Summary of Concrete Rehabilitation Projects

Sterling Fibers, Milton, Florida

(Formerly American Cyanamid Company)

Fibers Manufacturing Building

Concrete testing and evaluation of deteriorated concrete in manufacturing area; recommended repair methods; 1980-1982.

Evaluation of progress of deterioration, design of new framing configurations to prevent future

Contamination; 1984, preparation of bid documents.

Amity Dyeing & Finishing Partnership, Augusta, Georgia

Concrete condition survey and testing, repair recommendations on production floor of dyeing plant; 1992 – 93 Engineering Study.

PCS Nitrogen, Millington, Tennessee

(Formerly Arcadian Chemical Co)

Prill Tower

Repairs to interior walls of prill tower, major delaminations full height. Inspection, testing, design of repairs and monitoring of installation of shotcrete repairs during shutdown; 1993.

Engineering for exterior shotcrete repairs and metalized zinc cathodic protection system. Originally scheduled for 2003. Project canceled, plant closed.

PCS Nitrogen - Lima, Ohio

(Formerly BP Chemicals)

Prill Tower - 50’ Dia. x 240’ High

Inspection, testing and engineering evaluation of deteriorated concrete structure; repair recommendations, construction inspection of exterior formed and pumped repairs; 2001.

Triad Chemical, Donaldsonville, Louisiana

Prill Towers - 50' Dia. x 180' High

Inspection, coring and testing of deteriorated concrete structure, (high chloride level) recommended repair included shotcrete and trial cathodic protection; 1985

Design emergency repairs for collapsed rake floor and conveyor system beneath; 1988

Courtaulds Fibers, Mobile Alabama

Fiber Manufacturing Building

Inspection, concrete testing and evaluation of mechanism of chemical attack on concrete beams and girders exposed to process chemicals (principally sulfuric acid), in rayon fiber manufacturing plant; recommended repair procedures and preparation of plans and specifications; 1986 Engineering Study.

Foul Air Tunnel

Inspection, testing and analysis of brick lined reinforced concrete tunnel running beneath full width of manufacturing building exposed to severe sulfate attack; 1989.

Crown Vantage, St. Francisville, Louisiana

Bleach Plant

Condition survey and preparation of repair drawings for column, beam and floor slab repairs; 1997, 1999 .

Ethyl Corporation, Baton Rouge, Louisiana

Sodium Cell Building

Inspection, concrete testing and evaluation of deteriorated concrete roof deck of the sodium cell rooms; corrective repair drawings; 1976.

Exxon Company, U.S.A., Baton Rouge Louisiana

East Coker

Condition survey and evaluation of concrete column and beam deterioration on structure supporting east coker unit; recommended repair methods; preparation of plans for repair; 1990.

Engineering assistance to Exxon following major fire on the Coker Structure; repair recommendations regarding fire damage to concrete structure; Engineering Study.

Sulfur Storage Pit - 200 Unit

Inspection, concrete testing and analysis of deterioration involving combined effects of chemical attack, thermal stresses, structural loading and ground water intrusion, presentation of repair options, preparation of final plans for repairs, composite design steel plate, stiffeners, calcium

aluminate cement mix;1991-1993.

Sulfur Storage Pit - 100 Unit

Preliminary design and testing of shotcrete repair option utilizing calcium aluminate cement and stainless steel fibers design mix; bond to existing substrate. Final design of shotcrete repair options completed in December; 1999

R.O.C.C. Building

Investigation of thermal cracking in 9" concrete roof and structural frame and recommendations for repair: 1976.

Sulfuric Acid Tanks 96 and 396

Recommendations on substrate concrete repair and acid proof brick system in containment area; 1981 Engineering Study.

Georgia Pacific, Brunswick, Georgia

Chlor-Alkali Cell Building

Inspection, concrete testing and evaluation of deterioration of the 6" concrete slab and supporting prestressed precast supporting beams and girders in the cell rooms; 1982.

Chlor-Alkali Cell Building

Evaluation of progress of deterioration, design of beams and girder shoring system; 1984.

Bleach Plants Numbers 1, 2, & 3

Evaluation of concrete deterioration, recommended repair methods and preparation of detailed plans and specifications for contractor bidding; plans showed location and extent of all member repairs, suggested shoring methods and repair sequence, details and specifications for shotcrete, hand patch, and formed and poured repairs; concrete protection including U-drain trench linings, floors coating systems and concrete sealers; 1989.

Georgia Pacific, Port Hudson, Louisiana

Bleach Plant

Condition survey, determination of repair priorities, preparation of repair drawings for annual repairs; 1994.

International Paper Company, Bastrop, Louisiana

Central Furnish Basement

Inspection and evaluation of concrete slab, beam, girder, and column deterioration; preparation of plans and specification for contractor bidding; repairs included shotcrete mix with microsilica and polypropylene fibers; 1988.

Paper Machine Building

Inspection, testing and evaluation of deteriorated concrete in paper machine building; reinforced concrete slabs, beams and columns. Recommended repair methods and prepared repair drawings; 1983-1984.

International Paper Company, Mansfield, Louisiana

Roof Panels - Paper Machine Building

Testing and evaluation of deterioration of precast roof panels above paper machines in service only 8 years; carbonation effects on galvanized reinforcing investigated; 1989 Engineering Study.

International Paper Company, Natchez, Mississippi

Chlorination Tower Foundation

Inspection and analysis of existing tower foundation to support new tower following demolition of the original tower; recommended anchorage details; 1990

Rain CII, Gramercy, Louisiana

(Formerly Kaiser Aluminum & Chemical Corporation)

Caustic Chlorine Cell Rooms

Inspection, concrete testing, and evaluation of deteriorated concrete in cell rooms, components testing and evaluation program of repair materials; recommended repair methods, preparation of construction drawings for concrete repair of cell rooms support structure; 1985.

Coke Calciner Storage Dome Walls

Investigation and structural evaluation of 12" thick x 25' high reinforced concrete ring walls on a 225' diameter storage dome after a long duration high intensity coke fire; 1976 Engineering Study

Coke Calciner Storage Dome

Structural evaluation of corrosion effects on Calcined Coke Storage Dome Roof Structure. Recommended replacement of dome structure with laminated timber arches. Replacement dome members were near completion of fabrication when deteriorating existing dome collapsed due to excessive corrosion losses; 1985

Mississippi Phosphates Corp, Mississippi Chemical Corporation,

Pascagoula, Mississippi

NPK Fertilizer Plant No. 3

Six-story concrete frame plant unit. Inspection, evaluation of deterioration, computer analysis on wind frame, protective coating and repair drawings; 1979

North Dock

Inspection of deterioration in precast concrete deck slabs and recommended repairs, 1979 Study and Repair

Monsanto Company, St. Louis, Missouri

Sulfur Storage Pit

Inspection, concrete testing and analysis of deterioration involving combined effects of chemical attack, thermal stresses, structural loading and ground water intrusion, presentation of repair options, preparation of final plans for repairs, coordination of repair installation; 1994.

P.P.G. Industries, Lake Charles, Louisiana

Caustic and Salt Evaporator Platforms

Inspection, concrete testing, and corrosion survey of large reinforced concrete caustic and salt evaporator platform structures; recommended repair includes shotcrete and cathodic protection: 1985.

Plant A Mercury Cell Caustic-Chlorine Plant

Structural condition survey, concrete testing, and evaluation of concrete deterioration in elevated mercury cell caustic-chlorine production plant; recommended repairs on prestressed beams and girders, and normal reinforced columns; 1987 Engineering Study

Plant C Chlorine Cell Supports

Inspection, concrete testing of large pedestals (6' height) supporting chlorine cells; recommended repair methods; testing of two cathodic protection systems; updating of repair methods on annual basis for repair of 144 pedestals; 1988- current - Engineering Study

Plant A K306 Building

Structural condition survey, concrete testing, and evaluation of concrete deterioration in elevated

caustic-chlorine production plant; recommended repairs on 500 columns, beams and slabs, 2001

Plant A K307 Building Covered Roadway

Structural condition survey, concrete testing, and evaluation of concrete deterioration in elevated

roadway and large maintenance support building; recommended repairs on 450 columns, beams and slabs; 2001

Scott Paper Company, Mobile, Alabama

Bleach Plant No. 3

Structural condition survey, concrete testing and evaluation of concrete deterioration on concrete floor slabs in five story bleach plant structure; recommended repair procedures and prepared final plans and specifications for contractor bids; 1987

Bleach Plant N0. 2

Evaluation of repair methods for concrete beams, girders and columns undergoing severe deterioration supporting bleach plant washer floors; 1988

Concrete Silo Vessels

Concrete testing and evaluation of deterioration on concrete silo vessels storing chemicals for bleach plant processes; recommendation of repair methods, 1989

Recovery Boiler Floor Slabs

Condition survey and testing of concrete floor slabs on 8-story recovery boiler building; recommended slab repairs including resurfacing, crack injection and coating systems; 1991

Energy Recovery Cooling Tower Basin

Evaluation of concrete cracking in elevated cooling tower basin and recommended repair methods; 1991 Engineering Study

Star Enterprises (Texaco), Convent, Louisiana

FCCU Pipe Rack - Fin Fan Supports – Fire Damage

Inspection and evaluation of emergency repairs following fire

damage to prestressed members supporting fin fans and piping;

repairs planned to minimize shutdown of cat-cracker, 1988 Emergency repairs

H-Oil Structure – Fire Damage

Inspection and recommendations of emergency repairs

following fire damage to concrete support frames, 1994 & 1996 Emergency repairs

Reactor Structure

Inspection and recommendations of repairs to damaged

concrete columns supporting cat-cracker, 1995 Emergency repairs

Boiler Foundation

Inspection and recommendations of repairs to damaged

piers supporting boiler; repairs made during shutdown, 1995 Emergency repairs

VPS Exchange Structure – Fire Damage

Inspection, evaluation & design of emergency repairs Emergency Repairs

to multi-story concrete structure following fire damage