Article: Preventive and corrective strategies and action plans for concrete repair: lessons learned from a concrete structural defect at a steam power plant Journal: International Journal of Structural Engineering (IJSTRUCTE) 2025 Vol.15 No.3 pp.299 - 336 Abstract: Mass concrete, commonly used in power plant construction, often faces issues from temperature rise during cement hydration. This can lead to defects such as honeycombs (voids or air pockets), cracks, and cold joints (weak bonding between concrete batches). These defects may compromise structural integrity and reduce the efficiency of power plants, potentially causing financial losses. This study explores these challenges using a case from a steam power plant (PLTU) in Indonesia. It applies fault tree analysis (FTA), failure mode and effect analysis (FMEA), and analogies from simultaneous importance performance analysis (SIPA) to determine root causes and propose preventive strategies. Additionally, corrective actions are suggested through forensic assessment following American Concrete Institute (ACI) standards. The research underscores the need for controlled hydration and proper repair methods. It provides an in-depth approach to managing concrete defects in large infrastructure projects, aiming to improve construction quality and long-term performance. Inderscience Publishers - linking academia, business and industry through research

Title: Preventive and corrective strategies and action plans for concrete repair: lessons learned from a concrete structural defect at a steam power plant

Authors: Jason Lim; Prima Ranna; Elia Oey

Addresses: Civil Engineering Department, Pradita University, Tangerang, Indonesia ' Master of Civil Engineering, Graduate Program, Tarumanagara University, Jakarta, Indonesia ' International Business and Management Program, Management Department, Binus Business School Undergraduate Program, Bina Nusantara University, Jakarta 11480, Indonesia

Abstract: Mass concrete, commonly used in power plant construction, often faces issues from temperature rise during cement hydration. This can lead to defects such as honeycombs (voids or air pockets), cracks, and cold joints (weak bonding between concrete batches). These defects may compromise structural integrity and reduce the efficiency of power plants, potentially causing financial losses. This study explores these challenges using a case from a steam power plant (PLTU) in Indonesia. It applies fault tree analysis (FTA), failure mode and effect analysis (FMEA), and analogies from simultaneous importance performance analysis (SIPA) to determine root causes and propose preventive strategies. Additionally, corrective actions are suggested through forensic assessment following American Concrete Institute (ACI) standards. The research underscores the need for controlled hydration and proper repair methods. It provides an in-depth approach to managing concrete defects in large infrastructure projects, aiming to improve construction quality and long-term performance.

Keywords: mass concrete; fault tree analysis; FTA; failure mode and effect analysis; FMEA; simultaneous importance performance analysis; SIPA; risk priority number; RPN.

DOI: 10.1504/IJSTRUCTE.2025.148372

International Journal of Structural Engineering, 2025 Vol.15 No.3, pp.299 - 336

Received: 22 Jan 2025
Accepted: 26 Jun 2025
Published online: 02 Sep 2025 *

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Title: Preventive and corrective strategies and action plans for concrete repair: lessons learned from a concrete structural defect at a steam power plant

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