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U.S. Silica Frac Sand Mine

US Silica Frac Sand Mine - Exterior View of Conveyor System Construction

Engaged early in the project’s development, Boldt worked with Barr Engineering during the feasibility and detailed design phase providing budgeting, scheduling, constructability reviews and value management solutions to align the project with its budget. As the project moved from engineering to construction, Boldt worked with Barr Engineering to develop phased bid packages to allow for an early start to construction.

Soon thereafter, work began for U.S. Silica at their new 500 acre site in Sparta, Wisconsin. The initial projects were to construct a wet plant, cyclone tower, drying plants, storage building and administration building. Boldt self-performed concrete, masonry, steel erection and the installation of the conveyers. We were then awarded a second phase of construction near the end of the initial phase to double production at the facility.

The project included site improvements, a wet sand processing plant along with conveyor, wet scrubber and dryer installations along with supporting equipment. A dry sand screening and storage structure was erected and housed three Rotex mineral separators, nine process conveyors, four bucket elevators and a dust collection system, among other process equipment. Boldt was also responsible for the load out structure.


U.S. Silica

Sparta, Wisconsin

Barr Engineering

Boldt Role
  • Construction Manager
  • General Contractor
Project Type
New Construction

Industrial and Specialty Manufacturing

Project Highlights

  • This fast-track project was developed on a greenfield site. Project team collaboration through pull scheduling, self-performance of concrete, masonry, steel erection and the installation of the conveyors allowed production to begin on time.