Restoring Structural Safety of a Pharmaceutical Plant

A leading pharmaceutical company required a comprehensive restoration of its production and service buildings to ensure compliance with safety regulations and extend the service life of key infrastructure. Years of exposure, operational stress, and environmental factors had caused concrete deterioration, cracking, and localized reinforcement corrosion, posing risks to the facility’s performance and compliance certifications.

Targeted Repair and Durability Enhancement

The restoration process began with surface preparation, where all loose and spalled concrete from the slabs and beams was identified, marked, and chipped away. The cleaned areas were treated with an anti-corrosive coating and a corrosion inhibitor to prevent further degradation.

We used shotcreting method for slab restoration of the service block. We installed shear connectors by drilling holes and fixing them at specified intervals, with additional steel bars added to the soffit slab, if required. We then applied a 50-60mm thick shotcrete layer, containing a mix of cement, sand, and down aggregate with polypropylene fibers.

For the service block, we decided to treat the beams with Carbon Fiber Reinforced Polymer (CFRP) wrapping to provide structural support. We installed non-returnable packers, and performed epoxy injection grouting to fill cracks and improve structural integrity. The beams in both blocks were then wrapped with a single layer of 450 GSM fiber using a tamping roller to avoid air voids. Finally, the terrace slab underwent comprehensive waterproofing, where loose mortar was removed, the surface was ground, and a Polyurethane-based waterproofing solution was applied to ensure long-term protection. This dual approach ensured that the beams were fortified against future deterioration.

Project Outcome

The comprehensive restoration process ensured structural stability, improved operational efficiency and enhanced safety standards of the pharmaceutical plant. The key outcomes included:

• Enhanced structural integrity of both the production and service blocks.
• Prolonged lifespan of the building structures.
• Effective prevention against water leakage through terrace slabs.
• Improved safety and reliability of the pharmaceutical plant’s infrastructure.

Conclusion

This project showcases NVLN’s expertise in industrial repair. Through advanced repairs and waterproofing methods, we provided a durable, regulation-compliant solution tailored to pharmaceutical standards.