Cooling Tower Repair

1. Chipping & Loose Concrete Removal

• Action: Mechanical chipping using jackhammers was carried out to remove all spalled, weak, and deteriorated concrete from the beams and columns affected by high humidity and operational conditions.

• Objective: Clearing away compromised material until reaching a sound concrete substrate and fully exposing the reinforcing steel bars (rebar) for assessment.

2. Rebar Treatment & Preparation

• Action: Exposed reinforcing steel was thoroughly cleaned of rust and oxidation scale using wire brushes.

• Objective: Preparing the rebar for an anti-corrosion coating and bonding agent application to prevent future rust and ensure a strong bond with the new repair material.

3. Concrete Repair & Finishing

• Action: The concrete structural elements were rebuilt to their original dimensions using specialized, non-shrink, sulfate-resistant repair mortar.

• Objective: Hand-applying and finishing the repair layers to provide high water impermeability and protect the cooling tower’s structural integrity against harsh environmental loads.

Safety Compliance (HSE): All activities were executed under strict safety protocols, including the erection of secure scaffolding, the mandatory use of full Personal Protective Equipment (PPE), and fall protection body harnesses for working at heights.