United States Gypsum, CO (USG) Washingtonville, PA


Automatic Systems, Inc. supplied the design, fabrication, and installation of the synthetic gypsum delivery system from the PPL Power Plant to the new wallboard facility in Washingtonville, PA.


Traveling tripper car

This system consists of seven belt conveyors conveying gypsum from two different sources: the PPL Power Plant and rail hopper car. The gypsum byproduct transfers from the PPL Power Plant conveyors onto a series of 30”, 270 TPH belt conveyors, labeled U1, U2 and U3. Conveyor U3 deposits gypsum onto a 48”, 1170 TPH tripper conveyor, C4, which transports the synthetic gypsum material into the storage building.

Gypsum is also brought to the facility via rail hopper car. The cars are positioned under a rail car shaker and empty into hoppers above two 72”, 450 TPH belt feeders, labeled C1 and C2. These belt feeders transport gypsum into either side a pant leg underground hopper. The hopper feeds a 42” 900 TPH delivery conveyor, C3, that conveys the gypsum from the underground railroad area up to Transfer Tower U3; and deposits it onto conveyor C4.


Flying the tripper car into the storage building
Tripper conveyor C4Gypsum rail car unload hoppers
Conveyor deck truss being erectedGrain storage bin used for shell of transfer tower