Turn-key Capital Projects
From concept drawings and custom fabrication through erection, commissioning, and final start-up of your aggregate processing facility.
Capital projects live or die on coordination. The TSS Group self-performs plant design, structural fabrication, and field installation. Whether you are building a greenfield processing facility, replacing a primary jaw station, or retrofitting a multi-deck screening circuit, your project is delivered by a single accountable engineering and installation team, eliminating the delays, handoff gaps, and finger-pointing common with multi-contractor job sites.
- Concept-to-commissioning capital project delivery
- Crushing, screening, washing and material handling systems
- In-house structural fabrication and field erection crews
- Scheduled around your production and shutdown windows
Why Aggregate Producers Partner with TSS
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MSHA-Trained Field Execution:
Every field crew member is MSHA Part 46 certified and operates under strict Job Safety Analysis (JSA) protocols. -
In-House Structural Fabrication:
Heavy-duty catwalks, transfer towers, chutes, and support steel built specifically for abrasive aggregate environments.
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Single-Source Accountability:
One scope, one budget, one schedule, and one project manager from initial site scan to turn-key start-up. -
Minimized Unplanned Downtime:
Tie-in schedules engineered specifically around your planned maintenance outages and production cycles.
Complete Concept-to-Commissioning Delivery
We begin every capital project with a comprehensive site walk, laser scanning, and a detailed review of your production goals. From there, we develop detailed layout drawings, structural calculations, and equipment integration plans tailored to your site’s topography and flow requirements.
Once engineering is finalized:
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Commissioning:
We run cold and hot testing, calibrate drives, monitor vibration, and verify tonnage rates alongside your operational team before handoff.
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Installation:
Our experienced millwright and rigging crews set equipment, build conveyors, execute precision alignment, and tie into existing circuits.
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Fabrication:
Our shop fabricates structural towers, heavy-duty chutes, rock boxes, catwalks, and support steel to heavy industrial standards.
Core Plant Capabilities & Systems
| System / Capability | Services Included |
| Crushing & Screening Stations | Primary jaw replacements, secondary/tertiary cone circuits, VSI installations, double/triple-deck vibrating screen swaps, and grizzly feeder upgrades. |
| Sand & Washing Circuits | Complete wash plant erection, log washers, coarse material washers, hydrocyclones, dewatering screens, and settling pond pipework. |
| Material Handling Systems | Overland field conveyors, overland transfer towers, radial stackers, surge bins, turn-head chutes, and automated truck load-out structures. |
| Structural & Support Steel | Structural towers, heavy plate chutework, impact beds, access walkways, handrails, stairways, and maintenance platforms built to OSHA/MSHA specs. |
One contractor from drawing to start-up
We begin with a site walk and a production goal, then develop layout drawings, structural design and an equipment plan around it. Our shop fabricates the towers, chutes, catwalks and support steel; our millwright crews set the equipment, align the drives and commission the circuit. You approve one scope, one schedule and one point of contact.
- Conveyor systems, transfer towers and load-out structures
- Structural steel, chutework, platforms and access
- Greenfield plant design and installation
- Crushing station replacements and upgrades
- Sand and wash plant erection
Built for aggregate production realities
Our crews come out of quarries, sand plants and asphalt operations. Projects are staged so that tie-ins happen during planned downtime, laydown areas keep haul roads open, and the plant returns to full rate on the day we promised. Every field employee is MSHA Part 46 trained and works to a documented job safety analysis.
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Heavy Wear Protection:
Chutework and wear points are pre-lined with AR400/500 plate, rubber, or ceramic liners based on your specific material abrasiveness.
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Precision Outage Tie-Ins:
Major structural cut-ins and electrical/mechanical tie-ins are scheduled to align perfectly with your seasonal or scheduled shutdown windows.
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Smart Site Staging:
Equipment, crane paths, and laydown areas are mapped to keep active quarry haul roads and pit operations running safely without interruption.
Proven on multi-million dollar CAPEX work
The TSS Group has delivered CAPEX projects for national producers including CRH, Martin Marietta and Vulcan Materials, new tertiary crushing stations, primary jaw crusher replacements, grizzly feeder swaps, double screen replacements and complete sand plant erections across the Mid-Atlantic and Southeast.
Frequently asked QUESTIONS
Can you handle the engineering as well as the build?
Yes. Our engineering team produces the layout, structural and fabrication drawings, and the same organization builds and installs them, which removes the usual gap between the design set and what fits in the field.
Will you work around our production schedule?
Always. Most of our capital work is staged so cutovers happen inside planned shutdowns or weekend windows, with pre-fabricated assemblies ready to set.
Can single-source Design & Build reduce project costs?
Yes. By self-performing design, fabrication, and installation, we eliminate the 15% to 25% markup markup that general contractors typically add to sub-contracted work. Furthermore, because our fabrication team reviews drawing sets before steel is cut, we catch fit-up issues early in shop drafting rather than discovering costly alignment errors in the field.
Do you work with specific equipment brands?
We are brand-agnostic. We regularly design structures and integrate machinery from all major OEMs, including Metso, Sandvik, Superior Industries, KPI-JCI, McLanahan, and Deister. We can engineer structures around equipment you have already purchased or specify optimal machinery based on your target TPH and rock friction testing.
What geographical regions do you cover?
Our primary footprint covers the Mid-Atlantic and Southeast regions, but we regularly mobilize structural crews, heavy rigging equipment, and project management teams for major CAPEX build-outs and plant retrofits across the Eastern United States.
