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.

A cement facility on the East Coast was looking to have their steel structures repaired and replaced. The plant operates a 294’-tall kiln stack and a 153’-tall conditioning tower. The top 61.5’ section of the kiln stack was corroded, deteriorated and in need of replacement. Meanwhile, the conditioning tower had a specific section in the middle of the structure right below the cone that was severely damaged and requiring a replacement. Industrial Access (IA) mobilized to perform the repair and replacement work to ensure the facility could continue operating safely and efficiently.

To perform the kiln stack replacement, IA built a scaffold around the top section of the structure to enable effective access for the technicians. The crew utilized specialty access techniques as well as a crane to demolish the top of the kiln, then lift and install the new section. For the conditioning tower repairs, a combination of scaffolding, crane, and rope access techniques were utilized to safely remove and install sections of the structure.

IA began the scope by removing the ductwork just above the cyclone exhaust pantleg to facilitate crane access. Working from the 7th floor down, IA technicians systematically removed sections of the conditioning tower one by one, including the platforms, down to the 4th floor to gain access to and extract the damaged portion. Sections above the damaged area were carefully cut, rigged, and lowered. Once the damaged section was fully removed, a new 16’ diameter replacement—fabricated in stackable parts—was hoisted into position, then thoroughly bolted and welded.

Ultrasonic Thickness (UT) readings were conducted on the pantlegs, cone, and kiln stack to assess the overall condition and identify areas in need of reinforcement. On the ground level, removed sections, particularly the cone, underwent general maintenance—the crew performed a washdown, removal of buildup, and carried out any necessary replating. Then, the tower was reassembled in reverse order, ensuring stability and alignment with the existing structures. Following the conditioning tower rebuild, IA reinforced critical sections of the pantleg ducting to improve structural integrity.

Meanwhile, IA cut and removed the top 61.5’ of the kiln stack section by section. IA had fabricated the replacement structure, split into several sections for installation purposes. Each section was fitted with mounting brackets to be lifted and welded into place. Any demolished steel was cut into smaller pieces on the ground to facilitate easier disposal.

The partial conditioning tower and kiln stack replacement and repairs were completed successfully and on time, effectively following a tight schedule to get the entire scope of work finished. The facility is now better equipped for safe and smooth plant operation, with restored structural integrity and extended longevity of their kiln stack and conditioning tower. IA regularly services facilities in the Cement & Lime industry, providing inspection, repair, and engineering services as well as unique rigging and access solutions, offering experienced handling of complex situations.