Counter-flow Conversion
The failed cross-flow arrangement was replaced with a compact and robust counter-flow configuration.
YWT India · Project Case Study
From Ageing Timber Tower to Pultruded FRP Performance
Conversion of a three-cell timber cross-flow cooling tower into a pultruded FRP counter-flow cooling tower while reusing serviceable assets and the existing RCC basin.
A reputed sugar client from Uttar Pradesh
3 CellsCounter-flow configuration
5,400 m³/hrDesign circulation rate
6 WeeksTower erection period
5,400–6,000 m³/hrDesigned operating capacity
The challenge
An ageing timber tower had reached a structurally unsafe condition.
Original systemTimber cross-flow cooling tower serving the client’s sugar and power utility operations.
Observed conditionThe hot-water basin, supporting columns and beams had weakened because of prolonged decay.
Structural failureA longitudinal section collapsed, bringing down the water header, hot-water basin and supporting members.
Project objectiveReplace the failed timber arrangement with a durable FRP counter-flow system while preserving usable civil and mechanical assets.
01
Condition assessment
Existing tower and failure condition
The original tower showed extensive deterioration in the timber structure and hot-water basin. The failure confirmed that continued patch repair was no longer a dependable solution.
02
Reuse and conversion strategy
Retain what remained serviceable
The old tower was dismantled. The RCC basin, mechanical carrier, motor, gearbox, drive shaft and serviceable FRP fan stack were retained, reducing unnecessary replacement and shortening execution time.
03
Structural erection
Pultruded FRP counter-flow structure
The FRP grid was configured around the retained RCC columns. New FRP columns were anchored directly to the basin floor using SS 316 anchor plates and chemical anchoring.
04
Internals and mechanical integration
Equipment, fills and water distribution
The reused mechanical equipment was installed with crane assistance. Fill packs, molded FRP fan deck, fan stacks and water inlet headers were integrated into the new structure.
05
Access and enclosure
FRP stairway and casing replacement
The timber stairway was replaced with a ground-assembled pultruded FRP stairway. The old asbestos walling was replaced by FR-grade corrugated FRP casing.
Engineering solution
Key features of the conversion
Pultruded FRP Structure
Corrosion-resistant structural members replaced the deteriorated timber framework.
Asset Reuse
The RCC basin and serviceable mechanical equipment were incorporated into the rebuilt tower.
Site Assembly
Pre-engineered FRP members enabled rapid ground assembly and crane-assisted erection.
Vibration Isolation
Expansion bellows between the external riser and inlet headers limited vibration transfer.
Improved Access
New FRP stairways, fan deck and casing improved durability and maintenance access.
Project outcome
Three-cell tower completed in six weeks
- Three-cell pultruded FRP counter-flow tower completed
- Existing RCC basin reused without structural modification
- Serviceable mechanical assets successfully reintegrated
- External riser connected to individual FRP inlet headers
- Expansion bellows installed for vibration isolation
- Designed for 5,400–6,000 m³/hr circulation
Case-study value
What this project demonstrates
Brownfield capabilityConversion around existing civil and mechanical infrastructure.
Engineering judgementSelective reuse based on serviceability rather than wholesale replacement.
Rapid executionPre-engineered FRP construction supported a six-week erection programme.
Lifecycle improvementFRP replaced timber and asbestos components exposed to a severe environment.
Planning a cooling-tower rehabilitation or conversion?
YWT India can assess the existing tower, identify reusable assets and develop a phased conversion or replacement strategy.
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