SILO INTERSTICE CONCRETE LINER INSTALLATION & REPAIR

IA Mechanical performed structural concrete repairs within the silo interstice at a cement production facility. The confined space between the four interconnected silos exhibited cracking, delamination, and loose concrete requiring comprehensive rehabilitation. The project included removal of unsound material, crack repair, engineered formwork installation, and sequential concrete pours to rebuild damaged wall sections. A new lower interstice liner was installed, extending 36 feet from the base of the existing liner, restoring structural continuity and long-term durability within the silo system.

A cement production facility in the northeastern United States identified structural deterioration within one of their silo interstices. The walls exhibited widespread cracking, delamination, and loose concrete throughout the upper sections. In several locations, chunks of concrete had separated from the substrate, creating safety concerns and the potential for progressive structural damage if left unaddressed.

Inspection revealed vertical and horizontal cracking of varying widths, along with compromised concrete along the lower liner section. Delaminated areas indicated bond failure within the concrete matrix, raising concerns about moisture intrusion, continued material breakdown, and reduced wall thickness over time. Given the interstice’s structural role in supporting the silo group, restoring the integrity of the concrete liner system was critical. The facility required a comprehensive repair program to remove unstable material, rehabilitate damaged wall sections, and install a new lower liner extension for reinforcement.

Access to the silo interstice required a combination of rope access and scaffold support due to the confined environment. Industrial Access technicians performed the initial inspection and removed loose and delaminated concrete using rope access techniques. Interior scaffolding was then erected to provide stable platforms for forming, crack repair, and concrete placement. A temporary access door in the cone was installed to facilitate debris removal. This coordinated approach allowed crews to safely perform material removal, structural preparation, and sequential concrete pours while maintaining secure working conditions throughout the project.

To restore structural integrity, the team began by mechanically removing deteriorated and delaminated concrete, lowering it to grade. All loose material was cleared to expose sound substrate, eliminating hazards and preparing the surface for repair. Cracks and separations were cleaned and evaluated to determine the appropriate repair method based on width and depth.

Cracks wider than 1/8 inch were routed to solid concrete and rebuilt using high-performance vertical repair mortar. Hairline cracks were cleaned and sealed with structural epoxy to prevent moisture intrusion and further propagation. This ensured both surface-level and deeper defects were fully addressed, restoring continuity within the walls.

With substrate preparation complete, the crew installed engineered formwork and fabricated structural support plates to withstand the load of the concrete pours. A new lower liner section was constructed, extending 36’ from the base of the existing liner. Concrete was placed in controlled, sequential lifts to rebuild damaged sections. Forms were removed after curing, and all interior surfaces were cleaned and inspected. Final welding of support plates, securing of hatches, and sealing of the cone door completed the rehabilitation, resulting in a durable, fully restored interstice.

All interstice rehabilitation work was completed safely and in accordance with the facility’s structural and quality requirements. Removal of delaminated and loose concrete eliminated debris hazards and exposed compromised areas for proper repair. Crack sealing and mortar restoration reestablished wall continuity, mitigating the risk of moisture intrusion and further deterioration.

The installation of engineered formwork, controlled concrete pours, and the liner extension restored structural stability within the confined interstice. Silo interstice was returned to service with renewed integrity and long-term reliability in the demanding cement plant environment.