CONCRETE SILO ROOF SLAB & ROOF BEAM REPAIRS

Industrial Access performed inspection and structural repairs on a 75’ reinforced concrete silo. The structure exhibited severe roof slab deterioration and misaligned roof support connections that compromised safety and structural integrity of the silo. Industrial Access completed demolition and replacement of the damaged roof slab and inlet pipe system, reinforced the roof support beams and gusset plates, and applied protective coatings to restore structural integrity and extend the service life of the silo.

A manufacturing facility in the West Coast contracted Industrial Access (IA) to inspect and assess the condition of a 75’-tall reinforced concrete silo used for storing granite rock. The structure, one of a series of adjoining silos, required a detailed inspection to evaluate the condition of its roof slab, support beams, and beam pockets, as concerns had been raised about their structural integrity. IA was tasked with identifying any structural deterioration and determining the need for repairs.

During the initial review, it was evident that the roof slab and associated structural elements were exhibiting signs of severe wear, including spalling concrete, cracking, and compromised connections. These issues posed not only an operational challenge but also a significant safety concern, as the roof surface was unsafe for personnel access and continued deterioration risked further damage to the structure. The client required a timely inspection, reporting, and on-site repair strategy to stabilize the silo and restore its safe, functional use.

To complete the inspection and repairs, IA technicians utilized rope access techniques to safely reach the interior of the silo, including the roof support beams and beam pockets. Rope access provided a secure and efficient means of performing close-up evaluations and hands-on repairs without the need for extensive scaffolding or heavy equipment inside the structure. This method allowed the crew to navigate confined spaces and hard-to-reach areas while maintaining strict safety standards. IA’s certified rope access team is trained to deliver precise inspections and structural repairs on tall or enclosed concrete structures where traditional access methods are limited.

Once the inspection findings were reviewed and the repair strategy was confirmed, work commenced on stabilizing the roof structure and addressing the most critical deficiencies. The roof slab, which exhibited severe spalling and cracking, was demolished and removed, along with the connected inlet pipe.

To restore function and prevent recurrence of damage, IA fabricated and installed a new section of inlet pipe with a larger diameter, reducing the risk of hammering effect. The new pipe section was coated with a protective system, and a vapor barrier was applied prior to the placement of new concrete on the roof. Pipe flanges were reinstalled and secured both above and below the slab to ensure a reliable, long-term connection.

IA crew also addressed the compromised roof support beams. The misaligned gusset plates were reinforced by extending them with new channel beams, filling unused bolt holes, and installing new bolts through the plates and beam webs. Exposed steel reinforcement around the beam pockets was cleaned, coated, and shielded with sheet metal covers. Protective coatings were also applied to the gusset plates to strengthen and preserve the repairs.

All repairs were completed safely and effectively, addressing the most critical deficiencies of the silo. The replacement of the severely deteriorated roof slab and inlet pipe system restored safe functionality of the structure, while the reinforcement of misaligned gusset plates and application of protective coatings improved the stability and durability of the roof support system. These corrective measures were taken to improve the structural integrity of the silo, extend its service life, prevent the risk of collapse, and mitigate potential safety hazards for facility personnel. Continued inspection and proactive maintenance will remain essential to ensuring long-term performance and reliability of the structure.