Client Background

The client is a coal-fired thermal power plant in Poland that supplies electricity and heating to surrounding cities. As European environmental regulations become increasingly strict, the local environmental protection agency required the plant to enclose its existing open-air coal storage yard. This is to eliminate coal dust blowing in high winds and prevent rainwater from washing the coal and generating "black water" pollution. Due to the high building density on site and the complex network of underground pipelines and cables, traditional reinforced concrete coal sheds could not be built. The client urgently needed a semi-permanent, fast-installation covered coal yard structure that could be erected without damaging the existing ground.

Client Needs and Challenges

Strict Environmental Dust and Runoff Control

The structure had to be completely sealed against rain to prevent contaminated water. At the same time, it needed excellent sealing to ensure that coal dust would not escape through gaps during high winds.

High-Frequency Access for Heavy Machinery

Wheel loaders and heavy coal dump trucks need to drive directly inside for pushing and unloading. The client required fully open access at the front. There could be no obstructing columns. In addition, the clear height and width had to be generous enough to accommodate large machinery safely.

Ventilation and Combustion Prevention

Long-term coal stacking can lead to oxidation and heat buildup, creating a risk of spontaneous combustion. Because the structure is enclosed for rain protection, it was equipped with customized louvered vents that balance rain prevention with air circulation, preventing dangerous overheating.

No Damage to Existing Hardened Ground

The coal yard surface consists of thick hardened concrete, and the client strictly prohibited large-scale excavation. The fixing method had to be wind-resistant and safe while causing minimal damage to the original ground.

Solution

LINGTONG TENT planned two modular aluminium coal storage shed tents with a 20m span and 30m length on two vacant areas of the plant, enclosing a total area of approximately 1200㎡.

Structure and Layout

The main frame uses 6061-T6 high-strength aluminium alloy. The clear-span design means no internal columns, keeping the interior completely open. The front features a fully open design with no obstructions, allowing loaders to drive directly inside. To handle wind pressure from the open front, the frame was reinforced and densified at the entrance.

Dust, Rain, and Ventilation System

The roof and sidewalls use high-strength double-layer PVC-coated polyester fabric, providing waterproof and flame-retardant performance. To address the risk of spontaneous combustion, customized rainproof and dustproof aluminium ventilation louvers were installed on the upper-middle sections of the sidewalls. This design ensures internal air circulation to dissipate heat and dust while preventing diagonal rain from entering and coal dust from escaping.

Safety and Fixing

Because the ground could not be damaged, the tent bottom uses heavy steel beam bases, fixed to the concrete surface with localized chemical anchors and supplemented with extensive ballast blocks. This ensures absolute structural safety in the open, windy location of the power plant. Explosion-proof LED lighting was installed inside for night operations.

Product Information

Implementation Process

The project started in spring 2024. The LINGTONG engineering team confirmed the tent placement based on site videos and dimensions provided by the client, avoiding underground pipelines. All aluminium profiles, fabric, and louvers were prefabricated at the factory and shipped by sea to Poland.

On-site installation was carried out by a local team hired by the client. Since no heavy civil engineering machinery was required, only small cranes and lifts were used, greatly minimizing interference with the plant's daily power generation and coal handling operations. The installation sequence was: assemble the aluminium frame, lift the structure, install the fabric and side louvers, and install the front access and explosion-proof lighting. Both tents were delivered and put into use within 25 days.

Final Results and Client Feedback

After being put into operation, the two structures passed the strict inspection of the local environmental agency. The client reported that following several severe wind and rainstorms, the stored coal remained dry and no contaminated water was produced. The louver design effectively dissipated heat in summer, eliminating the risk of spontaneous combustion. The open-access front doubled the efficiency of loader operations, meeting the plant's 24/7 coal supply needs. The client noted that the whole process was highly efficient, from initial design to final commissioning.

Client Feedback

Summary

This project demonstrates the immense value of modular industrial structures in the environmental upgrade of traditional energy sectors. LINGTONG TENT quickly solved the dust and contaminated water issues of an open coal yard in Poland through customized louvers, fully open access, and foundation-free fixing methods. This enclosure delivers reliable performance with minimal damage to the original ground, making it an ideal choice for power plants and coking plants looking to enclose coal yards and expand storage capacity.

Supplementary Notes

This case study is based on a coal yard enclosure project at a thermal power plant in Poland. European countries have strict regulations on dust emissions and leachate from open coal yards, requiring enclosed upgrades. These prefabricated structures require no heavy civil machinery on site, making them highly suitable for existing plants with dense underground pipelines. These structures can be equipped with industrial-grade accessories such as fully open fronts, ventilation louvers, and explosion-proof lighting to meet the long-term or semi-permanent environmental storage needs of bulk materials like coal and ore.