Concrete repairs to Kusile Power Station’s ACC Column

BKV Holdings was appointed by Kusile Civil Works Joint Venture (JV), comprising WBHO and Stefanutti Stocks, to undertake concrete repairs to one of Eskom’s ACC columns at Kusile Power Station in Mpumalanga.

The ACC columns, about 5m in diameter and 50m in height, support the fans and condensers that are used to cool the spent steam and condensate from the boilers.

We were appointed to devise a solution to repair the various structural defects that were identified on column L41 during a routine inspection.

BKV Holdings designed and developed a concrete plug that would enable the concrete to be grouted all the way through to the inner core.

This was an extremely demanding project, considering that most of the repair work had to be undertaken at heights of more than 40m.

Work was stopped on a number of occasions when wind speeds exceeded 25km/h and the telescopic boom of the “cherry picker” started to sway.

Moreover, the repairs were restricted to one designated area and only two people could work on the platform at any given point in time.

The telescopic boom had to be raised and lowered to the correct working area up to two times a day, and our team had to, thus, also take into consideration the extremely long transit times to the workface.

BKV Holdings is also proud of the fact that there was not a single safety incident during the project – further evidence of our unwavering commitment to health and safety.

All work was successfully signed off by Kusile Civil Works JV’s own engineers and quality inspectors.

Our sophisticated solution entailed:

  • Removing the damaged concrete to prepare the surface;
  • Using Sikadur 52ZA to repair the cracks; and
  • Deploying ProStruct 528 VO for the concrete repairs.

We used the following equipment on this project:

  • A 50m telescopic cherry picker;
  • A high-pressure resin injection machine;
  • Grout plugs; and
  • Various small hand and power tools.