Problem: Deterioration of the concrete used in foundation wall as well as corrosion of reinforced steel bars. Also include corroded vessel anchor bolts, failed sluiced trench water nozzles and warped railroad rails. Areas undergone repair commonly experienced failure too.
Structural Details: Furnace is around 64 year old structure which include foundation wall, coke drum support structure and coke railroad sluiceway trench.
Cause: The structure was subjected to extreme environmental service include high temperature, chemical attack, water erosion, railroad car impact and thermal shock. This led
to the cracking, spilling and delaminating of concrete along with corrosion in steel members.
Our Approach: On the basis of the testing of the structure, it has been revealed that structure could support and integrate new concrete materials. Use of high-grade, shrinkage compensating repair concrete along with high capacity mechanical anchors was recommended.
The repairing approach includes wire-line-saw cutting of massive reinforced concrete and use of precast concrete segments involving post-tensioning anchorage and fastening, installation of waterproofing membrane systems and quick setting cementations backfill. Regarding the size of precast structure, each independently reinforced segment was evaluated with shipping load weight and size restrictions, dictating that only the sidewalls could be economically precast and transported to the site. Additional details regarding joint grouting, reworking the wash-down system and waterproofing and backfilling were detailed as the working conditions were not that favorable. 
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