KEY METRICS / TAKEAWAYS
- Project Scope: Removal of two turbine generators, a 400,000-gallon fuel oil storage tank, 120-foot elevated water tower and various connected utilities, in Sherman, Texas.
- Value: $402,992
- Volume:5 Acres
- Timeline: January 2025 – May 2025
- Safety: Zero recordable incidents
- Recycling: 4 loads of C&D in 40yd containers, 800 Tons of concrete recycled for onsite use, 482 GT of Steel Recycle. Nearly 100% of sites materials were recycled or used
- Peak Workforce: 14 Team members (6 days a week)
- Special Equipment: 2021 Kobelco SK500LC-10 Excavator, 2019 Kobelco SK350LC-10 Excavator, CAT 950F Front Loader 2023 54″ TAG Bucket (for E-354), Strickland Concrete Pulverizer CP60, Balderson Forks Front loader
- Digital Tools: TWE proprietary equipment tracking app, real-time cameras, telematics, DJI Mavic Pro 3 drone
OVERVIEW
Total Wrecking & Environmental (TWE) was selected by STEC Sam Rayburn Selectives’ project in early 2025 and tasked with removing several redundant pieces of process equipment from the active power plant.
There were extremely sensitive components such as the removal of two turbine generators, one fuel oil storage tank, one elevated water tank, and various utilities connecting the equipment to the process loop, all of which posed logistical challenges that demanded precision and efficiency.
The Total Wrecking & Environmental team completed the project ahead of schedule and they were able to do so under budget. Staying true to the “Environmental” part of their name, they were able to recycle nearly 100% of the project’s materials.
CHALLENGES
The project presented several significant obstacles from the outset. The two turbine generators were tightly boxed in by critical infrastructure, including an active cooling tower, gas boiler, switchyard, and surrounding roadways. This limited space left no room for traditional dismantling or removal strategies and heightened the risk of disrupting live plant operations.
The 400,000-gallon fuel tank added another layer of difficulty. Positioned in an earthen pit with narrow road access, the tank’s location made heavy equipment mobilization challenging and raised environmental concerns due to residual fuel still present inside.
The 120-foot water tower introduced its own set of constraints. Surrounded on three sides by active plant systems, the structure required careful consideration of proximity hazards, potential impact on live utilities, and worker safety at height.
Beyond these major structures, the site demanded careful attention to ancillary challenges. These included managing hazardous materials such as asbestos, universal waste, underground utilities, and residual chemicals or oils, each requiring specialized handling and coordination to avoid delays or incidents.
COLLABORATION SPOTLIGHT
The Sam Rayburn project required seamless coordination with STEC personnel to ensure active plant operations were never interrupted.
TWE supervisors worked directly alongside the plant’s project management team, holding daily safety and logistics briefings.
On-the-fly adjustments, from generator dismantling sequences to tank debris haul-off schedules, were made jointly to keep the project on track while protecting sensitive plant operations.
The collaboration earned repeated praise from STEC’s leadership for TWE’s professionalism and minimal disruption to operations.
PROCESS & HIGHLIGHTS
- Generator Removal: Turbine generators were dismantled in place using torch cutting and precision sequencing, with components safely downsized and recycled.
- Fuel Tank Decommissioning: Oil recovery and capping operations ensured compliance, followed by torch-cutting and controlled collapse of tank walls into the pit for efficient cleanup.
- Water Tower Felling: Controlled felling eliminated overhead risks and preserved surrounding infrastructure. The tower was quickly downsized and recycled with a full-sized shear.
- Foundation & Utility Work: Tank and tower foundations were demolished, voids backfilled, and utilities capped and removed to restore the site to original condition.
- Digital Oversight: Drones, telematics, and TWE’s proprietary tracking app were used for equipment monitoring, safety documentation, and real-time project visibility.
SUSTAINABILITY ACHIEVEMENTS
Nearly 100% of site materials were recycled or reused, including 482 gross tons of steel and 800 tons of concrete repurposed for onsite use! Oil, asbestos, and universal wastes were safely recovered and disposed of in full compliance with environmental regulations.
By combining careful planning with advanced equipment and recycling methods, TWE upheld its reputation for environmental responsibility and sustainability leadership.
RESULTS & CLIENT TESTIMONIAL
The Sam Rayburn project was completed ahead of schedule, under budget, with zero incidents, all while protecting live operations inside an active power plant.
STEC leadership praised the TWE team for its professionalism, communication, and precision, highlighting the ability to deliver high-quality results with minimal disruption.
“The Sam Rayburn demolition showcased the value of planning, skill, and teamwork. Despite the challenges of confined spaces, active infrastructure, and sensitive environmental conditions, TWE’s crew executed every task with safety and efficiency. Their performance exceeded expectations at every stage.”
— STEC Plant Manager
OVERALL
The Sam Rayburn Selective Plant Demolition is a clear example of how Total Wrecking & Environmental brings big-project expertise to even smaller-scale jobs.
By combining safety-driven planning, precise execution, and near-total recycling, TWE once again delivered results that reinforced its reputation as a trusted demolition partner capable of handling complex, sensitive industrial environments with confidence and care.