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Abyek Cement Factory is located at km 80 of the Tehran–Qazvin Highway.
The objective of this project is to increase the production capacity of the Abyek Cement Factory. The project includes the renovation and strengthening of the existing pre-heater, which remains in operation during construction. This makes the execution process particularly complex, as the production line continues to operate simultaneously. The execution works consist of adding and removing selected steel members and constructing a 64 m-high, three-story steel structure adjacent to the existing pre-heater. The kiln feed structure, located next to the new pre-heater, is a 38 m-high reinforced concrete structure with seven floors.
The additive and reject silos are 27 m and 38 m high, respectively, and are constructed of reinforced concrete with varying wall thicknesses. Since the roof of this structure is made of concrete and there are concrete tunnels inside and beneath the silos, the construction process is particularly complex.
The gypsum silo is a 22 m-high steel structure with a 7 m diameter, located adjacent to the aforementioned structures.
The Abyek Cement Factory Development Project involved the renovation, strengthening, and expansion of existing industrial structures to increase the production capacity of the cement plant. The project was executed under complex operational conditions, as the existing pre-heater structure remained in service during the construction period, requiring careful coordination between ongoing production activities and construction operations.
The scope of work included the modification and strengthening of existing steel members, construction of a new 64 m-high, three-story steel structure adjacent to the existing pre-heater, and execution of associated reinforced concrete and steel structures. The project also included the construction of a 38 m-high, seven-story reinforced concrete kiln feed structure, additive and reject silos with heights of 27 m and 38 m, and a 22 m-high steel gypsum silo with a 7 m diameter.
The construction activities comprised 6,000 m³ of concrete works, 800 tons of reinforcement, 14,000 m² of formwork, and 1,100 tons of steel works. Executed by Omran Maroon Engineers Co. as the Contractor, the project was completed in accordance with technical specifications and contractual requirements during the 12-month construction period, supporting the modernization and capacity enhancement of the cement production facilities.
The execution of the Abyek Cement Factory Development Project engaged multidisciplinary engineering, technical, and construction teams to perform complex renovation, strengthening, and expansion works within an operational industrial facility. The project required coordinated efforts from specialists in industrial construction, structural engineering, steel erection, reinforced concrete works, and site execution due to the simultaneous continuation of production activities during construction.
The modification of existing steel members, construction of new steel structures, execution of reinforced concrete buildings, and development of silo structures required skilled personnel capable of managing complex construction activities under operational constraints.
As the Contractor, Omran Maroon Engineers Co. organized and coordinated the project workforce, ensuring effective execution of construction activities and compliance with technical specifications and contractual requirements throughout the 12-month construction period.
Omran Maroon Engineers Co. manages the procurement and supply of construction materials, equipment, and site resources through an integrated supply chain management system. Procurement activities are carried out in accordance with project schedules, technical specifications, and quality requirements, ensuring the timely availability of materials and equipment while supporting efficient project execution.
