Introduction
The structural integrity of 1960s-era industrial silos is a critical concern for modern cement production facilities. When deciding between complex remediation and complete demolition, facility managers require definitive, data-driven insights. Traditional inspection methods involve extensive scaffolding, high-risk work-at-height and unacceptable operational downtime. To bypass these logistical barriers, we deployed advanced robotic Non-Destructive Testing (NDT) to assess four critical silos across two active UK cement plants.
The Diagnostic Investigation
The project demanded a comprehensive concrete condition assessment without interrupting the 24/7 logistics of the plants. To achieve complete asset coverage safely, we integrated cutting-edge wall-climbing robotics with targeted human engineering expertise.
Our technical team deployed a heavy-payload, wall-climbing robot to conduct extensive half-cell potential and cover meter surveys across the sheer vertical faces of the structures. Operating safely in winds up to 45 mph – conditions that would immediately ground drones or halt Mobile Elevating Work Platform (MEWP) operations – the unit mapped active corrosion zones and determined the exact depth and distribution of reinforcement steel.
While the robotic unit gathered over one kilometre of continuous surface data per silo, our specialist technicians executed highly targeted physical interventions. This dual approach included strategic core drilling, dust collection for chemical composition analysis and precise calibration breakouts to verify the robotic measurements. We conducted carbonation depth and chloride content testing in strict adherence to BS1881 and ASTM C876-91 standards, providing an uncompromising assessment of long-term concrete durability.
The Outcome: High-Yield Data & Operational Continuity
By replacing traditional access methods with advanced robotic NDT, we reduced high-risk work-at-height by 90% and completed the comprehensive diagnostic phase in just five days per silo. Crucially, the non-intrusive nature of the operation meant daily truck movements and core plant operations continued entirely uninterrupted.
The client received a detailed, holistic diagnostic report detailing the structural reality of their ageing assets. Armed with precise data regarding concrete alkalinity, microstructural integrity and reinforcement corrosion, the asset management team acquired the exact engineering intelligence required to formulate a safe, targeted and highly effective remediation strategy.