A reprint from proceedings of

Fauji Fertilizer Company

FFC Int’l Seminar on Ammonia &Urea Technology,
Bhurban, Murree, Sept. 1 & 2, 2003

Repairs and Rehabilitation of Cooling

Tower - A Case History
by

Dr. M. U. K. Afridi & Anwar Ahmed Khan,

Executive Director Manager (R&D)
Dadabhoy Construction Technologies (Pvt) Limited,
5th Floor, Maqbool Commercial Complex, Block 7&8, J.C.H.S.
Shahrah-e-Faisal, Karachi - 75350, Pakistan.

S. Naveed Haider,
Section Head, Project Engineering, Fauji Fertilizer Company Limited
Mirpur Mathelo, District Ghotki.

Dr. Ghous Bux Khaskhali,

Professor,
Department of Civil Engineering, Mehran University of Engineering
and Technology, Jamshoro, Hyderabad.

Summary

This is a very important paper discussing the usage of indigenously developed

modern, hi-tech chemical based construction materials, the Hi-Bond - Prepackaged
Polymer - Modified Mortars in the repairs and renovation of deteriorated, highly
damaged concrete structures of cooling tower at Fauji Fertilizer Company Limited,
Mirpur Mathelo, District Ghotki. This paper also provides a deep insight and
understanding that how modern chemical based construction materials are helpful in
the revival of civil structures. Usage of products belonging to Hi-Bond - Prepackaged
Polymer - Modified Mortars made it possible to repair and rehabilitate near to
unserviceable, highly damaged / deteriorated 3 cells of main cooling tower till now.
According to third party independent evaluation, the results of repairs are excellent
with high structural integrity. The compressive strength of unrepaired concrete as
tested by Schmidt Hammer test was very poor, about 700 - 800 psi, whereas that
repaired by Hi-Bond modified mortars and concrete was 3200 psi. Usage of Hi-Bond
has increased the strength of structures to sustain the required load and to perform
the particular duty. Strength upto 3200 psi is a great achievement and fully intact to
perform the required functions. Apparently repaired cells appear new as if these were
not repaired. The useful life of repaired cells is expected to be more than a decade.
Above repairs show very high cost benefit ratio due to the usage of locally
manufactured Hi-Bond - Prepackaged Polymer - Modified Mortars. On each cell huge
saving of Rs. 6 millions have been made. Hence, a large amount of 18 millions have
been saved just on the repair of 3 cells. Because of the above advantages, family of
products belonging to Hi-Bond - Prepackaged Polymer - Modified Mortars,
manufactured by Dadabhoy Construction Technologies, Karachi are recommended for
use in further repairs and rehabilitation work at Fauji Fertilizer Company Limited,
Mirpur Mathelo, District Ghotki and also elsewhere in similar situations.

Introduction and Background of Repairs and Rehabilitation Work

Fauji Fertilizer Company (FFC) acquired the control of Pak Saudi Fertilizer Limited
(PSFL) at Mirpur Mathelo, District Ghotki, Sindh (Plant - 3) in June 2002. Plant - 3
was commissioned in early 1980 with design capacities of 1000 metric tones of
ammonia and 1740 metric tones of urea per day. The plant employs Haldor Topsoe
design of late 1970’s and Snamrogetti process for urea plants. Initially there was one
main cooling tower with 8 - cells at plant 3. Later, two more cooling towers, one with
2 cells and another with 3 cells, were added due to poor performance of main cooling
tower with 8 cells.

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 A reprint from proceedings of
Fauji Fertilizer Company
FFC Int’l Seminar on Ammonia &Urea Technology,
Bhurban, Murree, Sept. 1 & 2, 2003

At the time of acquiring of plant - 3 by FFC, the civil structures of plant were heavily
deteriorated due to chemical attack originating from high chloride and chromate levels
as proper attention towards repair and maintenance work was not given before.

Since the cooling tower at any fertilizer plant complex plays a vital role in the
performance of plant, therefore repair of cooling towers was included among the top
priority areas.

Problem History

Main cooling tower was designed by M/s. FAVRA and Snamprogetti, Italy and was
commissioned in 1979. A heavy fire took place in this tower during erection phase in
which its complete packing was burnt and its civil structure was severely affected.
Packing was replaced with new local packing but no treatment was done on civil
structure.

With the passage of time, civil structure of cooling tower deteriorated severely.
Almost all the external surfaces have damaged badly and in most of the areas re-bars
have been exposed and severely corroded. Overall concrete structure has become
very brittle and soft and is falling by its own weight. Presently due to extensive
corrosion and increase in roughness of external surfaces more penetration of
high chloride and chromate water is occurring and damaging the structure at faster
rate. As a result, this concrete structure is falling into cooling tower basin and is
causing serious choking problems in exchangers and pipe lines.

The most seriously damaged parts are the fan stacks and louvers. Top edges of these
stacks and louvers were corroded completely including re-bars. Large through holes
are visible at some locations in walls. Repairs made on the stacks some years back by
using ordinary sulphate resistant cement has adversely affected the original structure
due to poor bonding and formation of cavities.

All the above damages to the civil structure can mainly be attributed to following
reasons :-

1. Sealing of external surface of cooling tower against chemicals, water, ions, gases
and salts was not included in the original design.

2. During erection, due to a major fire, all packing of the cooling tower was burnt
causing adverse effects on civil structures.

3. Afterwards proper repairs, rehabilitation and maintenance of structure has never

been done over a long period of time.
4. Severe chemical attack caused serious damages to the structure.

Repair Plan

A. Selection of proper repair, renovation, chemical resistant and

waterproofing materials.

Before takeover of plant by FFC, the management of PSFL had contacted several
reputable and well renowned companies for the repair of this cooling tower. Almost all
the expert companies gave similar comments and observations on the condition of the
structure and suggested very lengthy and expensive repair procedures. The repair
procedures suggested by such companies involved various costly imported
construction chemicals. These construction chemicals are to be used as ordinary
cement mixes are unable to repair such damages due to their technical limitations like
lack of bond strength, negligible elasticity and improper sealing characteristics. Cost
of repair was more than the cost of construction of an entirely new cooling tower.

All the technical proposals for this repair of cooling tower available at that time were
reviewed thoroughly but none of them was found feasible. Therefore after detailed
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 A reprint from proceedings of
Fauji Fertilizer Company
FFC Int’l Seminar on Ammonia &Urea Technology,
Bhurban, Murree, Sept. 1 & 2, 2003

review of situation it was decided to search for an agency who can offer some
practical and economical solution to the problem. As a result, Dadabhoy Construction
Technologies (Pvt) Limited (DCTL), Karachi, the local manufacturers of a series of hi-
tech, advanced construction materials were contacted through M/s. Dada Traders.
Experts of DCTL were requested to visit the site and give a detailed presentation
about their series of chemical based construction materials sold under the brand
name of Hi-Bond - Prepackaged Polymer - Modified Mortars. Another reason to invite
experts of DCTL was that all literature already sent by DCTL was thoroughly reviewed
and due to the good results of a sample of Hi-Bond (Universal) supplied previously by
DCTL. The sample was applied on the affected cooling tower almost two years ago on
a fan stack, the most seriously damaged area of cooling tower. The sample was fit as
no further deterioration to the original structure had occurred at the place where
sample was applied. Its bonding with the original structure was excellent. Moreover,
no damage had occurred to the sample itself in previous two years although water
proofing to the sample had not been provided.

Dr. Afridi gave a detailed presentation about the family of products belonging to
Hi-Bond. It was told that a good repairing and sealing material must have the
following properties over the ordinary cementitious materials : (i) improved bonding
or adhesion to the substrate, (ii) improved elastic behaviour, (iii) proper compressive
strength, (iv) ability to resist adverse environmental conditions including resistance
against chemicals, ions, gases, salts and water, (v) ability to withstand changes due
to moisture and temperature, (vi) ability to revive alkanity on the affected area after
repairs. Dr. Afridi explained, since family of products belonging to Hi-Bond comprise
cement, sand, film forming redispersible polymer powders, shrinkage reducing
components, antifoaming agents, therefore products related to Family of Hi-Bond
qualify the criteria mentioned above for a proper repairing material needed for
repairs, rehabilitation and maintenance of concrete structures at Fauji Fertilizer
Company Limited, Mirpur Mathelo. Following table shows the comparison of properties
of Hi-Bond (Universal) and Ordinary Mortars:-

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 A reprint from proceedings of
Fauji Fertilizer Company
FFC Int’l Seminar on Ammonia &Urea Technology,
Bhurban, Murree, Sept. 1 & 2, 2003

Technical Data

Comparison of Hi-Bond (Universal) with Ordinary Mortars

a. Fresh Mortar Properties

Hi-Bond Ordinary or
S.No. Property (Universal) Un-modified Mortar

01. Unit Weight (kg/1) 1.9 2.0

02. Air Content (%) 8.2 6.1
03. Water Retention (%) 96.6 70

b. Hardened Mortar Properties

Hi-Bond Ordinary
S. No. Property
(Universal) Mortar

01. Total Pore Volume (x10-2cm3/g) 10.3366 11.2531

02. 28-day Compressive Strength (kgf/cm2) 320 234

03. 28-day Flexural Strength (kgf/cm2) 130 74

04. 28-day Tensile Strength (kgf/cm2) 47 24

05. Max. Deflection (x10-1mm) 1.0 0.42

06. Max. Extreme Tensile Fiber Strain (x10-6) 1231 385

07. Max. Tensile Strain (x10-6) 380 82

08. Flexural Modulus of Elasticity (x104 kgf/cm2) 6.31 7.36

09. Tensile Modulus of Elasticity (x105 kgf/cm2) 2.27 2.63

10. Crack Coefficient (x10-2cm2/kg) 0.020 0.037

11. Adhesion in Tension (kgf/cm2) 22 5

12. Water Absorption (%) 9.3 12.2

13. Water Permeation (g) 6 66

14. Freeze-Thaw Durability Factor 72 10

15. 91-day Carbonation Depth (mm) 10 21

___ ___
2.43 x 10-4 √ t + 0.15 5.57 x 10-4√ t + 0.53
16. Index of Resistance to rate of Diffusion of CO2
(γ=0.99) (γ=0.99)

17. 91-day Chloride Ion Penetration Depth (mm) 10.5 22.5

Apparent Chloride Ion Diffusion Coefficient
18. (x10-9 cm2/s) i.e. Index of Resistance to c1- ion 0.2 13.2
Diffusion.

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 A reprint from proceedings of
Fauji Fertilizer Company
FFC Int’l Seminar on Ammonia &Urea Technology,
Bhurban, Murree, Sept. 1 & 2, 2003

It was also explained that repairs, renovation and water - proofing done by using
Hi-Bond in the past at various projects (1) showed good cost benefit - ratio and are
performing excellently.

In the above background, following decisions were made :-

(i) Following products belonging to Hi-Bond will be used for purpose specified in front
of each :-

a. Hi-Bond (Universal): For making bond coats, as an admixture to ordinary

mortar/concrete.

b. Hi-Bond (Sealer) Grey Sanded (old name: Hi-Bond Waterproof Coating): For
making the repaired surfaces chemical resistant, weather resistant and water-
proofed.

c. Hi-Bond (Tile Adhesive): For pasting of the tiles, stones and }optional, when-
marble. } ever required.
d. Hi-Bond (Grouts):For grouting of the tiles, stones and marble.}

ii. One cell will be repaired first. After seeing its success, further work will be done.

iii. M/s. DCTL shall train the contractor free of cost for the use of Hi-Bond.

iv. M/s. DCTL shall send their experts to inspect the work of contractor during
execution.

v. Third party inspection will be carried out after completion of work at 3 cells.

B. Procedure for repairs and renovation

(a) Repair of Stack, Beams, Columns, Riser and Inside Floor

a-1. Light hammering, chipping and removal of damaged concrete will be done till
sound concrete is obtained.
a-2. Proper cleaning of the surface will be done with wire brushes to remove dust
and debris.
a-3. Binding of fresh steel bars dia 3/8" will be done for replacement of badly
damaged / rusted steel bars.
a-4. V-grooves upto 3/4" deep will be made wherever the cracks are visible.
a-5. Wire mesh (24 BWG) will be fixed on V-grooves.
a-6. Priming coat of Hi-Bond (Universal) will be made by dissolving 1 kg Hi-Bond
(Universal) in about 600 - 700 ml potable water and will be applied on the
prepared surface obtained as a result of points mentioned above.
a-7. Repair of damaged concrete will be done using Sulphate Resistance Cement
Concrete (1 : 11/2 : 3) and Hi-Bond (Universal) will be used as an admixture
at a ratio of 20% to the weight of cement in the concrete mix. Chinote coarse
aggregate of size of 3/8" and hill sui sand will be used.
a-8. After repairs, plastering of complete surface will be done with sulphate resistant
cement - sand mortar in the ratio of 1:3 by mixing Hi-Bond (Universal) as an
admixture at a ratio of 20% to the weight of cement in the mortar mix.
a-9. Water proofing will be done by applying Hi-Bond Waterproofing Coating
(new name Hi-Bond Sealer) in form of slurry coating by brush. Slurry will
be made by dissolving 1 kg Hi-Bond (Sealer) in 700 - 800 ml potable
water. Application will be done in two coats with 1.5 - 2 mm thickness.
a-10 Wet curing of repaired area, plastered surface will be done for atleast 3 days.

a-11 Removal of debris and site clearance will be done immediately.

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 A reprint from proceedings of
Fauji Fertilizer Company
FFC Int’l Seminar on Ammonia &Urea Technology,
Bhurban, Murree, Sept. 1 & 2, 2003

(b) Repair of Louvers

Same as a-1 to a-11 above, except that changes were made in point a-7 and a-8 as
follows to reduce costs :-

b-1. Repair of only damaged concrete will be done using Sulphate Resistant Concrete
(1 : 11/2 : 3). Chinote Coarse Aggregate of size 3/8" and hill sui sand will be used.

b-2. After repairs, plastering of complete surface will be done with sulphate resistant
cement - sand mortar in the ratio 1:3 after fixing chicken wire net (04 holes per sq.
inch and 24 gauge) at the front edge of louvers.

(c) Repair of Top surface of Roof

c-1. Light hammering and chipping will be done in order to remove loose material so
as to obtain sound concrete surface.

c-2. Proper cleaning of the surface with wire brushes will be done to remove dust,
debris and oils, etc.

c-3. 2" thick screed with ratio of (1 : 1 1/2 : 3) in line level and slope, etc will be
provided. Sulphate resistant cement, chinote coarse aggregate and hill sui sand
will be used.

c-4. Wet curing of repaired area will be done for atleast 3 days.

c-5. Removal of debris and site clearance will be done immediately.

Execution of Repair Plan

1. As decided, DCTL trained the contractor about the application of the products
belonging to Hi-Bond Family. They also sent their experts at the time of the start of
repairs and rehabilitation job and also during the work.

2. Repairs and rehabilitation work on 1st cell of main cooling tower was started in
December 2002 and finished in February 2003.

3. Seeing the satisfactory results of the repairs and rehabilitation work of 1 st cell of
main cooling tower, it was decided that repairs and rehabilitation should be extended
to other cells as well.

4. Repairs and rehabilitation work at 2 nd cell of main cooling tower was started in
February 2003 and finished in March 2003 whereas that for 3 rd cell of main cooling
tower such work started in April 2003 and finished in May 2003. Hence, till now
repairs and rehabilitation work at 3 cells of main cooling tower have been completed
successfully. It is obvious that about one and a half month is required for repairs and
rehabilitation of each cell.

5. Since in the summer season, it is not possible to spare cells of cooling tower for
repairs and rehabilitation, so work is now stopped. Further work will be done possibly
in October due to lowering of atmospheric temperature

Results

1. The results of repair were excellent. Adhesion of Hi-Bond modified mortars and Hi-
Bond modified concrete to old substrate is superb. The weakened structure has been
restrengthened. The surface came out to be extremely compacted, strong and tough
giving new look to deteriorated concrete structures. Figures 1 - 12 show condition of
structures before, during and after repairs and rehabilitation.

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 A reprint from proceedings of
Fauji Fertilizer Company
FFC Int’l Seminar on Ammonia &Urea Technology,
Bhurban, Murree, Sept. 1 & 2, 2003

2. After 3 months of repair and rehabilitation work, slight surface micro cracks
appeared on the surface of fan stack possibly because of non compaction of new
mortar and concrete in some areas of the stack and also possibly due to excessive
water sprinkling on the repaired surface. Other factors include thrust of large fan
running inside the stack and consequent vibration in the structure. However, these
surface cracks are of minor nature and harmless to structural integrity.

Cost Comparison

Cost of new cell Rs. 7 Millions

Repair cost per cell using imported construction chemicals Rs. 8 Millions
Repair cost per cell using Hi-Bond Family of Products Rs. 1 Million
Cost saving per cell due to usage of Hi-Bond Family of Products Rs. 6 Millions

Third Party Inspection

Dr. Ghaus Bux Khaskhali, Professor of Civil Engineering Mehran University of

Engineering and Technology, Jamshoro was requested to inspect and assess the
quality of work carried out upto this first phase. Prof. Dr. Khaskhali visited the Fauji
Fertilizer Company Limited, Mirpur Mathelo, District Ghotki on 17 th June. His report is
enclosed as Annexure – 1.

Conclusions

1. Usage of products belonging to Hi-Bond - Prepackaged Polymer - Modified Mortars

made it possible to repair and rehabilitate near to unserviceable, highly damaged /
deteriorated 3 cells of main cooling tower till now.

2. According to third party independent evaluation, the results of repairs are excellent
with high structural integrity. The compressive strength of unrepaired concrete as
tested by Schmidt Hammer test was very poor, about 700 - 800 psi, whereas that
repaired by Hi-Bond modified mortars and concrete was 3200 psi. Usage of Hi-Bond
has increased the strength of structures to sustain the required load and to perform
the particular duty. Strength upto 3200 psi is a great achievement and fully intact to
perform the required functions. Apparently repaired cells appear new as if these were
not repaired. The useful life of repaired cells is expected to be more than a decade.

3. Above repairs show very high cost benefit ratio due to the usage of locally
manufactured Hi-Bond - Prepackaged Polymer - Modified Mortars. On each cell huge
saving of Rs. 6 millions have been made. Hence, a large amount of 18 millions have
been saved just on the repair of 3 cells.

4. Because of the above advantages, family of products belonging to Hi-Bond -

Prepackaged Polymer - Modified Mortars, manufactured by Dadabhoy Construction
Technologies, Karachi are recommended for use in further repairs and rehabilitation
work at Fauji Fertilizer Company Limited, Mirpur Mathelo, District Ghotki and also
elsewhere in similar situations.

Acknowledgments

Management of Fauji Fertilizer Company Limited is to be thankfully congratulated for

allowing the above repairs and rehabilitation work at highly economical rates.

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 A reprint from proceedings of
Fauji Fertilizer Company
FFC Int’l Seminar on Ammonia &Urea Technology,
Bhurban, Murree, Sept. 1 & 2, 2003

References

1. M.U.K.Afridi, Anwar A. Khan, Syed Ali Rizwan, Ghous Bux Khaskhali,

“Hi-Bond - Prepackaged Polymer - Modified Mortars with Field Applications and
Economic Advantages”, Proceedings, IQRIP 2003, International Conference on
Investment and Quality Control in Road and infrastructure Projects, Lahore, Jan 21 -
23, 2003, pp. 11 - 19.

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 A reprint from proceedings of
Fauji Fertilizer Company
FFC Int’l Seminar on Ammonia &Urea Technology,
Bhurban, Murree, Sept. 1 & 2, 2003

Fig.1 Heavily damaged fan stack structure at Pak Saudi Fertilizer, Mirpur Mathelo before
repairs/renovation by Hi-Bond Prepackaged Polymer Modified Mortars/Concretes. Debonded concrete
cover, corroded rebars and through holes are clearly evident.

Fig.2 Fan stack outer surface before repair. Cracking and debonding of concrete cove is
visible.

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 A reprint from proceedings of
Fauji Fertilizer Company
FFC Int’l Seminar on Ammonia &Urea Technology,
Bhurban, Murree, Sept. 1 & 2, 2003

Fig.3 Fan stack outer surface before repair – another view.

Fig.4 Fan stack outer surface before repair, after chipping. Badly damaged concrete surface, corroded
rebars and through boles at a closer view.

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 A reprint from proceedings of
Fauji Fertilizer Company
FFC Int’l Seminar on Ammonia &Urea Technology,
Bhurban, Murree, Sept. 1 & 2, 2003

Fig.5 Fan stack outer surface before repair, after chipping – another area. Cracked
concrete and corroded rebars at closer view.

Fig.6 Fan stack structure at Pak Saudi Fertilizers, Mirpur Mathelo during repair. After chipping, new
reinforcement was fixed at required place – A close view.

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 A reprint from proceedings of
Fauji Fertilizer Company
FFC Int’l Seminar on Ammonia &Urea Technology,
Bhurban, Murree, Sept. 1 & 2, 2003

Fig.7 Fan stack structure at Pak Saudi Fertilizers, Mirpur Mathelo during repairs. After fixing of new
reinforcement, Hi-Bond Polymer – Modified Concrete Patch was applied.

Fig.8 Fan stack structure at Pak Saudi Fertilizers, Mirpur Mathelo after completion of repairs/renovation
with Hi-Bond – Prepackaged Polymer – Modified Mortars/Concretes and coating with Hi-Bond (Sealer).
Good appearance of structure compels to think that as there have been no repairs.

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 A reprint from proceedings of
Fauji Fertilizer Company
FFC Int’l Seminar on Ammonia &Urea Technology,
Bhurban, Murree, Sept. 1 & 2, 2003

Fig.9 Condition of louvers before repair – heavy scaling and debonding is apparent.

Fig.10 Excellent appearance of louvers after repair.

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 A reprint from proceedings of
Fauji Fertilizer Company
FFC Int’l Seminar on Ammonia &Urea Technology,
Bhurban, Murree, Sept. 1 & 2, 2003

Fig.11 Comparison of repaired and unrepaired cooling tower structure – A general view.

Fig.12 Comparison of repaired with unrepaired cooling tower structures – A close view.

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