The Silo - Chestertown, MD

In 2021, Blacksmith Sawyer Co. was approached with the proposition of transforming a deteriorated 1920’s Terracotta Tile silo into an observatory tower. Upon initial inspection of the site, we encountered a silo in a state of severe disrepair. Over its lifespan, the silo had undergone modifications, including the removal and subsequent patching of its chute with structurally inadequate red bricks. Additionally, an unsafe makeshift scaffold had been erected inside the silo.

Collaborating closely with the owner and architect, Blacksmith Sawyer undertook the task of bringing their vision to fruition. The process began with conceptual design and renderings, providing a tangible demonstration of the project's feasibility. Subsequently, a comprehensive budget was established. Upon approval, we orchestrated the removal of the existing inner and roof structures, affording a thorough examination of the silo's integrity.

Given the compromised condition of the structure, it was determined that a complete restoration of the silo and its foundation was essential before finalizing the survey and design. A suitable donor silo was identified in Lancaster County, PA, matching the original's shape, size, and finish. We acquired the silo and subcontracted its meticulous dismantling, utilizing its tiles to replace the previously applied red brick patchwork. Furthermore, we relocated the entrance door to a more desirable location and ensuring weather resistance.

Utilizing 3D preliminary design, we estimated the structural weight and engineered an appropriate foundation. Excavating 3 feet of material from the silo's interior, we installed a reinforced concrete foundation, incorporating a rebar cage. Upon completion of the restoration work, a final site survey was conducted using 3D scanner technology, allowing us to precisely define the inner shape and tilt of the 32-foot structure.

The stair structure, was fabricated in three modular segments in our workshop, transported to the site and positioned using a crane. The octagonal turret, constructed with heavy timber, fully insulated, and featuring eight windows for a 360-degree view, was crowned with a dual-wall copper dome roof insulated with closed-cell foam. This assembly was meticulously placed atop the stair structure. The interior was finished to the highest standards, from reclaimed white oak flooring to integrating a comprehensive electrical system and custom lighting.  The Silo will stand for generations to enjoy.