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Due to client confidentiality, it would be inappropriate to name this Concrete Process Stack project site.
We were invited to submit our proposal to carry out an in-depth survey to the 150mtr concrete windshield, to refurbish the stainless steel liner housed within the windshield, and to design, fabricate and install a termination Ventura cone to accommodate three individual production levels.
To accommodate the three levels of production, the Ventura cone was designed with two removable bolted flange areas that provided the specific diameters to produce efficient efflux velocity to the atmosphere for the various production requirements. The design allowed sections to be removed with minimum effort and, more importantly, minimum production loss.
To prevent air induction and process gas escaping through the horizontal flange connections on the stainless steel liner, a specialised circular platform had to be fabricated and suspended on motorised climbing wires. This was to provide access to the internal area of the liner enabling us to weld the flange connections together.
The original 902 stainless steel cone had to be removed, and a new flange was welded on to the termination point of the liner in preparation for the introduction of the new three stage Ventura cone.
Upon completion of the Ventura cone, the access scaffolding was modified to provide a support system for the suspension of external motorised platforms.
From the motorised platforms a complete in-depth survey was carried out to the concrete windshield, locating and charting a variation of defects which were all a direct result of insufficient depth of the reinforcing bars, producing fractures allowing rainwater ingress which resulted in spawling.
An extensive repair project was undertaken, and the defects were rectified using FOSROC Renderoc preparation and repair mortars.
The project was completed ahead of the planned shutdown period and to the satisfaction of all concerned.
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