Cooling Tower Roof Rehabilitation
Restoring Structural Integrity and Protecting Critical Power Plant Operations
An 8-chamber cooling tower roof unit, positioned above critical motor control units, had deteriorated due to aging concrete and repeated thermal cycling. Over time, the concrete fatigued and fractured into hundreds of pieces, posing a risk to both structural integrity and waterproofing.
The plant required a long-term repair solution to restore the structure while addressing concerns about large icicles forming at 30 feet, which could potentially damage a traditional FRP liner. A&G Industrial was commissioned to design and implement a reinforced composite system to ensure durability, impact resistance, and water-tight performance.
Experience always overcomes challenges
CFES addressed the repair needs by overcoming two critical challenges:
The floor had cracked into hundreds of pieces, requiring comprehensive stabilization before reinforcement.
Large icicles, forming 30 feet above the floor, posed a risk of penetrating and damaging a traditional FRP liner
Inspection and Preparation
Before reinforcement, a thorough assessment and surface preparation were necessary to ensure long-term adhesion and durability.
Condition Assessment:
Extensive cracking and concrete fatigue were identified as primary structural concerns.
Risk analysis confirmed icicle impact resistance needed to be integrated into the repair system.
Surface Preparation:
Cracks were sealed using a self-leveling polysulfide caulking system, restoring the floor to a monolithic state.
The surface was cleaned and prepared to enhance the adhesion of composite materials.
Innovative Repair Methods
Advanced materials and techniques were employed to ensure reliable and durable repairs:
Kevlar-Reinforced Composite System
Instead of traditional fiberglass, A&G utilized heavyweight Kevlar fabric, providing:
Superior impact resistance to withstand falling icicles.
Increased durability in extreme environmental conditions.
100% Solids Epoxy Topcoat
A high-performance immersion-grade epoxy coating was applied, ensuring:
Long-term waterproofing to eliminate water loss.
Chemical and thermal resistance for sustained structural performance environmental conditions.
Key Outcomes
Watertight Concrete Basins: The repair sealed all cracks, preventing water loss and ensuring long-term durability.
Protection Against Equipment Failure: The motor control center was no longer at risk of tripping offline due to water intrusion.
Enhanced Impact Resistance: The Kevlar-reinforced FRP system successfully resisted damage from falling icicles, preventing future structural failures.
