11014 Case Studies of Concrete Repair and Strengthening of Coal Storage Silos in Eastern Australia

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Product Number: 51300-11014-SG

ISBN: 2011 11014 CP

Author: Bradley J Dockrill and Warren K. Green

Publication Date: 2011

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Two 3000-ton capacity reinforced concrete coal silos and one 5000-ton capacity reinforced concrete coal silo in the Hunter Valley, New South Wales, Australia were deteriorated due to corrosion of steel reinforcement. The storage silos are a critical asset necessary to facilitate the efficient delivery of coal. Serious concrete deterioration of the silos and corrosion to external post-tensioned cables had the potential to catastrophically interrupt the supply chain. A risk and structural assessment of the silos was undertaken and a condition investigation completed.

A remedial option scenario analysis was conducted for each silo to provide a serviceable strengthening solution.

The remedial solutions ultimately adopted used either carbon fiber laminates (CFL) and/or post tensioned cables, all externally applied. In both cases where delaminated (drummy) zones of concrete were present or where concrete had severely spalled (internally and externally) concrete repair was undertaken with a sprayed repair mortar. An elastomeric anti-carbonation coating system was then applied to external silo concrete surfaces.

Keywords: reinforced concrete, silos, risk assessment, condition survey, concrete repair, structural strengthening, and carbon fiber laminates.