Concrete Silo Rehabilitation

Hindle Mason Projects has already refurbished and returned to service 25 large silos for a leading mining client. At the start of this week, we started repairing the final silo in the complex.
 
All silos are subject to deterioration which, if not addressed in a proactive manner, can result in structural failure. Encompassing a variety of cutting-edge maintenance and repair techniques, we have a more than 30-year-long track record extending the lifecycle of these critical production assets. This is undertaken at a fraction of the cost of constructing these notoriously expensive concrete structures.
 
Mobilising to site in 2014 to commence repairing the silos, this project has been an extensive undertaking. Each silo has between 350m and 700m of cracks and no less than 80m3 of spalled concrete that require urgent attention.
 
We are using a high-quality injection system to repair the cracks. It forms an effective barrier against water infiltration and corrosion-promoting media. The system also structurally bonds the concrete sections together.
 
Spalled and damaged concrete is repaired with a state-of-the-art mortar. It has been specifically formulated to restore or replace original profiles and functions of concrete. When applied by a competent contractor, it can restore structural integrity and increase the durability of concrete structures.
 
Pultruded carbon-fibre polymer strips are then used to reinforce the silos, with about 320m of this sophisticated structural-strengthening system applied to each structure.
 
To complete the repair procedure, we wash the silos again and then apply a cementitious waterproofing slurry.
 
As part of the work scope, we are also completely refurbishing the silos’ inline chutes.
 
Our work starts by removing all existing bolts and core drilling new holes for fasteners after the steel plates have been removed. Thereafter, we break up the surrounding damaged concrete, enabling the installation of new rebar and concrete placement.
 
To cast the various elements, we use a free-flowing, high strength, cementitious micro concrete with a maximum aggregate size of 9mm. It is easy to mix, apply and finish and provides excellent adhesion properties.