Great Island Power Station, Wexford- Crack Injection Project

Project Overview

AQL was engaged to complete active water stopping by resin crack injection methods to two tanks in a power station. 1300 linear metres of cracks were injected, filled and overcoated. Pipe penetrations were injected, along with the installation of as screed and a heat-resistant coating to an inlet chamber. After the completion of works, all cracks were sealed and protected for many years to come.

client objectives

Seal all cracks within the tanks Fill and apply a protective coating to all cracks Seal around all pipe penetrations Install a 60mm floor screed to inlet chamber Apply a heat-resistant coating to inlet chamber

Scope of works

AQL carried out active water stopping methods and a restoration to inlet chamber, including: Crack Injection- 1300 linear metres of cracks were injected to stop any water ingress/egress. Holes were drilled every 200mm, injecting nipples installed and resin pumped into cracks. Protecting Cracks- After the injection was completed, all cracks were filled and a heat-resistant coating was applied to protect the concrete Pipe Penetrations- Crack injection was also completed around all pipe penetrations to stop any water egress through these voids. Screed- The floor of the inlet chamber was scabbled to create an optimal surface to apply the screed. The floor was then primed and a level 60mm screed was installed. Heat-Resistant Coating- A heat resistant lining was then applied to the inlet chamber to protect the new screed from the hot water entering.

Challenges

Heat- These tanks were used to cool water which was entering at close to boiling point, so a specification which could tolerate this was important. A system was therefore used which could stand up to this heat and resist it over the cracks and in the inlet chamber. Timeframe- A large crew of trained operatives was needed to complete this task as works had to be completed during plant shutdown. Therefore, crews were present on site 7 days a week while the project was in operation. Water Ingress/ Egress- Due to the cracks, our clients experienced a loss in water while the water within the tank also appeared to be getting contaminated. After the cracks were injected, this stopped any water from escaping the tanks and prevented any dirty ground water from entering the tanks.

Results

No Water Ingress/Egress- The tanks are now watertight, with no leaks. Water therefore cannot exit the tank and dirty groundwater cannot enter. Heat Resistant- A coating which was resistant to the extreme heat the tank experiences was applied to protect the repairs and concrete. Pipe Penetrations- The areas where the pipes go through the concrete walls are now sealed allowing no water to pass through them.

Conclusion

The successful completion of this water stopping project highlights AQL’s expertise in waterproofing, resin crack injection and active water stopping across all sectors including the power generation industry. Through meticulous planning, industry-leading materials, and specialist application techniques, AQL delivered a high-quality, long-lasting solution that ensures the tanks are now sealed from any water ingress/egress.

Related projects