Problem: Deterioration,
corrosion of embedded steel, and water leakage through the shells.
Structural Details: The
towers that need repairs are about 370ft high above the normal ground level with
the diameter of 248ft and repairs can only be carried out during scheduled
outages to avoid disruptions in the area’s power supply.
Testing: Using visual
inspection, hammer sounding throughout both towers, and laboratory testing of
core samples, investigators identified the types and extent of concrete
deterioration. In addition to the spalling, corrosion, and leakage already
noted, cracks were found in the support columns and ring beams at the bases of
the towers.
Challenges in repairing:
Providing access to the interior and exterior of the towers to allow thorough
inspection and repair was difficult. Careful structural analysis was required
to maintain the towers structural integrity while repairs were under way.
Repair materials had to be evaluated and selected for their ability to
withstand the unusual conditions within the towers.
Our Approach: Repair crew removed the deteriorated concrete from the tower shells with pneumatic chipping hammers and filled the created voids with dry-mix shot-crete. They sealed the cooling tower’s interior surfaces with water and vapor proof epoxy coating. They cleaned out cracks in the supporting columns and ring beam and sealed them with epoxy. Meticulous quality control testing and inspection during repairs helped ensure the project’s success.
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