Project 792-30 for Kemmerer WY Natrium tank

Project Overview

The scope of work centered around producing underground heavy-wall liners designed to support pressure vessels used in sodium-based energy production. We were provided with final engineering and fabrication specifications. From there, our responsibility was to deliver high-precision results on time and on budget.

Fabrication began at our Anacortes, Washington, facility. We produced several 13-foot diameter pipes from ¾-inch carbon steel plate, ranging from 36 to 48 feet in length. Each was fitted with a bottom plate and reinforced with studs for concrete embedment. The pieces were then coated using an epoxy system suitable for the expected conditions.

Larger components, including a massive 216-inch ID tunnel liner, were too big to fabricate completely in-shop. For these, T BAILEY LLC pre-rolled shell plates to radius, which were shipped loose and later assembled in the field by our team. Surface prep was conducted using our in-house Wheelabrator for the plate, while pipes were sandblasted to ensure ideal coating adhesion.

After fabrication and painting, the entire system was shipped to the final location, where our field crew mobilized for final assembly.

Challenges Faced

Executing this work on a next-generation energy facility meant we had to operate with minimal design context. While unusual, this wasn’t a hurdle because T BAILEY LLC specializes in projects where engineering is handled externally. By focusing exclusively on execution, we were able to streamline the production phase and deliver quality without delays.

The real challenges began at the site. In late fall, the location is known for its high winds and fast-changing weather, and the general contractor enforced strict safety protocols. Any wind events or lightning strikes within 10 miles resulted in an immediate work stoppage, which meant our team had to plan carefully and move quickly when conditions were favorable.

We also had to adapt our normal field erection methods. Typically, we stack and weld shell courses vertically one at a time. On this project, that approach would have left 30-foot sections exposed overnight, a major safety and structural risk in high winds. Instead, we pre-assembled five to six shell courses independently and staged them off to the side. When the weather window opened, the team quickly transitioned to vertical assembly, reducing exposure and improving efficiency.

For the larger-diameter tunnel liner, we used a modified erection process due to high wind conditions (up to 40 mph) on site. Instead of stacking and welding shell courses vertically one at a time, we erected each shell course independently and set it aside to avoid the risk of incomplete structures being blown over overnight. Once all courses were completed, we finished the round seam welds to finalize vertical assembly. This approach allowed us to complete each section by the end of the shift and significantly reduce safety risks.

The site itself added another layer of complexity. While we were erecting liners, other contractors were drilling 60-foot holes just 50 feet away. We also depended on them for crane support. This required daily coordination and precise planning to avoid operational conflicts. Thanks to strong communication and experienced foremen, interference was minimal, and progress remained steady.

The Key to Our Successful Outcome

This project highlighted what sets T BAILEY LLC apart: the ability to deliver full-service steel fabrication and erection under one roof. While most contractors either fabricate or field erect, we do both. That gave our client a streamlined, single-source solution at a time when no other team could deliver the complete package.

Our internal surface prep and coating capabilities played a critical role. The Wheelabrator system allowed us to process plates efficiently and ensure consistent surface quality. Combined with experienced in-house painters, we delivered fully finished liners that required minimal field touch-ups.

We also excelled in logistics. Moving 50-foot-long, 13-foot-diameter components weighing over 100,000 lbs from the Pacific Northwest to the final location was no small task, but for T BAILEY LLC, it’s standard. We routinely handle heavy-haul loads and know how to navigate complex transport scenarios safely and on schedule.

Most importantly, we adapted. From modifying our field erection strategy to coordinating with multiple contractors and complying with strict safety shutdowns, our team stayed ahead of potential delays by building proactive solutions into our plan from day one.

With our experienced workforce, in-house capabilities, and proven ability to deliver in dynamic environments, T BAILEY LLC successfully completed the fabrication and field erection of this critical infrastructure — safely, efficiently, and without compromise.

Final Thoughts

This project reflects the strengths that define T BAILEY LLC: adaptability, coordination, and the ability to self-perform complex work from fabrication to field erection. By delivering high-quality results under a tight schedule, in challenging weather, and with strict site conditions, our team once again proved why we’re trusted by leaders in next-generation energy.

Looking for a partner who can handle your next critical infrastructure project from start to finish? Contact T BAILEY LLC today to discuss how our in-house capabilities and field expertise can support your goals.