During a filter replacement project the cleaning of the bypass and surrounding area uncovered severe corrosion to support steelwork. One side of the supporting structure was corroded to a degree which could have resulted in a collapse of the walkway gantry.

Key Findings

• Ad hoc structural surveys ineffective for a complex cement site.
• Material spillages in contact with rainwater accelerate corrosion.
• Insufficient resources for proper housekeeping and cleaning activities.

• A detailed written scheme is being developed with the third-party structural engineers, ensuring all areas of the plant are inspected at the required frequency.
• Existing structures need to be deep cleaned, and a housekeeping planned maintenance check to be implemented.