High-pressure resin injection of the Coal silo barrel of Medupi Power Station

BKV Holdings was contracted by the Karenna Concor Joint Venture (JV) to high-pressure (HP) resin inject the floor barrel of the 10000 tonne coal silo at Eskom’s Medupi Power Station in Lephalale, Limpopo.

Water entered through the floor of the silo and started corroding the structure. This is as a result of the failure of the waterproofing material that was initially used to seal the silo’s floor joint.

BKV Holdings proposed a state-of-the-art HP injection solution to seal the floor barrel as it would be impossible to reinstate the waterproofing seal under conventional circumstances.

Most of the work was undertaken at heights of about 12m and rope-access systems were deployed in instances where it was impossible to access areas using our Kwikstage platforms.

Meticulous scanning was also required to avoid the heavy reinforcement inside the structure when drilling the packer holes.

BKV Holdings completed this project without a single safety incident on site and our high quality work was successfully signed off by Karenna Concor JV’s own engineers and quality inspectors.

Our sophisticated solution entailed:

  • Scanning the concrete surface for reinforcement and core drilling multiple packer/injection holes as part of the surface preparation phases;
  • Injecting NUI Polygrout 520-262 expanding resin; and
  • Applying Epoxerite E151 Mastic for the concrete repairs.

The following equipment was used on this project:

  • 20 tonnes of Kwikstage scaffolding;
  • Rope-access systems;
  • Two HP resin-injection pumps; and
  • Various small hand and power tools.