EXTERIOR CONCRETE REPAIR & COATING OF COAL SILOS

Industrial Access performed multi-phase repairs and maintenance on three large coal storage silos. The reinforced concrete structures had developed areas of concrete deterioration, coating failure, and corrosion on connected steel infrastructure due to long-term environmental exposure. Over the course of three project phases, IA crew completed concrete restoration and protective coating installation on the silos and their steel appurtenances. These repairs restored damaged areas, improved corrosion protection, and helped extend the operational life of the silos.

A coal mine in northwestern United States required repairs and protective maintenance on their 172’-tall reinforced concrete coal storage silos. Due to constant exposure to harsh weather conditions and operational wear, some areas of the exterior silo encasements, particularly the top sections, had begun to show signs of deterioration, including cracking, spalling concrete, and coating failure, as well as corrosion on exposed steel components.

The facility retained Industrial Access (IA) to perform inspections and repairs aimed at restoring the structural condition of the silos and protecting them from further degradation. Initial evaluations identified damaged concrete on the silo walls, roof edges, and structural features, along with widespread coating failure across the exterior surfaces. In several locations, cracking and spalling had exposed reinforcement within the concrete, creating pathways for moisture intrusion and accelerating the risk of long-term structural damage if left unaddressed.

In addition to the concrete deterioration, the facility’s steel infrastructure—including ladders, walkways, guardrails, and rooftop equipment—showed signs of corrosion and coating failure. To address these issues, the client required a comprehensive and accessible multi-phase repair program to restore damaged areas, renew protective coatings, and implement preventative measures that would extend the service life of the silo structures while maintaining safe operation of the facility.

To complete the inspections, repairs, and coating work, IA technicians utilized rope access techniques to safely reach all work areas across the tall silo structures. Rope access allowed crews to efficiently access the full exterior height of the silos while enabling fast mobilization. This method provided a safe and flexible solution for accessing the silos without the need for costly large-scale scaffolding or heavy equipment. IA technicians are highly trained in rope access techniques, enabling them to perform detailed inspections, structural repairs, and coating applications on complex industrial structures while minimizing disruption to ongoing facility operations.

To complete coating applications, IA first prepared the surfaces of each silo by pressure washing exterior surfaces to remove accumulated dirt, contaminants, and loose material, ensuring proper adhesion of subsequent repair materials and coatings. Areas of deteriorated concrete were identified across the silo exteriors, including spalls, cracks, and sections with exposed rebar. Damaged concrete was carefully removed and prepared, after which high-performance repair epoxy and mortar were installed to restore the structural integrity of the silo shells, drip edges, and roof beam pockets.

IA applied a protective coating system to the exterior concrete walls and rooftop of the silos and their associated steel components. Multiple layers of industrial-grade coating were installed to protect the structures from corrosion and environmental exposure. In addition to the silo shells, crews coated ladders, walkways, guardrails, crane components, and other steel infrastructure located on and between the silos to provide consistent protection.

To further protect the structures from moisture intrusion, sealant was installed along the reinforcement hoops that encircle the silo exteriors. This work helped close gaps between the hoops and the concrete shell, preventing water infiltration that could accelerate internal deterioration. Additional repairs were also performed on rooftop structures, including crack sealing on silo roofs and repairs to deteriorated concrete curbs and structural footings supporting rooftop equipment. Through this phased approach, IA was able to systematically address structural deterioration, restore protective coatings, and extend the service life of the silo infrastructure.

All repairs were completed safely and efficiently, addressing key areas of deterioration across the silo structures and associated steel infrastructure. Through the phased repair program, IA restored damaged concrete surfaces, sealed vulnerable areas susceptible to moisture intrusion, and installed new protective coatings to mitigate corrosion and environmental degradation. These measures were designed to improve reliability, durability, and longevity of the silo infrastructure. Since the project is ongoing, further work is being scheduled to address the condition of the remaining silos on site to support safe operations and long-term structural resilience.