Rendering Plant

Introduction

Incon was engaged to undertake a structural assessment of the existing roofing structure at the Thomas Foods International Rendering Plant in Murray Bridge, South Australia. The project formed part of an operational upgrade to support the installation of mechanical ventilation systems aimed at improving process efficiency and environmental performance. The scope focused on evaluating the structural capacity of the existing roof to safely accommodate new roof-mounted exhaust fans within a live industrial processing facility.

Project
description

The project involved assessing the suitability of the existing roof structure to support multiple mechanical ventilation fans installed across key processing zones, including meal processing, blood processing, wet processing, and tallow areas. As illustrated in the design layout, the proposed system included roof-mounted axial fans with a design flow rate of approximately 6.049 m³/sec, strategically positioned to

The assessment was undertaken within an operational rendering plant environment with complex internal layouts and existing services.

Challenge

The existing roof was not originally designed for additional mechanical loads, requiring careful verification of structural capacity and load distribution.
The installed fans introduced not only static loads but also potential dynamic effects such as vibration and operational loading.
Installation locations were within highly congested processing areas, requiring coordination with existing services, ducting, and equipment.
Different fan options (3-fan and 4-fan configurations) required assessment of varying load cases and structural implications
All assessments and proposed solutions needed to minimise disruption to plant operations.

Solution

Incon delivered a practical and engineering-driven structural assessment:

Evaluated the impact of fan units on the existing roof structure, including dead loads, operational loads, and potential vibration effects.
Assessed key structural elements (roof beams, purlins, and connections) to confirm adequacy or identify strengthening requirements.
Developed structural sketches for fan mounting that ensured:

Efficient load transfer into primary structural members
Avoidance of over-stressing secondary elements
Compatibility with existing roof geometry and services

Reviewed multiple fan configurations to provide flexibility in design and installation options.

Outcome

The project enabled Thomas Foods International to proceed with ventilation upgrades by:

Confirming the structural suitability of the existing roof system
Providing clear guidance on fan installation and support requirements
Minimising risk of structural overstress or long-term performance issues
Supporting improved airflow management and plant efficiency
Enabling upgrades with minimal disruption to ongoing operations

Incon’s approach ensured a balance between structural integrity, operational requirements, and constructibility within a complex industrial environment.

Key Engineering Value Delivered

Integration of new mechanical loads into existing structures without full redesign
Risk mitigation through detailed structural capacity assessment
Flexible design options supporting multiple fan configurations
Practical, construction-ready recommendations for live plant environments

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