Case Studies - Power Generation, Cement & Lime, Pulp & Paper

Case Studies

REPAIR & COATING OF TWO CONCRETE CHIMNEYS

Two reinforced concrete chimneys at a power plant required protective maintenance to address surface deterioration and component wear. Industrial Access completed comprehensive repairs that included exterior crack sealing, spalling concrete remediation, application of a protective coating system, and more. All work was executed with engineered access solutions to ensure safety and efficiency while restoring the chimneys’ integrity and extending their service life.

PARTIAL REPLACEMENT OF CONDITIONING TOWER & KILN STACK

Cement plant needed to replace deteriorated sections of their steel kiln stack and conditioning tower. Industrial Access provided engineering, specialized access, demolition, installation, and reinforcement services in order to perform partial removal of the structures, install newly fabricated sections, and repair any compromised areas of the steel shell. Experienced technicians worked around the clock to complete all services during a single mobilization and return the facility to safe operation.

STEEL STACK REPAIR & GUNITE LINER REPLACEMENT

Power generation facility was operating a steel stack unit that was in need of liner replacement services. The existing gunite was severely deteriorated and signs of steel shell damage were present. Industrial Access delivered gunite liner system replacement and then easily adapted to the changing scope of work when additional urgent repairs were required. The damaged stack shell was repaired, and the stack was covered with a protective coating system to restore stack integrity and its defenses against the harsh environmental conditions.

REPAIR & COATING OF SIX SILOS & GRAIN ELEVATOR BUILDING

Industrial Access inspected six grain storage silos and a grain elevator building to examine their condition and consequently develop a repair strategy to address any areas in need of attention. Many anomalies were observed, but the most concerning one was the exterior concrete spalling and deterioration across all of the structures. Industrial Access performed concrete shell repairs and a protective coating application to restore the structures’ safety and longevity.

CEMS UMBILICAL REPLACEMENT IN HRSG STACKS

Two 164’ steel HRSG stacks needed to have their CEMS umbilical lines replaced. Industrial Access mobilized to remove the existing umbilical cable systems and install new ones. Maintaining functional CEMS components is necessary to ensure uninterrupted performance of the stack emissions monitoring system in order to adhere to regulatory requirements.

CHIMNEY INSPECTION, PAINTING & EXTERIOR REPAIRS

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 ensure stack safety and longevity.

SILO DISTRIBUTION REPLACEMENT

IA Mechanical was contracted to replace the distribution system in a cement silo. The existing system consisting of screw conveyors were to be replaced with an updated air slide system. The air slide will enable smooth, efficient, low-maintenance distribution of bulk material. IA Mechanical team has a wide range of experience at providing customized mechanical solutions to industrial facilities and their equipment.

REINFORCING DAMAGED SILO ROOF BEAM POCKETS

Multiple roof beam pockets across several silos exhibited particularly severe deterioration. In addition, concrete spalling, delamination, and exposed reinforcement were observed on exterior shells and wall joints of multiple silos. Industrial Access performed recommended concrete repairs and installed an additional steel beam pocket reinforcement system to ensure silo safety and sufficient structural integrity.

FRP LINER BLISTER REPAIRS

A FRP smokestack had been experiencing a multitude of blisters forming on its FRP liner. These blisters were causing liner delamination and putting the liner at risk for more extensive damage. Industrial Access devised a repair strategy to address each of the blisters and patch the liner up to prevent further deterioration and to return the liner to an effective and safer operating condition.

ROOF BEAM POCKET REPAIR IN CONCRETE SILOS

Industrial Access carried out a custom-engineered repair service, delivered to failing roof beam pockets will ensure that the structural steel roof support system has the capacity to carry the expected load and that the silo is structurally sound and safe to operate.

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