Fuel Terminal Expansion

Fuel Terminal Expansion

Location: Milwaukee

Client: Flint Hills Resources

Completion Date: 2006

Flint Hills Resources contracted with Burns & McDonnell for complete design-build services for the expansion of the existing Milwaukee Fuel Terminal. This facility has operated continuously as a petroleum storage and loading terminal since the late 1950s. These significant facility improvements included:

  • Upgrading the existing entrance
  • A new exit gate at the southeast corner of the property
  • A new truck loading rack with a pre-engineered steel canopy (85 feet long and 132 feet wide) with four product loading bays, one service bay, drivers kiosks, truck loading controls and a card reader system
  • New bill of lading facility
  • New foam building
  • Renovation of the existing operations and shop buildings
  • Relocation of the filter building
  • Paved access road to the truck rack facility
  • Upgraded site utilities, mcc and additive system
  • New trans-mix tank (5,000 bbl)
  • Demolishing existing pavements and grading the area to provide a wet bottom detention pond and storm sewer conveyance to control runoff from the site
  • Operations building repairs and improvements including a new roof replacement, doors and windows, new HVAC and electrical systems, restroom, and interior finishes
  • The installation of all pumps and piping systems necessary for function of the site’s facilities within the tank farm containment area

All project goals set by the owner for this project were met, including:


  • Improve rack reliability
  • Replace the loading controls with a new PLC system
  • Allow ratio blending of gasoline products to reduce busted load frequency
  • Provide blending capability for octane levels of 87, 88, 89, 90, 91 and 92
  • Increase rack size and load arm number for higher volumes
  • Decrease truck loading times
  • Automate the truck access system
  • Increase trans-mix storage capacity

Site Management

  • Provide for increased on-site waiting to load truck storage, and reduce the number of trucks stopped on public roads waiting to enter
  • Provide for separate entrance and exit gates to improve traffic flow
  • Install a foam/water fire protection system on the new truck loading rack
  • Develop a stormwater management and control system, including a storm sewer system and detention pond 
  • Replace deteriorated pipe supports and pump foundations
  • Minimize the down time to switch from the existing to the new systems