EXTERIOR REPAIR & COATING OF 4 STEEL STACKS

Industrial Access carried out structural repairs and surface restoration on four 200’-tall steel stacks exhibiting corrosion, coating failure, and unsafe access systems. The project involved removal of deteriorated ladders and platforms, steel shell prep, and full stack coating. To provide long-term protection, stainless steel caps were fabricated and installed on two retired stacks, and all four received a high-performance coating system to extend service life and ensure safe ongoing operation.

A university power plant in the Midwest needed assistance with their four 200’-tall riveted steel stacks, two of which were decommissioned. They were identified as requiring maintenance to address advancing corrosion, insufficient safety systems and existing hazards, and structural concerns. Previous inspections had noted severe deterioration of miscellaneous steel items at the stack tops, including compromised caps and platform railings, as well as coating breakdown that left the shells vulnerable to ongoing oxidation and corrosion.

The client’s priority was twofold: to eliminate immediate safety hazards posed by unstable ladders, platforms, and fall protection systems, and to restore protective measures that would extend the service life of the stacks. One of the stacks also required safe lead paint abatement during the process of steel shell preparation. Industrial Access (IA) was engaged to perform a comprehensive program that addressed hazard mitigation and long-term preservation and code-compliance.

To complete the scope of repairs, IA crews utilized a crane and man-basket system as well as exterior swing stages to reach elevated work zones along the full height of each stack. Torch-cutting and platform demolition were carried out with the assistance of rigging systems to safely hoist and lower steel sections for disposal. During lead paint abatement, additional containment systems were implemented, including HEPA-filtered vacuum equipment and protective enclosures, to ensure safe and compliant access while handling hazardous materials. These specialized methods allowed technicians to perform repairs efficiently and securely while minimizing risks associated with working at extreme heights and in sensitive conditions.

IA began the project with a comprehensive review of all four steel stacks to confirm conditions and finalize the repair plan. With site safety protocols in place, crews prepared each stack exterior with thorough power washing and surface cleaning of oxidized steel to remove deteriorated coatings and corrosion prior to repairs and coating application.

The following phase of work addressed critical safety hazards. IA removed non-functional fall arrest systems and corroded ladders from all four stacks, along with miscellaneous deteriorated steel items at the stack tops, including painter’s trolleys, platforms, guardrails, and ladder standoffs. To improve protection, sixteen unused CEMS ports were sealed with rolled steel patch plates to eliminate potential points of water intrusion, corrosion, and leakage, and three existing failing patch plates were rewelded and repaired over damaged rivets.

Surface protection were other key aspects of the project. One of the stacks underwent OSHA-compliant lead paint removal, which included mechanical scraping, tool grinding, and safe containment. Once surface preparation was complete, all four stacks received a high-performance coating system applied in multiple layers to ensure a durable, anti-corrosive, abrasion-resistant protective barrier. To finish up the project, IA installed custom stainless steel caps on the decommissioned stacks to provide long-term weather protection.

All repairs were completed successfully and on-time, resolving critical safety concerns and addressing areas of deterioration across the four stacks. Removal of the corroded ladders, platforms, and miscellaneous steel eliminated safety hazards, while patch welding and port sealing restored protection, integrity, and prevented further degradation. The lead paint abatement was performed in full compliance with OSHA standards, reducing environmental and health risks at the facility. With stainless steel caps installed and a protective coating system applied, the structures are now better protected against weather conditions, corrosion, and long-term wear.