Slipform Construction for RCC Digester Tanks

Why Slipform Technology is perfect for BIO-CNG Digester tanks

Slipform construction is a continuous, vertical pouring method of reinforced concrete, supported by a hydraulically operated jacking system. Unlike traditional formwork that involves pouring concrete in multiple segmented lifts, slipform allows the entire structure to be cast as a single monolithic unit. As concrete is poured into the formwork at the base, the slipform system gradually moves upward, enabling seamless construction of tall, vertical structures. Slipform technology is especially beneficial for constructing circular, tall, and high-capacity digester tanks used in Bio-CNG projects. In Bio-CNG projects, the digester tank is the heart of the entire operation. These tanks must withstand internal pressure, corrosive gases, and prolonged chemical exposure during the anaerobic digestion process. As such, they must be built with precision, strength, and durability. Slipform construction is especially effective for building circular, vertical RCC digester tanks due to its unique ability to construct tall, cylindrical structures in a single, seamless operation.
 
Key Advantages of Slipform for Digester Construction
  • Uniform Wall Thickness & Smooth Curvature: Slipform construction ensures a perfectly circular profile with uniform wall thickness throughout the height of the tank. This is critical for structural balance and internal pressure resistance. The smooth inner surface also improves the flow and mixing of sludge, enhancing digestion efficiency.
  • No Horizontal Joints or Weak Zones: Traditional shuttering methods require stopping at intervals to allow curing, creating horizontal cold joints that are often weak points in the structure. Slipform eliminates this issue by continuously pouring concrete, resulting in a single monolithic wall without any breaks or bonding inconsistencies.

  • Faster, Crack-Free Construction: Because the pour is continuous, the chances of differential shrinkage and thermal cracking are significantly reduced. With 24/7 operation and real-time adjustments, slipform drastically reduces the construction timeline without sacrificing quality or finish.

  • Superior Structural Integrity & Leak Resistance: Bio-CNG digesters must be leak-proof and gas-tight to retain biogas effectively and prevent contamination. Slipform walls, being joint-free and monolithic, offer excellent impermeability and structural durability, outperforming conventional tanks in demanding bio-processing environments.

Conventional Shuttering

✘ Multiple joints between pours

✘ Slower due to staged formwork setup

✘ Higher chance of cold joints and cracks

✘ Complex & time-consuming for round forms

✘ Labor-intensive & dependent on skilled carpenters

✘ Repetitive manual operations with higher risk

Slipform Construction

✔ Continuous casting with no joints

✔ Faster completion time (24/7 casting)

✔ Monolithic, crack-free RCC walls

✔ Ideal for circular structures

✔ Reduced manpower & labor cost

✔ Higher safety & process automation