EMERGENCY STEEL LINER STRUCTURAL REINFORCEMENT

Industrial Access performed an emergency assessment and structural repair of a 396’-tall steel chimney liner that had experienced severe corrosion, thinning, cracking, and buckling, particularly near the false-floor elevation. The deterioration had caused the upper section of the liner to lean off-axis, requiring immediate stabilization. Repairs focused around liner suspension and realignment, false-floor replacement, and steel plate reinforcement to extend the operational lifespan of the structure.

A waste-to-energy facility in the northeastern USA contracted Industrial Access (IA) to perform an emergency condition assessment of a 396’-tall steel chimney liner after severe deterioration was identified near the false-floor elevation. The liner had experienced extensive corrosion, thinning, cracking, and buckling around the lower section, causing the upper portion to lean and bear against the roof-level bumper system. IA performed a visual assessment and ultrasonic thickness (UT) readings to evaluate the condition of the entire liner, identifying corroded holes, circumferential cracks, and significant steel loss near the damaged area.

The false floor was found to be severely deteriorated due to accumulated corrosive fluid caused by a closed drain valve, resulting in collapse of the upper plate and exposure of the supporting steel below. The liner movement had also damaged the roof-level bumpers, framing, and elevated platform components. Based on these findings, the client required an emergency repair solution to stabilize and realign the liner, reinforce the compromised steel, restore drainage, and address associated structural damage to protect the liner from collapse.

To complete the inspection and repair work, IA technicians utilized rope access techniques and scaffolding systems to safely access the chimney liner and surrounding work areas. Rope access was used to perform the interior liner inspection from the upper elevations, allowing technicians to document conditions and collect UT readings throughout the structure. Scaffold access was utilized to reach the exterior liner areas near the false-floor elevation, providing a stable work platform for detailed repair work. IA’s trained crew and specialized access methods enabled safe, efficient work execution while allowing comprehensive evaluation and repair of hard-to-reach areas.

IA began the project by performing a detailed condition assessment of the steel liner to evaluate the extent of corrosion, thinning, cracking, and structural damage. Following the inspection and review of the findings, the repair approach was developed to stabilize the liner and reinforce the most damaged areas. The liner was temporarily supported using sixteen equally spaced structural members installed around the circumference. This emergency stabilization system provided critical support while further repairs were being completed.

To correct the liner’s displacement, IA removed insulation around the existing lifting ring and suspended the upper section of the liner from the roof framing using the original suspension points. Chain hoists were installed and adjusted to level the liner and restore it to a plumb position. Once the liner was properly aligned, the temporary support system was reconnected to secure the structure during the reinforcement process.

IA continued with the structural repair work by installing rolled steel reinforcement plates on the interior of the liner across the damaged elevation and extending above the area of severe thinning. An exterior reinforcement ring was also installed over the circumferential crack to restore structural continuity and seal the damaged area. The severely corroded false floor was removed and replaced. The drainage system was extended beyond the chimney structure to direct collected fluids away from the false floor and help prevent future corrosive accumulation.

Additional repairs were completed to address damage caused by the liner’s previous displacement. IA reinforced the damaged roof framing, replaced the roof-level bumper system, repaired the roof slab, and applied a protective coating system to the roof surface. The elevated platform was also addressed through the installation of missing grating clips to secure the existing panels. Once the permanent repairs were complete, the temporary supports and lifting equipment were removed, and insulation was restored around the lifting ring.

All emergency structural and associated repairs were completed safely and efficiently, addressing the severe corrosion, cracking, thinning, and misalignment that put the chimney liner at risk for collapse. The targeted repair approach stabilized the damaged section, restored the liner to a level and plumb position, and reinforced the compromised steel to improve structural integrity. Replacement of the severely corroded false floor and extension of the drainage system also addressed the conditions that contributed to the deterioration and helped reduce the potential for future corrosive fluid accumulation. All of the corrective measures were designed to eliminate the imminent danger of liner’s structural failure and improve the liner’s stability for continued reliable operation. Ongoing inspection and preventive maintenance remain important to monitoring the condition of the structure and preserving the long-term performance of the repaired system.