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.

A power generation facility in the southern United States contracted Industrial Access (IA) to perform coating and structural repair services on their two 260’-tall concrete chimneys. Previous inspections had identified several concerns, including eroded concrete surfaces, cracking, and failing breeching duct flashing. In addition, surface corrosion was observed on the access platforms, along with missing or deteriorated components of the lightning protection system (LPS). IA was brought in to address these concerns and restore the chimneys’ integrity and protective systems, ensuring continued safe and efficient operation of the plant.

To perform the repair and coating services, IA utilized rope access techniques to reach all required elevations of the stacks. The crew also made use of existing platforms to carry out select tasks. This access strategy allowed technicians to safely and efficiently complete work across the exterior surfaces and platforms without the need for heavy scaffolding or cranes, helping to reduce overall project duration.

IA began the project by pressure washing the exterior surfaces of both chimneys to prepare for repairs. Any cracks in the concrete shell were ground out and filled with repair adhesive to prevent moisture intrusion and further deterioration. Areas of spalling concrete were patched, with protective coating first applied to exposed rebar before placing repair mortar on top.

A three-layer protective coating system was then applied to the upper 150’ of each chimney, where the shell is the most exposed and vulnerable to harsh operational and environmental conditions. A protective coating system was also applied to the stacks’ platforms and ladders. During the process, heavily oxidized platform grating was removed and replaced.

As work progressed, additional repairs were completed. Flashing on the breeching ducts for both units was repaired and reinforced with new flashing and support steel. One of the stacks’ LPS system was partially replaced, including a new lead-covered cable, air terminals, jumper components, and encircling cables. Finally, a missing toe board was installed on one of the platforms to address a fall protection gap.

All repair and coating work was completed successfully and on time, restoring the protective barrier of the chimneys and addressing the most concerning structural issues. The newly applied coating system and crack repairs will extend the service life of the concrete shells, while repairs to the platforms, the breeching duct, and the lightning protection system help ensure continued safety and reliability. By performing this routine maintenance, the facility has reinforced the long-term performance and durability of their stacks. Regular inspection and timely intervention remain critical to preserving the integrity of aging industrial structures and avoiding costly emergency repairs.