Furnace cooling tower repairs

Hindle Mason Projects (HMP) is finalising large external concrete repairs to a furnace cooling tower on behalf of one of the country’s leading Platinum Group Metals producers. We commenced work on the project in March 2025, and we are well on track to completing it in November 2025.

HMP has extensive experience repairing these reinforced-concrete structures which endure extended exposure to deleterious agents present in the steam that they emit. These can include trace amounts of dissolved sulphates and carbonates, oxygen and carbon, metal ions and microorganisms. This is exacerbated by protracted exposure to warm, moist conditions which, when combined with chlorides or carbon dioxide, facilitates corrosion.

Notably, these structures are at greater risk of cracking than chimneys and flue stacks due to their significantly larger circumference and diameter with a much lower mass to surface area. This is due to settlement and adverse thermal temperatures imposed on the surfaces.

Working alongside the client’s engineer, HMP undertook a comprehensive structural investigation of the condition of the cooling tower after high pressure washing the substrate to remove debris and dirt. This revealed the true extent of the damage, with findings informing our cutting-edge repair methodology to restore the structure to its original state. Thereafter, we will implement an effective corrosion protection solution to prolong the structure’s design life.

We found that the concrete cover had been severely compromised due to attack by aerosolised corrosion products over a protracted period. This provides the aggressive gases direct access to the reinforcing, accelerating corrosion.

The project has entailed a myriad of technically correct repair techniques, including skimming and patching, as well as reinforcement treatment, using quality products and systems. This is after undertaking extensive surface preparation, which included surface grinding and cleaning exposed reinforcing steel.

Leaking and deteriorating concrete expansion joints are also being replaced, as well as adhesion and cohesion joint sealant failures addressed, before applying a hydrophobic impregnation to waterproof the structure.