770-255-1313
24hr Emergency Service
770-255-1313
24hr Emergency Service
Multi-Craft Services
Silo Services
Mechanical Services
Multi-Craft Services
Silo Services
Mechanical Services

CHIMNEY INSPECTION, PAINTING & EXTERIOR REPAIRS

Mining & Minerals

WORK PERFORMED

  • Inspection of stack exterior, annulus & liner
  • Repairing cracks & spalling on stack exterior
  • Washdown of stack exterior
  • Applying new layer of paint to chimney’s outer shell
  • Replacing platform grating, toe board, knee braces
  • Various repairs on ladder & other steel appurtenances

SUMMARY

500’-tall reinforced concrete chimney received a comprehensive condition assessment. Industrial Access inspected stack exterior and interior and prepared a recommended repairs plan. Observed cracks and areas of spalling were patched up and the chimney was coated with fresh layers of FAA paint, while the platform and ladder received a series of repairs to insure stack safety and longevity.

TIME

Project completed in about 6 weeks

COST

Completed during a pre-scheduled outage

SAFETY

Completed without any near misses or safety incidents

CLIENT NEED

A mining facility in the southeastern USA operates a 500’-tall reinforced concrete chimney that was in need of condition inspection. Industrial Access (IA) mobilized for a thorough visual assessment and a Rebound Hammer test across the entire height of the chimney. The inspection revealed large areas of failed coating on stack exterior, cracks and spalling on outer shell, oxidation and missing coating on steel components, defects of ladder and platforms, damaged tension bands and bricks on annulus, flaking and cracking liner, and more. IA provided the client with a detail list of repair recommendations, and the client contracted IA to perform a series of recommended repair items.

ACCESS

The technicians at IA are highly trained in rope access rigging and techniques to deliver services at maximized efficiency and safety. For the inspection, experienced technicians performed two rope access drops for the exterior and interior assessments each. A single drop allowed for a 180-degree access around the stack, enabling the technician to observe the structure up-close and perform any testing. During the repairs, three swing-stage work platforms were installed to allow for a safe and efficient full-height access to the chimney exterior.

SOLUTION

The inspection determined that the chimney’s exterior surface needed to be addressed due to severe coating failure and signs of concrete cracking and spalling. So IA first conducted repairs on any identified cracks, holes, and areas of missing concrete across the chimney shell. All of these defected areas were cleaned, raked out, and filled with repair mortar. The base of the stack exhibited damage and stress-cracking in its concrete surface, which also received appropriate treatment and were filled with repair mortar.

Before the full stack coating could take place, the crew first performed a complete chimney exterior washdown. Thorough power-wash of the entire height of the stack ensured that any dirt and debris were removed. After that, IA proceeded to follow a meticulous two-coat process for protective paint across the chimney. Primer was first applied to ensure optimal adhesion and protection, followed by a topcoat to provide long-lasting durability and a clean finish that adheres to regulations. Protective coating was also selectively applied to steel appurtenances where areas of oxidation and missing coating had been observed – ladder, cage, guardrails, and AWL attachments.

The inspection also revealed defects on the platforms of the chimney. IA had observed heavy oxidation on the platforms’ toe boards, damaged and oxidized grating, detached knee braces, and more. The crew removed old grating from the top platform and installed new grating. Detached knee braces on a rest platform were repaired while the deteriorated toe board was replaced. The ladder required various repairs throughout, such as welding and securing detached components (standoff, rails, cage) and tightening or replacing bolts. Any missing or faulty anchors on the LPS system were repaired.

RESULTS

The repairs were completed successfully and on time, restoring the chimney’s protective surface and ensuring structural safety and longevity. The client made a responsible decision to make sure that most of the recommended repairs were carried out right after the inspection, which prevents already identified defects from developing into major problems in the future. Detecting occurring damage early allows for more efficient repairs and effective failure prevention that saves money long-term.

Smokestack repairs, inspections and painting in Pittsburgh, PA & Denver, CO

For additional information about our company and services we provide, please give us a call anytime

770-255-1313
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