Spalling on Concrete Smokestacks and Industrial Chimneys

As industrial maintenance, rope access professionals, we spend a lot of time with smokestacks & industrial chimneys. One of the most common issues we encounter is spalling on the surface of concrete chimneys. While spalling may seem like a small problem compared to other maintenance requirements, it’s a clear indication that the structure is suffering from water intrusion which can lead to expensive future repairs if not addressed immediately. An industrial chimney inspection is the first step in identifying a plan to prevent or repair spalling concrete.

What Causes Spalling in Concrete Stacks?

Although concrete is a durable & sturdy material used in plants and facilities across the world, thermal strain caused by rapid heating, water intrusion and the internal pressure that forms due to the removal of water can break down the concrete over time. When water reaches the rebar inside the wall of a cement stack, it will create visible corrosion and spalling on the surface of the structure.

As pieces of concrete flake and peel off, the embedded rebar will eventually become exposed, leading to the rusting and deterioration of this important structural component. Failure to repair spalling concrete at the first sign of trouble can impact the stack’s long-term durability. Rusted rebar is not sufficient enough to provide the necessary structural strength needed for these large structures, leaving the industrial chimney or smokestack susceptible to failure or collapse.

While spalling is often visible to the naked eye on the outside of a concrete stack, unseen internal problems can also cause similar deterioration. A common internal threat that can cause spalling in industrial chimneys is acid attack. Water mixing with gases inside stack liner can create acidic agents that may accelerate deterioration. If the acid-resistant lining in the chimney or stack fails, gas can leak through open mortar joints or defective refractory lining and will condense and erode the internal face of the concrete chimney. Over time, this defect will appear on the chimney exterior as rust-colored staining.

Because concrete industrial chimneys and stacks are subject to their own set of unique problems, it makes sense to have our rope access professionals provide regular maintenance and inspection services to help identify potential problems or vulnerabilities like spalling. Whether we need to replace sections of seriously deteriorated or apply water resistant coatings, we can offer the most efficient repair plan that will save time & money, thanks to our innovative rope access methods and experienced technicians & engineers.

Speak with our industrial chimney & smokestack experts today to find out how to prevent and manage spalling and the related issues that arise with this common condition. Our engineers and rope access specialists can quickly inspect your structure and identify damage and potential problems that can lead to spalling.