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.

An agricultural manufacturing facility in the southeastern USA contracted Industrial Access (IA) to perform a comprehensive exterior inspection of their six grain storage silos and the adjacent grain elevator building. The reinforced concrete silos are 90’ tall each and 17’ in diameter, and the reinforced concrete elevator structure is 118’ tall. IA documented any defects and anomalies on the exterior walls, roofs, platforms and ladders of the silos and the elevator building. The general condition was determined to be poor, with many recorded signs of spalling concrete, exposed reinforcement, unknown growth covering exterior walls, deteriorated shell coating, oxidation on steel appurtenances, failing welds, abandoned objects on the roof and catwalk, improper guy wire connections, and more. IA developed a recommended repair strategy to restore the structural integrity, safety, and longevity of the silos and the elevator building.

To carry out the inspection, IA’s qualified, experienced technicians utilized rope access techniques to perform 10 drops down the silos and 10 drops down the elevator building to take visual documentation and Rebound Hammer readings. IA continued using rope access techniques to ensure safe and efficient execution of the repair strategy, allowing the crew to access every area of the silos’ and elevator’s exterior surface.

IA first addressed the abandoned objects left on roofs, catwalks, and elevated platforms, removing them to eliminate safety hazards for the employees. The crew then proceeded to perform a very thorough pressure washing of the silos and grain elevator building, removing any dirt, debris, and foreign growth. This served as a crucial precursor to the concrete repairs and the coating application, ensuring optimal adhesion and durability of the protective coat.

Any areas of spalling concrete, cracks, and holes were filled with repair mortar. Places with exposed steel reinforcement were coated with a protective bonding primer first. Once the exterior surfaces of the silos and the elevator were dry and ready, IA applied a comprehensive double-layer coating system, which will provide elastomeric protection against harsh, fluctuating environmental conditions. Lastly, the crew re-tensioned loose guy wires and some bolt heads were recessed and covered as needed.

The repairs were completed successfully and on time, restoring the optimal structural stability and protection of the silos and the grain elevator building. The repairs performed addressed the potential compromise of structural integrity and ensured all silos as well as the elevator building maintain their strength and durability, upholding their long-term performance and safety. Meanwhile, the new coating system application will ensure enhanced protection and lifespan of these structures by fortifying their resilience against damage. It is crucial that facilities carry out regular inspections and condition assessments to catch any signs of deterioration early and prevent extensive damage.