A Tight Squeeze — Solving a Complex Tank Repair Through a Tight Partnership

The environment of a tank repair can determine the difficulty level of the job. In this case, the job was challenging because of the tight space where the repair was completed and because a plant shutdown needed to be avoided. It was also on-site at an ethanol plant, where safety is of the utmost priority. 

At United Ethanol's facility in Milton, Wisconsin, an imploded tank needed to be repaired in tight quarters while minimizing disruption to ongoing plant operations. The challenge required a solution that considered constructability, safety, and field fabrication while avoiding impacts on the facility infrastructure.

Adaptive Stainless mobilized our team of experienced craftsmen with proven build methods and unique equipment to repair the vessel in place without removing infrastructure and the roof.  Paul Mueller Company supported the manufacturing effort through component preparation, quality assurance, and on-time delivery.

Adaptive Stainless utilized its specialized jack-and-build methodology, which allowed the existing tank to be dismantled level by level while the damaged portions of the vessel were replaced within the same footprint. Together, the teams successfully executed the replacement while minimizing disruption to ongoing plant operations. 

The innovative approach reduced costs, minimized operational disruption, and ensured project safety. By combining manufacturing support with field-driven problem-solving and execution, Adaptive Stainless and Paul Mueller Company successfully completed a complex tank repair within an active operating facility, demonstrating how strong partnerships and practical solutions deliver results even in the most constrained environments.

Not only were the customers impressed with the rigging used for this job, but they were also impressed by Mueller's ability to adapt to higher safety standards at United Ethanol because of the product processed in their facility.