PARTIAL REPLACEMENT OF DEFORMED CONDITIONING TOWER

Industrial Access performed emergency partial demolition and replacement of a damaged conditioning tower following a structural failure that caused inward buckling and tearing of the steel shell. The scope of work included removal of compromised duct sections, modification and installation of prefabricated replacement sections, and correction of alignment issues at the expansion joint. The repairs were designed to restore the structural integrity and operational functionality of the conditioning tower.

A cement manufacturing facility in the southeastern USA retained Industrial Access (IA) to perform emergency repairs on a severely deformed 115’-tall conditioning tower. The structure had experienced inward buckling that resulted in yielding and tearing of the shell. The damage compromised the integrity of the tower and required immediate action to restore safe operation.

Initial assessments indicated localized damage near the top of the structure; however, further field inspection revealed that the extent of the failure was greater than originally anticipated. Additional damage was identified below the spray lance level, including the section supporting a full-circumference platform and associated piping. The tower also incorporated an expansion joint at the upper duct interface, which was affected by the deformation and misalignment caused by the failure.

The client required a rapid-response contractor capable of safely demolishing the damaged portions of the tower, adapting prefabricated replacement sections to unanticipated field conditions, and coordinating closely with on-site engineering, fabrication, and plant personnel. The primary objective was to restore the conditioning tower to a safe, operable condition while minimizing downtime and addressing structural deficiencies discovered during the repair process.

Access to the conditioning tower was achieved through a combination of crane-supported lifts, existing platform access, and scaffold systems. Damaged duct sections and replacement assemblies were installed and removed using controlled crane lifts to safely handle large structural components at elevation. Scaffolding was erected from the circumferential platform level to provide stable, hands-on access for installation, welding, and alignment work. These access methods allowed IA crews to safely perform demolition, fabrication, and installation work on the tall cylindrical structure while maintaining precise control during critical lifting and fit-up operations.

IA mobilized under emergency conditions to stabilize and repair the damaged conditioning tower following a structural failure at the upper portion of the duct. The project began with a detailed field assessment to determine the full extent of the damage, which was found to be more severe than initially anticipated. Based on these findings, IA developed a demolition and replacement plan to ensure the correct fit.

The damaged portion of the conditioning tower was sectioned using gas-cutting torches and removed in controlled lifts with crane support. As demolition progressed, additional damage was discovered beneath the spray lance platform, requiring an expansion of the original scope. The affected duct section and its existing full-circumference platform were disconnected and removed in preparation for reinstallation on the replacement duct sections. To accommodate the revised demolition elevation and existing field conditions, IA performed on-site fabrication, including the installation of an extended skirt on the base of the first replacement section.

Replacement duct sections were assembled at grade and installed in a staged sequence to maintain alignment and structural stability. Sections one and two were connected together and fitted with the reinstalled existing circumferential platform and associated piping prior to being lifted into position. Once set, additional structural reinforcement was added in accordance with on-site engineering direction, including the installation of stiffener plates around the circumference of the extended skirt to increase load capacity and rigidity.

As subsequent sections were installed above the initial assembly, a misalignment was identified between the existing upper duct and the new replacement sections. IA addressed this condition by field-modifying the upper section and installing a slip-sleeve configuration to achieve proper alignment while maintaining the required expansion joint clearances. New expansion joint components were then installed to complete the repair.

All demolition and replacement work was completed safely and in accordance with engineering direction, restoring the structural integrity and operational functionality of the conditioning tower. The emergency repairs addressed the buckled and torn duct sections, reinforced critical load-bearing areas, and resolved any alignment issues. These corrective measures allowed the facility to return the conditioning tower to service and resume normal operations.