REDDY ICE Condensor Support Structure

Project Background

The Reddy Ice Condenser Support Structure project, located in Oklahoma City, OK, involved the design and construction of a structural steel support system for a 30+ ton industrial condenser. This condenser plays a crucial role in supplying cooling water for the entire manufacturing operation at the Reddy Ice facility. Given the significant weight and operating requirements of the condenser, the supporting structure required meticulous engineering to meet both performance and tolerance criteria. Dr. Gregory P. Wilson, P.E., of The Wilson Geotechnical Group, LLC, led the structural design effort in collaboration with InnerCool Corp. and Lamar Industrial Contractors, Inc. The team’s goal was to deliver a safe, efficient, and constructible support solution that met stringent deflection limits and complex erection constraints.

"The use of the DIRECTOR application within the software was without question a key component to "round-trip" between 3D, FOUNDATION, and CONNECTION."

— Dr. Gregory P. Wilson, PE

About the Structure

The completed design includes a steel-framed structure supported by a system of drilled piers. All structural steel members were designed to withstand dead, live, and wind loads, and to maintain deflections within a strict tolerance of 0.375" to 0.50", as required by the condenser manufacturer. Meeting this narrow deflection limit was critical to ensure proper condenser operation and long-term performance. The foundation design featured custom-drilled piers engineered to handle both vertical and lateral loads while minimizing movement. An additional software package was used to validate the deflection behavior of the piers, but the final design was performed using RISAFoundation for consistency and integration. To facilitate construction and provide flexibility for the erection crew, a combination of welded and bolted steel connections was utilized. The use of both methods allowed for more streamlined on-site assembly without compromising structural integrity or cost-effectiveness.

How Were RISA Products Utilized?

The structural design was completed using a suite of RISA software, including RISA-3D, RISAFoundation, and RISAConnection. These tools enabled Dr. Wilson and his team to efficiently move between modeling, foundation design, and connection detailing. RISA-3D was used to model the full steel structure, apply loads, and analyze frame deflections. Its ability to visualize behavior and generate detailed reports was essential for optimizing member sizes and confirming code compliance. RISAFoundation was employed to model and analyze the drilled pier system. Given the tight deflection tolerance, it was especially important to validate soil-structure interaction and pier behavior. Results from RISAFoundation were then compared to those from an additional third-party pier design software, adding confidence to the final design solution. RISAConnection played a key role in detailing both welded and bolted connections. The software enabled rapid iteration and checking of connection designs, helping to ensure constructability while maintaining cost efficiency. This was especially valuable in coordinating with the general contractor’s erection plan. Finally, the use of the RISA Director tool made it seamless to transition between the different RISA modules—allowing for true “round-trip” design coordination between the frame, foundation, and connection models. While Dr. Wilson noted limited use of RISASection, he emphasized that the ability to verify and re-verify connections was instrumental in delivering a highly efficient and economical final design.