Inspection by plant personnel revealed cracking in the concrete frame of a 326-ft-tall, 7-level preheater tower. On-site plant engineers deemed the cracking significant, as the structure supports critical manufacturing process equipment. A structural engineering consulting firm was retained to evaluate the extent of the problem and formulate a repair plan. The firm mobilized at the site in less than 24 hours and performed an initial structural safety assessment. A comprehensive structural evaluation indicated that the structure required strengthening.

Restoration consultants were engaged to assist locally with engineering and construction administration. A specialty repair contractor also was engaged to review the constructability of several alternate repair schemes and maintain the fast-track schedule.

After considering structural capacity and serviceability requirements, durability issues, the high-temperature operating environment, constructability, and an aggressive construction schedule, the team recommended a retrofit consisting of bonded post-tensioning within internal holes drilled in the beams. This solution was quite extraordinary, as it required precision-drilling horizontal holes up to 87 ft long in the beams of the elevated frame structure, without cutting existing embedded reinforcement.

Nondestructive impulse radar testing was used to locate existing embedded reinforcing steel, as well as to monitor the drilled holes' trajectory. This process helped ensure proper tendon alignment and prevent damage to embedded steel. The cored holes served as post-tensioning ducts.

The structrural strengthening repairs were executed quickly and under challenging circumstances, including working high on the exposed structure through a cold winter with severe wind conditions. The unique retrofit resulted in a structure that is stronger, more serviceable, and more durable than the original tower.