scheduled closure in 2016, the priority was to identify a solution that was cost-effective, fit for purpose, and could reliably support the kiln for its remaining operational life.
The solution? A bold and first-of-its-kind approach—installing a laminated tyre, a method never before used in this application.
Six Months of Strategic Planning
Given the technical complexity and operational sensitivity, the project required six months of detailed pre-planning. Kernohan took on the lead project management role, working closely with Holcim and specialist suppliers to explore, design, and deliver the laminated tyre solution.
Our responsibilities included:
Coordinating all stakeholders and contractors
Managing risk and logistics
Overseeing the delivery of critical components
Planning and scheduling 24/7 work rotations
Execution Under Pressure: 12 Days, 40 Tradesmen, Zero Incidents
The on-site installation phase was completed in just 12 days, with 40 tradesmen working around the clock in rotating shifts. Despite the demanding pace and high-stakes environment, the project was completed on time, under budget, and with zero incidents—a testament to thorough planning, collaborative execution, and an unwavering focus on safety.
A Landmark Project in a Long-Term Partnership
This tyre replacement not only extended the life of a critical kiln but also demonstrated Kernohan’s ability to deliver innovative, large-scale industrial solutions under pressure. It remains a standout example of what’s possible through trusted partnerships, smart engineering, and disciplined project delivery.
