REPAIRING OF CHIMNEY

BY
EXTERNAL PRE-STRESSING


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BY
HRUSHIKESH J. PATEL ( SD1007 )
& H. L. PATEL
CONTENT
1. INTRODUCTION TO SITE
2. FAILURE OF CHIMNEYS
3. ALTERNATIVE TECHNIQUES OF REPAIR
4. CRACK REPAIR TECHNIQUE ADOPTED
5. RETROFITTING BY CIRCULAR PRESTRESSING

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1 . INTRODUCTION TO SITE
NAME & TYPE OF SITE :
Dhuvaran Thermal Power Station, GEB

LOCATION :
Dhuvaran, Near Khambhat, Gujarat.
Its near Sea Cost of Dhuvaran
=> Very severe exposure condition




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The power plant was established in 1970.

5 chimneys are built at that time only,
whereas 2 more chimneys were built after
around 4-5 years or so.

All 7 chimneys are made up of RCC shaft.

They all are circular in plan tapered in
elevation.




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Chimneys
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Power house
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An internal fire brick layer was provided all
around inner periphery of the chimney wall to
protect the RCC wall from tremendous heat
produced by the flew gases passing through it.

No External painting on the surface of the
chimney was done at the time of construction,
though very severe exposure prevails.

Dimensions of all chimneys are nearly equal and
they are :
Height = 61 mt
Bottom Dia. = 6.75 mt
Top Dia. = 4.75 mt
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2. FAILURE OF CHIMNEY
After about 25-30 years of service life the
deterioration of the chimney started.

The Vertical tension cracks were observed on
the face of the surface of the chimney.

This is because of the cyclic expansion and
contraction due to temperature variations.

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More over the internal fire brick layer got damaged,
due to long term exposure to extreme heat.

So the RCC wall directly exposes to the extreme heat
generated inside the chimney.

As the temp. outside is very less as compared to
internal temp., steep temperature gradient occurs,
which caused the non-uniform expansion and
contraction of concrete, so cracks propagated.

Almost All the chimneys were damaged severely.

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DAMAGED COMPONENTS OF CHIMNEY
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DAMAGED COMPONENTS OF CHIMNEY
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TYPE OF DAMAGE IN THE CIRCULAR RCC
WALL
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Repair of chimney by external prestressing 14
DAMAGE
IN
RCC SHAFT WALL
CRACKS SPALLING
CORROSION OF
REINF.
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SPALLING
OF
CONCRETE
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SPALLING
OF
CONCRETE
HRUSHIKESH PATEL (SD1007)
Repair of chimney by external prestressing 18
SPALLING
OF
CONCRETE
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SPALLING
OF
CONCRETE
3. VARIOUS METHODS OF REPAIR OF
CRACKS
1. Grouting

2. Routing & sealing

3. Stitching

4. Drilling & plugging

5. Polymer impregnation
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3. VARIOUS METHODS OF REPAIR OF
CRACKS
6. Epoxy injection

7. Flexible sealing

8. Dry packing

9. Additional reinforcement
Conventional reinf.
Prestressing steel

10. Crack arrest


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22
4.CRACK
REPAIR
MATHOD
ADOPTED
TYPE OF
CRACKS
MICRO
CRACKS
(C) SEALING BY
EPOXY MORTAR
+
LOW VISCOUS
EPOXY
INJECTION
WIDE
CRACKS
(B) SEALING BY
EPOXY MORTAR
+
CEMENT GROUT
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24
CRACK REPAIR METHOD ADOPTED
5. RETTROFITING BY EXTERNAL CIRCULAR
PRESTRESSING
Earlier before about 7-8 years when the
chimneys got cracked, the attempts were
made to seal these cracks through epoxy
filling, guniting etc.

But it was in vain, as the root cause of the
crack was not eliminated and only sealing of
cracks was done, the cracks again appeared
soon, And also the corrosion of reinf. Started
again.
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Now to prevent the cracks to be formed again,
concrete should never experience TENSILE
stresses, which also would prevent the
penetration of moisture and oxygen to reinf.,
and prevent corrosion.

To do that 2 options,

Expansion and contraction of wall is to be
prevented by maintaining temperature gradient.
(root cause) not practicable

Do some arrangement so that concrete always
remains in compression.

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Prestressing may help in that.

Circular prestressing imparts hoop compression ,
so the whole concrete core remains in
compression.

But the concrete chimney is already casted, so
prestressing strands cannot be inserted and
embedded into concrete.

The only solution is to go for EXTERNAL CIRCULAR
PRESTRESSING WITH POST-TENSIONING
TECHNIQUE.



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PROCESS OF PRESTRESSING


Scaffolding was first erected.

for single chimney only scaffolding erection
take @ 20 to 35 days time.
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Scaffolding
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Prestressing is done after 15 days of
completion of crack repair.

Chimney divided into 7 levels.

Between each levels the no. of bars and
spacing was varying as per

Different density of the cracks ( so Different need
of hoop compression )
Obstructions like platforms & other utilities.

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Components in the circular prestress.
HT (High Tensile) strand
2 no. of different size HDPE sleeves
(HDPE = HIGH DENSITY POLY ETHELENE)
Grease
Concrete grout

X Anchorage
Anchorage grip

Jacking units

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Procedure of Prestressing...
Mark the positions of all the strand on the
core wall itself.

Find the external perimeters at the position of
the strands.

Cut the HDPE sleeves and the strands in the
corresponding length of the perimeter.

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Insert the strand with heavy duty grease in the
smaller dia. sleeve which again inserted in
larger dia. sleeve.

Put them in position at corresponding level.

Now to hold them in position, fasteners are
also inserted in the wall.

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Why sleeves??
To reduce friction losses
To protect the strand from weather action.

The ends of the strand should be joined in
such a way that as possible as less eccentricity
is generated. But how this can be done?

The answer is X-anchorage.




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The X anchorage should be able to
withstand twice the design load of strands.

Now, ANCHORAGE GRIP is used at the ends of
the X-anchorage to hold the strands.

It prevents the slippage of strand from the X-
anchorage.

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Anchorage grip
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The strands are stressed at 330 kg/cm2.
(grouting in cracks is done at 3.5 kg/cm2)

The hoop tension to be applied varying from
15 tonnes/m height at the lower region of the
chimney to 10 tonnes/m height at its top.

The stressing of the strand is done, by jacking
device, simultaneously by both the ends.

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Procedure of Prestressing
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The consequent strands are to be tied in the
alternately at 180 degree rotation.

This is done for the prevention of stress
concentration at a single side face.

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Procedure of Prestressing
SPECIFICATIONS FOR PRESTRESSING
strands USED

HIGH TENSILE strand
Nominal size of strand = (12.70 mm)
Cross sectional area = 98.82 mm
2
Ultimate load = 19200 kgs

As per Code : IS 14268
Modulus of elasticity E = 20235 Kg/mm
2

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PERFORMANCE GUARANTEE
Performance guarantee of entire work shall be
one year from the date of completion
certificate.
Guarantee shall be in form of 10 % of work
order amount, which shall be released after
one year if the performance is found
satisfactory.
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SLIPING OF
PRESTRESS
STRANDS
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TOTAL COST OF REPAIR AND RETROFFITING
OF SINGLE CHIMNEY = 20,14,697 Rs.
COST OF REPAIR
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OVER HEAD WATER TANK REPAIRING
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DAMAGE IN THE TANK
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50 MM
50 MM
50 MM
50 MM
10 MM dia
stirrups at 150 c/c
12 MM dia bar
50 x 50 x 6 mm
angle
Existing column
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CORROSION IN COOLING TOWER
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