Cooling Tower Rebuild and Louver Fabrication for an Adhesive Manufacturing Plant

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Cooling Tower Rebuild and Louver Fabrication for an Adhesive Manufacturing Plant

Pumpcoat was approached by a customer in the adhesives manufacturing industry to evaluate a cooling tower that was long overdue for maintenance. After a thorough inspection, and despite the numerous corrosion and structural issues, we determined that a rebuild would be an economical and more environmentally friendly solution than a full replacement.

Inattentive maintenance causes cooling towers to lose their efficiency. Flowing water corrodes the metal, mold builds, and water stagnates in areas where it cannot run freely. Moist conditions lead to rust in the metal framework and eventual structural instability. This cooling tower was suffering severe corrosion, distribution trays had rusted in several places and were leaking, and there was structural damage to the frame and crossbeam. The distribution tray covers that would normally keep debris out of the water were missing, and the louvers on the outside frame were rusty and inhibiting air intake.

This project was more comprehensive in scope than a typical refurbishment, but our expert project managers, fabricators, and repair crews were up to the challenge. While one crew of technicians was busy cleaning, sandblasting and coating the cooling trays, our welders were executing repairs to the cross beams and frame and fitting in new structural supports. In addition, our fabricating team reverse engineered and manufactured new distribution tray covers, as well as the louvers on the outside frame.

Operating like new with restored air intake and water flow, it was a solid effort on our part that brought new life to this cooling tower. Its new corrosion-proof coating and regular maintenance should significantly extend its service life. Don't give up on old equipment, rebuilds can effectively restore it to like new condition at considerably less expense than replacement. Contact us today to learn more.

Highlights of this Cooling Tower Rebuild and Louver Fabrication Project

Project Description

An Adhesive Manufacturer had a Cooling Tower that was in a sad state of structural disrepair and suffering from severe corrosion. After several years, cooling towers lose their efficiency because the water flowing through them will start to corrode the metal, build up mold and become stagnant in areas where it cannot run freely. The moist conditions also can lead to rust in the metal framework, and eventual structural instability.

Scope of Work/Inspection

With this tower we found several issues: the distribution trays had corroded in several places and were leaking. There was structural damage with the frame, and once the pan was removed, we found the crossbeam had corroded as well. The distribution tray covers that would normally keep debris out of the water were also missing. The louvers on the outside frame were rusty and not allowing proper air intake.

Capabilities Applied/Processes

Primary:
Building Inspection
Cleaning, Sandblasting and Coating of Cooling Trays
Weld Repairs to Cross Beams and frame
Metal Fabrication of Louvers and Distribution Tray Covers
New Structural Supports

Material Used for Repairs

Metal for repairs & louver fabrication
CIM Rubber Membrane for the basin coating

Industry for Use

HVAC – Adhesive Manufacturing Plant

Delivery Location

Lowell, MA

Standards Met

Customer Specifications

Product Name

Cooling Tower Rebuild