CLINKER SILO SPALLING CONCRETE REPAIR

IA Mechanical performed structural concrete restoration on multiple clinker silos showing extensive cracking, spalling, and drip edge deterioration. The project involved epoxy injection of a 30-foot vertical crack between the silos, reconstruction of damaged roof beam pockets, and restoration of the degraded drip edge to prevent further water infiltration and corrosion. All repairs were completed to restore the structural integrity and durability of the silos.

A major cement production facility in the southeast identified significant exterior deterioration on multiple of their clinker silos. The damage included severe cracking and concrete spalling, particularly around the upper sections of the silos and the drip edge areas. A 30-feet-long crack was present between two of the interconnected silos, likely the result of differential settlement within the silo group. This type of structural distress posed a long-term risk of water intrusion, accelerated rebar corrosion, and potential compromise of the silos’ load-bearing capacity. Additional spalled regions, measuring up to several feet in width and depth, were noted on the silo exterior walls, leaving rebar exposed and vulnerable.

To safely perform the concrete restoration work at elevations exceeding 130 ft, IA Mechanical (IAM) technicians utilized existing catwalk, plant-provided scaffolding and manlifts to reach all designated repair areas along the silo exteriors. These access methods allowed the crew to perform precise, hands-on concrete removal, rebar treatment, and repair mortar application while maintaining strict safety protocols.

IAM first began chipping out deteriorated concrete using pneumatic tools to expose the underlying compromised steel reinforcement. Each area was cleaned and inspected to ensure all loose debris was removed while preserving sound concrete. The existing rebar was then cleaned of corrosion, coated with a rust inhibitor, and supplemented with new rebar where additional structural reinforcement was required. A high-performance bonding agent was applied to ensure proper adhesion between the existing surface and new concrete. Low-pressure epoxy injection and quality repair mortar were used to fill every crack and spalled area on the silos, sealing against water intrusion and restoring the walls’ integrity.

Once the substrate preparation and crack injection were complete, IAM constructed new formwork for the damaged drip edge and began the concrete placement process using durable repair mortar. The team also reconstructed the deteriorated beam pockets and reinstalled steel plates to restore load-bearing capacity. Upon curing, a final seal coat was applied to protect the concrete from future moisture penetration.

All concrete restoration work was completed safely, efficiently, and in full compliance with the facility’s structural and quality standards. The repairs successfully eliminated areas of cracking, spalling, and rebar exposure, preventing further moisture intrusion and corrosion within the silo walls. Reconstruction of the drip edge and roof beam pockets restored proper drainage and load support at the upper sections of the silos. These corrective measures were performed to improve the structural integrity and long-term durability of the silos, ensuring continued safe operation.