The challenge
A steel cement silo and its conveying ducts were exposed to tropical rain, salt air and cement dust. Coatings had blistered and flaked, and erosion inside plus corrosion outside were thinning the shell and duct walls.
Welds and bolted flanges were under cyclic loads, and active truck loading below made scaffolding unsafe and uneconomic.
Scope of works
- Dual-rope rope access with re-anchors to reach shell curves, duct undersides and cones
- 100% visual testing of shell, stiffeners, ducts and supports, with rust grading
- Ultrasonic thickness of shell plates, duct bends and cone sections against design allowances
- Inspection of welds and bolted flanges under vibration
Outcome
Critical thinning zones and weld fatigue points were found before they could cause a rupture, and the plant received a full integrity register, with dispatch running throughout. The same method was used on steel silos in Greece. See our NDT services.
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