Gunite Lining Replacement in a 159’-9” x 22’-0’ ID Steel Stack

Gibraltar Chimney was contracted to replace the acid resistant gunite lining in the Unit #4 Stack at Con Edison's East River Generating Sta.

Limited outage constraints necessitated 'round-the-clock' work, seven days a week.  The roof mounted stack required workers to remove debris from the access opening at the roof elevation and then lower material to grade elevation for disposal.  Several project highlights included: 

• Tear-out of approximately 4,000 CF of existing gunite lining and reinforcing steel and mesh.
• Sandblasting of all exposed interior steel surfaces to a SSPC-6, commercial blast finish.
• The installation of a 2½” thick gunite lining; including a over 20,000 refractory anchors and 425,000 lbs. of calcium aluminate cement.
• Platform repairs, grating replacement, testport installation and other miscellaneous repairs.
• Painting the exterior surface of the stack.