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Industrial SolutionsS P E C I A L T Y C O N T R A C T I N G S E R V I C E S ? T E C H N O L O G I E Swww.structural.netTECHNOLOGIESInnovative Solutions for Turnarounds & MaintenanceSTRUCTURAL collaborates with clients to improve infrastruc-ture by combining our award-winning specialty construction, repair and maintenance services with our proprietary technolo-gies to provide innovative solutions for demanding engineering and construction challenges. Ranked among the largest firms of its kind by Engineering News-Record, STRUCTURAL serves owners and their engineers, architects and contractors.Whether you are building a new structure or repairing an existing one, STRUCTURAL has extensive experience and an unparalleled commitment to quality, safety and timeliness – helping you meet pressing demands to control costs and mini-mizing disruptions while enhancing the value of your property.Safety – A Core ValueSTRUCTURAL’s commitment to Safety 24/7 creates a culture of safety at work and at home. Frontline Safety puts this commit-ment into action...providing specific strategies to empower our technicians, craftsmen and mechanics to create a safe work environment and holding all levels of personnel accountable for their safety and the safety of others. Every project employs the same Frontline Safety strategies:? High level management and technician/craft involvement? A project specific safety committee? Continuous task hazard analysis? Safety observation processes? Regularly scheduled jobsite safety audits? Continuous improvement planning and executionFrontline Safety strategies have proven effective in creating safe and healthy work environments while improving productivity and reducing delays, costs and liability. Each project and structure presents unique requirements, and STRUCTURAL makes a point to fully understand and fulfill those objectives. Our project managers and field personnel have extensive experience and carefully plan each project – incorporating the highest commitment to quality in every job we perform and always meeting or exceeding industry stan-dards and customer expectations.Proprietary TechnologiesSTRUCTURAL is recognized globally for expertise in perfecting proven and innovating new technology. These technologies, comprised of products, processes and systems, present options for improving safety, saving time and money, increasing durability and extending asset life on every project. Partnering STRUCTURAL’s technologies with our extensive industry experience and engineering expertise enables us to tackle the toughest challenges and meet customer needs.? Forensic Investigation & Engineering ? Concrete Repair? Steel Structure Upgrades? Moisture Control & Waterproofing? Thermal & Protective Linings? Corrosion Protection? Force Protection / Blast Resistance? Strengthening? Equipment Foundations? Refractory? Refining / Petrochemical? Chemical Processing? Food & Beverage Processing? Metals & Minerals? Manufacturing? Pulp, Paper & Wood? Waste & Water Treatment ? Power Generation & Distributionqe tyuw rq Clarifier tank external post-tensioning repair w Sulfur pit full structural liner installation e Coke drum support structure repair r Forensic investigation of fireproofed columnt Cyclone refractory repair Industrial SolutionsSTRUCTURAL ‘S SOLUTION FOR SUCCESSFUL REPAIR PROGRAMSSAFETY:A CORE VALUEA project isn’t successful unless it is completed safely. At STRUCTURAL, safety is our number one priority. Our teams work closely with clients to address all areas of concern throughout the repair process. Crews receive ongoing training, not only to address typical safety requirements, but also to develop specific safety and communication plans for every project. Additionally, STRUCTURAL crews assemble daily to perform a Job Safety Analysis (JSA) to identify potential hazards and to implement the proper safety measures.EDUCATIONOur innovative approach to structural repairs includes an educational process that is designed to build a unified partnership between your plant personnel and STRUCTURAL’S highly skilled operations, engineering and specialized workforce. The goal of this team is to gain a collective understanding of the facility and process environment, as well as different repair options, methods and materials available. This educational process establishes a solid foundation for a successful repair program. qq wwwww.structural.netqe tyuw rINNOVATIONAND IMAGINATIONAfter addressing what to repair, we assemble a variety of specialists to formulate repair solutions. With our vast expertise and experience, we analyze each project to identify the best possible repair solutions, taking into account cost, production, down-time and other variables that can impact an owner’s bottom-line. Clients benefit from the brainstorming and imagination of experts gathered to create the optimal solution that meets their specific needs.PREPLANNINGOnce a repair program has been selected, we engage in a rigorous preplanning process involving plant personnel, engineers and other team members to examine project details and working conditions. This process is designed to maximize safety, minimize down-time and ensure that the project meets schedule expectations. Because unforeseen circumstances sometimes do occur, we draw upon our experience working on more than 14,000 projects to help us respond to each situation.INVESTIGATIONAND DESIGNBy conducting a forensic condition survey, our goal is to determine the root cause of a structure’s distress. We first observe the outward signs of deterioration and then dig deeper to pinpoint the underlying cause of the problem. Following the condition survey, our team of evaluators analyzes the collective data from both a material science and structural design perspective to develop a report that locates, qualifies and quantifies areas in need of repair.eerrttC a s e s t u d i e sC a s e s t u d i e sDelayed Coking UnitRepairs to sluiceway, drum support structure and vacuum tower completed simultaneously in a four-week turnaround.Sulfur Recovery UnitComplete rehabilitation of severely deteriorated sulfur pit with new lids cast and set in a two-week turnaround.qe tyuw rqe tyuw rC a s e s t u d i e sConcrete Repair & Upgradesq On-site mixing of specialized concrete for high-temperature and chemical resistance w Removal of deteriorated concrete to expose reinforcing steel e Investigation of concrete column r Finishing of concrete for trench repair t Extracting core samples for forensic investigation of coke pit y Placement of precast concrete blocks for sluiceway construction u Removal of concrete to expose corroded reinforcement on concrete columnDelayed Coking UnitRepairs to sluiceway, drum support structure and vacuum tower completed simultaneously in a four-week turnaround.Sulfur Recovery UnitComplete rehabilitation of severely deteriorated sulfur pit with new lids cast and set in a two-week turnaround.qew rqew rwww.structural.netqe tyuw rqe tyuw rSTRUCTURES / ELEMENTS? Beams, Columns & Slabs? Equipment Foundations? Cooling Towers? Chimneys, Stacks & Silos? Marine Docks & Piers? Tanks & Pits? Pipe Racks / Supports? Dams & Basins? Wastewater Treatment? Fluid Catalytic Cracking Units? Secondary Containment? Coking Units? Sulfur Recovery UnitsThe goal of any repair program is to extend the service life of the structure. Each repair challenge is distinct in nature, and an effective repair strategy must draw upon a variety of repair materials and methods most appropriate for the particular challenge. STRUCTURAL’s repair resources enable us to replace defective, damaged or deteriorated concrete; restore structural function; protect the surface or underlying concrete from aggressive environments and restore any lost performance requirements to reinforced concrete and steel structures. From cooling towers to chimneys, piers to pits, we have the experience and expertise to extend the service life of any type of industrial structure.tyur tyurC a s e s t u d i e sC a s e s t u d i e sqe tyuwC a s e s t u d i e sq Prestressed concrete cylinder pipe (PCCP) strengthened using fiber reinforced polymer (FRP) composite sheets w Column strengthening with carbon FRP composites e Form and pump enlargement of column using self-consolidating concrete r Support structure strengthened using multistrand external post-tensioning system encased in a concrete enlargement t Tower beams strengthened with internal multistrand post-tensioning tendons, placed in 87ft long core-drilled holes y Enlargement of beam and girder connection u Chimney strengthened using FRP compositesCement Storage SilosSix reinforced concrete silos strengthened using external near surface mounted (NSM) carbon FRP bars, then coated with an acrylic topcoat for durability and aesthetics.Preheater TowerThe 328ft tall preheater tower’s beam-to-column connec-tions strengthened using internal, bonded multistrand post- tensioning system.Structural Strengtheningqew rqew rwww.structural.netqe tyuwThe need for strengthening may arise from deterioration, change in use and/or missing, misplaced or deficient reinforcement. STRUCTURAL utilizes the latest technologies to increase a structure’s load-carrying capacity and stiffness and to control cracking and deflections.STRUCTURAL continues to develop new applications, materials and systems to restore or add load-carrying capacity to industrial structures. As a leader in the strengthening of existing structures, we offer a unique blend of design support, contracting services, systems and materials to deliver the optimal strengthening solution for each project. STRENGThENING SYSTEMS? Section Enlargement? Bonded Steel Elements? Fiber Reinforced Polymer Composites? Steel Reinforced Polymer Composites? External Post-Tensioning? Internal Post-Tensioning? Epoxy Injectiontyuryt urC a s e s t u d i e sC a s e s t u d i e sqe tyuwC a s e s t u d i e sq Installation of thermally sprayed zinc on reinforced concrete dock w Testing of cathodic protection system on elevated reinforced concrete slab e Repair of fireproofed sphere supports r Completed LifeJacket® cathodic protection system on submerged dock piers t Installation of LifeJacket® cathodic protection system on hyperbolic cooling tower support columns y Measuring remaining thickness of corroded steel beam u Application of thermally sprayed zinc on steel sheet piles Cooling Tower SupportsLintel beams and columns suffering from corrosion- induced deterioration strengthened using traditional concrete repair techniques, then protected with a cathodic protection system incorporating zinc anode technology.Water Intake StructureDeteriorated beams and girders strengthened and protected using a hybrid repair strategy consisting of high-quality surface repairs combined with a sacrificial sprayed zinc cathodic protection system.Corrosion Control & Preventionqew rqew rwww.structural.netqe tyuwCORROSION CONTROL SYSTEMS? Thermal Sprayed Coatings? Impressed Current Cathodic Protection? Sacrificial Systems? LifeJacket® Cathodic Protection System? Alloy Mesh? Chloride Extraction? Galvanic Systems & CoatingsCorrosion of reinforced concrete or steel structures in industrial facilities can occur for a variety of reasons. Whether the result of chloride penetration or carbonation, environmental factors or chemical processes, the result is the same: diminished structural integrity. If ignored, corrosion can lead to safety issues as well as environmental concerns for the surrounding area. STRUCTURAL offers corrosion control and prevention services to restore structural capacity and extend the service life of reinforced concrete and steel structures. STRUCTURAL’s corrosion control specialists evaluate the various environmental and working conditions that are causing the corrosion. Based on this information, the most efficient corrosion control system can be implemented to control and prevent further corrosion of the structure. Our complete corrosion control services include evaluation, design, installation and performance monitoring.tyuryt urC a s e s t u d i e sC a s e s t u d i e sqe tyuwC a s e s t u d i e sq Polyshield® Foundation / Baseplate System installed w Replacement of waterstop in containment structure e Locating reinforcement in concrete slab r Surface preparation of secondary containment area prior to coating t Completed coating in secondary containment areay Installed polymer resin floor u Application of floor coating in high-traffic areaPolyshield® InstallationPlant upgrade featured installation of 93 ANSI Polyshield® units to increase reliability and lower vibration signatures.Food Processing FacilityConcrete floor subjected to thermal shock, vehicular traffic and harsh cleaning environments is coated with a durable floor coating incorporating aisle markings.Coatings, Linings & Protective Systemsqew rqew rwww.structural.netqe tyuwCOATINGS, LININGS & PROTECTIVE SYSTEMS? Waterproofing Systems? Anti-Microbial Systems? Urethane Systems? Epoxy Systems? Expansion Joints? Chemical Injection? Fireproofing? Thermal Sprayed Coatings? Polyshield® Foundation / Baseplate SystemCoatings, linings and protective systems may be necessary to protect certain structures against deterioration. These systems, when properly installed, prevent water, chemicals and other materials from entering or exiting a structure through cracks, joints or failed waterstops. Protective systems extend the time of the maintenance cycle and can shield structures against environmental elements and chemical exposure.By evaluating factors such as cause-and-effect relationships, useful life, constructability, installation timeframes, environmental conditions and cost-benefits, STRUCTURAL is able to deliver the comprehensive waterproofing and protection techniques for the most appropriate and effective solution. tyuryt urC a s e s t u d i e sC a s e s t u d i e sqe tyuwC a s e s t u d i e sBoiler RepairFully integrated stainless steel v-anchor pumpcast system to reduce unit downtime and increase the service life of the structure. Cement Kiln LinerDurable brick lining system installed in new state-of-the-art rotary kiln to reduce future corrosion of unit. Refractory Liningsq Stud welded K bars on regenerator air line w New shotcrete liner in boiler ash bottom e New formed and pumped regenerator r Brick liners with V anchors t Regenerator jig stand y Abrasion resistant refractory u Applying abrasion resistant liningqew rqew rwww.structural.netqe tyuwMAJOR REFRACTORY CAPABILITIES ? Lining Investigation? System Design Support? Preplanning? Project Execution? QA / QCtyuryt ur? Thermal Expansion ? Curing / Material Selection? Leaks / Cracks ? Chemical Attack? Joints ? Abrasion / Erosion? Failed RepairsSTRUCTURAL is recognized globally for expertise in perfecting proven and innovating new technology, including refractory liner installation, repair and replacement. We apply industry-leading experience and expertise to develop and implement solutions to assure effective, long-lasting repairs and reduce or eliminate the risk of failure – commonly caused by issues such as:Each project is carefully planned by our technology experts, project managers, and our Quality Assurance and Safety Teams to ensure that all work is conducted in accordance with Customer Specifications and API Standards.866-354-8436LOCATIONS NATIONWIDEwww.structural.net©2011 Structural Group, Inc. ? IV_14pg_Cap0711 ? EOE