Blue Circle

Technical Centre
Structural Integrity of Buildings
and Plant
Dr Max Blackler
Head of Civil Engineering
BCTC Greenhithe, UK
by
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Buildings and Plant Structures do not last forever. What
we seek to achieve is reliable service from these items
throughout the productive life of the Plant.
Buildings and Plant Structures fail only rarely, but when
they do, it usually makes headline news - something none
of us wants!
This Paper considers some of the issues that need to be
considered if the management of these assets is to be
effective and SAFE!


Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Fitness for Purpose
Design Life
Changes that Occur
Causes of Degradation
Signs to Watch out for
Countermeasures

In this paper the following issues are considered:
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Load Carrying Capacity
Limiting Deflection
Durability
Codes of Practice
Quality of Construction

FITNESS FOR PURPOSE
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Typical heavy build up of dust
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Heavy Spillage on Open Grid Plant Floor
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Honeycombing in
Original Concrete
Beam
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Failure of interconnected
(Clustered) Silo for
Storage of Coal
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
A New Multi
Compartment Silo in
which one of the
internal radial dividing
walls has torn way
from the outer wall
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
A New Steel Silo that
developed a series of
Horizontal Folds as the top
descended 20ft towards the
Ground!
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
60,000t Cement Storage Dome Collapsed
during Construction
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Twin Steel Hopper for Rail
Car Loading - Failed in
the Armpit between the
Two Pyramidal Bottoms
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Empty Rail Car
Folded beneath
Falling Cement and
Structural Debris
during Collapse of
Hopper above

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Load Carrying Capacity
Limiting Deflection
Durability
Codes of Practice
Quality of Construction

FITNESS FOR PURPOSE
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
DESIGN LIFE

Operational life of the Plant
Changes of Use
Fair Wear and Tear
Changes that Occur

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Note how the
Horizontal Stiffeners
on this Feed Hopper
are not connected at
the corner

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
CHANGES THAT OCCUR

Silos and Hoppers
Warehouse Buildings
Diagonal Bracing
Gypsum and Corrosives
Modifications to Machinery

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Kiln Feed Silo attacked by Acidic
Fumes from Baghouse

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
200yds of 4x16 Line Pipe Collapsed onto Yard Area
when Retrofit Strongpoint let go

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
THINGS THAT CAUSE DETERIORATION
Water
Chemicals

- Gypsum
- Fluorspar
- Calcium Chloride/De-Icing Salt
- Sea Salt
- Coal Leachate
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Water/Corrosion Damage to Rebar in
Concrete Column in Derelict Plant

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Reactive Chemical (Fluoride?) Stacked
against Kiln Pier

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Side of Kiln Pier eroded by Chemical Attack

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Typical Heat + Rain Damage on Kiln Roller Station

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Back End of Kiln Floor Weakened by Chemical Attack
from Kiln Seal Leakage

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
SIGNS TO WATCH OUT FOR:

Water
Line and Level
Cracks in Steelwork
Cracks in Concrete
Suspended Hoppers
Rectangular Hollow Steel Sections

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Heavy Dust Spillage+Rainwater Ponding on Silo Roof

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Silo Roof Rotted Away Beneath Ponded Rainwater. Note
Steel Girders OK in this Instance

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Define and agree Performance Requirements before
Design is started
Identify who is to do what before Project starts
Pre-qualify Bidders before Tender Invitation
Confirm Key Performance Requirements before
starting contract negotiations

COUNTERMEASURES
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Watch out for Water and deal with it properly
Apply Permit to Work Procedures
Train Operational Personnel in Structural Awareness
5Yearly Independent Structural Inspection Surveys

COUNTERMEASURES (cont.)
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Group of post-tensioned (Pre-Stressed) Silos - note
Pilasters in the Walls

Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Fitness for Purpose
Design Life
Changes that Occur
Causes of Degradation
Signs to Watch out for
Countermeasures

We have now Looked at our List of I ssues. These were:
Blue Circle
Technical Centre
Structural Integrity of Buildings and Plant
Dr Max Blackler
Head of Civil Engineering
BCTC Greenhithe, UK