Gubbi Civil Engineers Limited®

Cooling Tower Repair and Rehabilitation

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Cooling tower repair companies in India

At GUBBI Civil Engineers, we specialise in comprehensive cooling tower repair and maintenance services for both Induced Draft Cooling Towers (IDCT) and Natural Draft Cooling Towers (NDCT). Whether your facility needs structural rehabilitation or preventive maintenance, our experienced team ensures your cooling tower operates safely, efficiently, and reliably.

Why Cooling Towers Need Expert Repair

Cooling towers are exposed to harsh conditions: continuous water flow, chemical scaling, high humidity, thermal cycling, wind, and sometimes airborne contaminants. Over time, these stresses cause deterioration, such as:
Without timely cooling tower repairs, these issues can lead to safety risks, downtime, regulatory compliance failures, and high operational costs.

Types of Cooling Towers: IDCT vs NDCT

Understanding the differences between NDCT and IDCT helps in planning proper repair and maintenance.
Natural Draft Cooling Towers (NDCTs):
These use large hyperbolic concrete chimneys to drive airflow naturally (chimney effect), with no mechanical fans. Because of their size and height, repairs are very challenging, require working at height using specialised access platforms and often involve concrete shell repairs, structural reinforcement, corrosion control and protective coatings due to their proximity to coastal areas.
These are more common in industrial plants. Air is drawn or forced through the structure by fans. Components such as fan motors, louvres, drift eliminators, RCC shells, basins, and water distribution systems are under constant wear. Because they have mechanical parts, they need both structural and mechanical repair & maintenance. Also, IDCTs tend to show deterioration in RCC members (columns, beams, slabs) due to alternating wet/dry exposure, chloride attack, carbonation, etc.

Our Cooling Tower Repair Services

We are the topmost cooling tower repair companies with hands-on experience in both NDCT and IDCT repair & rehabilitation. Our services are time-tested during the SHUTDOWN periods. Our services include:

Condition Assessment & Diagnostics

  • Visual inspection, mapping of defects
  • Non-destructive testing (NDT): ultrasonic pulse velocity, cover thickness, core testing, half-cell potential, etc.
  • Structural analysis: shell, support columns, beams, basins

Structural Repair & Concrete Rehabilitation

  • Repair of cracks, spalling, and delamination in concrete shell or support members
  • Restoration of concrete cover, restoration of reinforcement protection
  • Application of corrosion inhibitors, overlays, or protective coatings

Mechanical Component Repair (mainly for IDCTs)

  • Fan & motor replacement or refurbishment
  • Louvres, drift eliminators, fill media work, nozzle and water distribution system repairs.

NDCT-Specific Shell & Chimney Repairs

  • Upper shell section repairs (above throat), shell reinforcing, and shell rebuilding if required
  • Protection against delamination, ensuring the structural integrity of the hyperbolic shell

Water Basins & Leakage Control

  • Repair basin floors, joints, and waterproofing
  • Ensure leak prevention and water tightness

Corrosion Control & Protective Measures

  • Cathodic protection systems (galvanic or impressed), especially required for NDCT shells exposed to a marine or humid environment.
  • High-performance coatings, sealants

Preventive Maintenance & Scheduled Service

  • Routine inspections, cleaning of fills, nozzles, and drift eliminators
  • Monitoring for early signs of distress.
  • Maintenance contracts to ensure regular upkeep

Our Expertise & What Sets Us Apart

How the Repair Process Works

Benefits of Choosing Quality Cooling Tower Repair & Maintenance

Frequently Asked Questions (FAQs)

How often should cooling towers undergo inspection?
For IDCTs, bi-annual inspections are often recommended, especially for mechanical components, fans, water distribution and fill. For NDCTs, annual inspections are essential due to the large shell structure and exposure. Regular preventive inspections help catch damage early, reducing repair costs.
Key attributes include certified engineers, use of non-destructive diagnostics, proven track record with NDCT and IDCT projects, use of quality materials, transparent pricing, safety compliance, and ability to customise solutions for complex structure types.
NDCT shell repair often includes repairing or replacing upper shell sections (especially above the throat), treating or rebuilding the concrete shell, reinforcing steel, controlling corrosion, applying protective coatings, and sometimes employing cathodic protection systems.
Common signs: outlet water temperature higher than design, reduced range or increased approach, visible leaks or spalling, rust stains, fan vibrations (for IDCT), uneven water distribution, damage to fill or drift eliminators, scaling or bio‐growth.
It depends on the severity and location of damage. Some repairs (fill replacement, louvres, mechanical parts) can be phased or done during off-peak operations. However, major structural shell/NDCT repairs often require partial or full shutdown for safety and access.
Costs vary greatly depending on type (IDCT vs NDCT), size, severity of damage, location, accessibility, materials deployed, and mechanical vs structural work. After our diagnostic inspection, we provide a clear, itemised proposal so you’ll know the exact scope and cost.
Minor repairs or component replacements might take a few days to a week. Major structural repair or full shell rehabilitation (NDCT especially) can take several weeks or even months, depending on size. We schedule to minimise disruption and coordinate with plant operations.