Concrete testing for a multinational cement manufacturer
The Challenge
Our team faced a complex challenge when approached to assess four different silos across two cement plants in the UK. These plants are crucial in producing cement, the world's most versatile building material, essential for constructing homes, hospitals, and vital infrastructure. The project required comprehensive concrete condition assessments on the 1960s-era silos to determine whether they should be repaired or demolished. We needed to achieve complete asset coverage without disrupting the plants' busy operations, minimise safety risks, and complete inspections rapidly, all while adhering to strict industry standards and battling unpredictable weather conditions.
The Solution
We implemented an innovative combination of cutting-edge robotic technology and human expertise. The centerpiece of our approach was a state-of-the-art wall-climbing robot, capable of carrying a substantial payload and overcoming significant obstacles on various surfaces. We partnered with a leading corrosion services company to bring additional concrete assessment expertise to the project.
This version maintains the essence of your solution while removing specific brand and model references. It emphasizes the innovative nature of your approach and the capabilities of the technology used, without tying it to particular products. The partnership aspect is preserved, highlighting the combination of robotic technology and human expertise in concrete assessment.
The Process
The robot, equipped with advanced sensors, conducted comprehensive half-cell potential and cover meter surveys on the silo surfaces. These non-destructive tests mapped potential corrosion areas and determined the depth and distribution of reinforcement steel. Simultaneously, our skilled human inspectors performed complementary tasks requiring hands-on expertise, including strategic core drilling, dust collection for chemical composition tests, and calibration breakouts to ensure robotic measurement accuracy.
The inspection process combined cutting-edge technology with traditional methods. Visual inspections using the robot's high-resolution cameras and our experienced technicians identified surface defects, cracks, and other deterioration signs. We conducted carbonation depth measurements to assess concrete alkalinity, chloride content testing to evaluate corrosion risk, and petrographic examination of core samples to analyse microstructure and long-term durability. All tests adhered strictly to industry standards like BS1881 and ASTM C876-91, ensuring reliable and comparable results. This robotic-human collaboration gathered over 1km of survey data per silo, providing our client with a detailed, holistic view of their silos' condition for informed decision-making on repair or demolition strategies.
The Result
Our method delivered impressive outcomes. We collected over 1km of survey data per silo and completed each inspection in just five days. The comprehensive data gathered provided the client with crucial information for decision-making on silo repair or demolition. The robot operated efficiently in winds up to 45mph, outperforming drones and MEWPs. We maintained plant efficiency, avoided disruption to daily truck movements, and adhered to all relevant industry standards.
Discover how our cutting-edge concrete testing technology can revolutionise your structural assessments. Whether you're dealing with ageing infrastructure or complex industrial sites, our innovative solutions can help you make informed decisions while prioritising safety and efficiency. Contact Structural Repairs today to learn how we can address your unique challenges.
Structural Repairs are a leading global specialist