AssetStackAssetStack response to Eagle Materials: asset baseline, condition capture and maintenance system
One asset base for every Eagle plant,
built from the field up.
Response to Eagle Materials Inc.
Asset baseline, condition capture and bottom-up maintenance across eight cement plants and beyond.
AssetStack proposes to give Eagle one consistent asset register, one condition standard and one maintenance strategy method for all eight cement plants, prove it on a single facility with a LiDAR / 3D scan in November, and then extend the same standard to Eagle's wallboard, paperboard, aggregates, concrete and slag operations.
The work starts as an engineering service that builds the asset base. AssetStack is the platform that holds it, so nothing is lost at handover: the register, the evidence and the maintenance plan stay connected and become Eagle's asset and maintenance management system.
Why this is the right tool for the job
- Standard first, software second. The asset standard is built into the platform, so every plant is structured the same way from day one.
- Field to plan in one place. Hierarchy, condition, 3D scan and maintenance plan share one asset record, with no re-keying between tools.
- Bottom-up, not generic. Maintenance tasks come from each asset's own failure modes, criticality and condition.
- Cement engineering behind it. SAXUM and Lycopodium bring cement process and asset-management experience to the services.
- Already working. The pilot build is live in this platform today. See it.
What Eagle needs, as we understand it.
From our discussions with Eagle and SAXUM. We will confirm each point against Eagle's asset management requirements summary.
A consistent asset base.
The core problem
Plants acquired and built at different times hold their asset data in different structures and levels of detail. Eagle needs one register that compares like with like across every plant.
What we will deliver
- Common functional-location coding
- Shared departments and asset classes
- Criticality assessed the same way everywhere
Condition you can trust.
Evidence, not opinion
Condition must be captured on one scale, with evidence, so that capital and maintenance decisions across plants rest on the same basis.
What we will deliver
- 1–5 scale with written criteria
- Photos and defects per asset
- LiDAR / 3D context for the pilot facility
Maintenance built from the asset up.
The services opportunity
Eagle is interested in the bottom-up maintenance system development we have delivered for mining clients: strategies derived from failure modes and criticality, not copied from generic schedules.
What we will deliver
- Failure-mode-based task library
- Intervals, crafts and hours per plant
- Templates loaded into the platform
How each requirement is met.
Every requirement maps to a working screen in the platform, a configuration step, or an engineering service.
| Ref | Requirement | How AssetStack meets it | Where | Status |
|---|---|---|---|---|
| R1 | One consistent asset register across all 8 cement plants | Single functional-location standard (SITE-AREA-CLASS-NN), nine shared cement departments and a common class library applied by template to every plant. | Asset hierarchy & standard | In pilot build |
| R2 | Extend the same register to wallboard, paperboard, aggregates, concrete and slag sites | Line-specific department sets and classes already defined for each business line; sites carry a rollout wave and status. | Portfolio & rollout | In pilot build |
| R3 | Capture asset condition on a consistent basis | One 1–5 condition scale with written criteria, class-specific inspection prompts, photo evidence and full history per asset, usable on phone or tablet. | Condition capture | In pilot build |
| R4 | Rank assets by consequence of failure | A/B/C criticality rules covering safety, environment and production; criticality decides how much maintenance each asset receives. | Asset hierarchy & standard | In pilot build |
| R5 | LiDAR / 3D scan of a pilot facility linked to the register | Scan register, in-app point-cloud viewing for PLY/PCD/XYZ extracts, master E57/LAS files linked from Eagle storage, and scanned equipment tagged to its functional location. | LiDAR pilot | In pilot build |
| R6 | Bottom-up maintenance system development | Tasks generated from each asset’s class failure modes, filtered by criticality and tightened by condition, with intervals, crafts and annual hours, published as maintenance templates. | Bottom-up maintenance | In pilot build |
| R7 | Load existing data from Eagle’s CMMS and spreadsheets | Import and mapping to the standard, with data-steward checks (tag format, class, criticality, orphans, duplicates) before sign-off; CSV load sheet back to the CMMS. | Data import · Hierarchy checks | Configure |
| R8 | Work management once the baseline is in place | Work orders, maintenance planning, spares, shutdown planning and reliability analytics in the same platform, against the same asset record. | Maintenance & work orders | Configure |
| R9 | Field verification and data governance services | Walkdowns, nameplate capture, criticality workshops and FMEA facilitation by engineers with cement plant experience (SAXUM / Lycopodium). | Services | Service |
The same structure at every plant.
The Eagle asset standard is held in the platform and applied by template, so a kiln at Fairborn and a kiln at Nevada are recorded, assessed and maintained the same way.
Functional location convention
FAI-400-KLN-01-GBX
Site · department · asset class · sequence · maintainable component. Applied identically across Eagle's plants and readable by any CMMS.
Nine shared cement departments
100 Quarry & crushing · 200 Raw material storage & prehomogenisation · 300 Raw milling · 400 Pyroprocessing · 500 Clinker cooling & storage · 600 Finish milling · 700 Cement storage, packing & dispatch · 800 Utilities & power distribution · 900 Solid fuel preparation
35 asset classes, 83 failure modes
From crushers and vertical roller mills to kilns, coolers, baghouses and substations, plus classes for wallboard, paperboard, aggregates and ready-mix. Each class says what to inspect and how it fails.
Condition and criticality
| 1 | Very good | As new. No visible defects. Full design function. |
| 2 | Good | Minor wear or cosmetic defects. No effect on function. |
| 3 | Fair | Moderate wear, early defects (corrosion, leaks, vibration trending). Function maintained. |
| 4 | Poor | Significant defects, reduced capacity or reliability. Failure likely within 1–3 years. |
| 5 | Very poor | Failed, unsafe or failure imminent. Function lost or at risk now. |
Criticality
- A · Critical: Full strategy: condition monitoring + preventive + critical spares.
- B · Important: Preventive and inspection tasks, standard spares.
- C · Minor: Statutory and lubrication tasks only; run to failure otherwise.
Every load is checked for tag format, a valid class, an assessed criticality, orphans and duplicate tags, so the register stays consistent as more sites join.
Prove it on one facility first.
We will scan one Eagle facility with terrestrial LiDAR and 360° imagery, walk down the critical equipment, and build the facility's baseline and maintenance plan inside AssetStack.
Prepare
Confirm facility and scope, collect the CMMS extract and drawings, map the existing register to the Eagle standard.
Capture
Terrestrial LiDAR and 360° imagery of the agreed areas; condition walkdown of A and B critical equipment.
Build
Register the point cloud, tag scanned equipment to functional locations, generate the facility’s bottom-up maintenance plan.
Review
Readout with Eagle and SAXUM: verified baseline, findings, and the plan for the remaining seven cement plants.
Scan linked to the register.
Each scanned item carries its functional location and a point-cloud reference, so the 3D view, the register and the condition record open on the same asset.
Deliverables Eagle keeps.
- Registered point cloud (E57) and 360° imagery
- Verified hierarchy for the facility
- Condition scores, defects and photos for A and B assets
- Bottom-up maintenance plan and CMMS load sheet
A decision at the end.
The readout gives Eagle a measured baseline and a costed plan for the other seven cement plants, so the rollout decision rests on results from one of its own facilities.
From baseline to maintenance system.
Once the asset base exists, the maintenance strategy is generated from it, and the same method rolls out site by site.
Bottom-up maintenance
- Each asset inherits the failure modes of its class.
- Its criticality decides which failure modes get a task: A gets condition monitoring, preventive work and critical spares; C gets statutory and lubrication tasks only.
- Poor condition (4–5) halves inspection intervals until the asset is repaired.
- The result is a task list with intervals, crafts and annual hours per plant, exported to the CMMS or run in AssetStack.
Criticality and FMEA-based maintenance, CMMS implementation, risk-based inspection, root cause analysis and critical spares, as delivered for mining clients.
Rollout
| Wave | Sites | Outcome |
|---|---|---|
| 0 | Pilot facility (November) | Method proven, baseline verified |
| 1 | Remaining seven cement plants | One register and maintenance strategy for Eagle cement |
| 2 | American Gypsum wallboard and Republic Paperboard | Same standard, line-specific classes |
| 3 | Aggregates, concrete, slag and terminals | Whole-of-Eagle asset base |
| Run | All sites | AssetStack retained as the asset and maintenance system |
Engineering experience,
built into the platform.
AssetStack combines an asset platform with the engineering people who know what a cement plant needs from it.
Cement process understanding.
SAXUM brings cement and lime experience across crushing, grinding, pyroprocessing, materials handling, storage and terminals, which is what the standard and the walkdowns are built on.
One record from field to plan.
Point solutions split the scan, the register, the condition survey and the maintenance plan across tools and consultants. AssetStack keeps them on one asset record, so the services work becomes a system Eagle keeps using.
Open, and Eagle's to keep.
Eagle owns its data. The hierarchy, condition and maintenance plan export to CSV and CMMS load sheets at any time, and the platform connects to existing systems rather than requiring them to be replaced.
For Eagle's IT review
Access
Invited access for the pilot; named user accounts with roles for production use.
Single sign-on
Sign-in with Eagle's identity provider can be configured for production.
Data
Eagle data held in a dedicated application, separate from other clients, with full export.
Audit
Changes to condition and maintenance records keep their history.
What we need from Eagle to start.
Assumptions.
- Eagle nominates the pilot facility and scan areas by early November.
- Site access, inductions and an escort are provided during capture.
- An extract of the existing asset register and maintenance plans is available.
- Kiln and mill counts used in this response are estimates until confirmed.
Exclusions.
- Changes to Eagle's existing CMMS configuration.
- Structural or statutory certification arising from the scan.
- Control-system changes; AssetStack supports decisions and does not control plant.
Next steps.
- Confirm the pilot facility and dates.
- Share the asset register extract and drawings.
- Agree pilot scope and commercial terms.
- Kick-off call with Eagle, SAXUM and AssetStack.