Integrated Inspection Framework for Reinforced Concrete Structures in Petrochemical Plants

Abstract Reinforced concrete (RC) structures in petrochemical industries are subjected to aggressive environments that accelerate deterioration, thereby compromising structural integrity and operational safety. This study presents a systematic inspection and rehabilitation program for RC structures, integrated with the SAP Plant Maintenance (PM) Module to ensure effective planning, documentation, and maintenance execution. The framework employs both routine and diagnostic inspections, including preliminary and detailed evaluations, to identify early signs of deterioration, quantify structural damage, and recommend appropriate repair strategies. Risk-based classification of structures into critical, semi-critical, and non-critical categories is adopted to optimize inspection intervals and prioritize repair activities. The methodology aligns with international standards (ACI and ASTM) and employs a combination of visual inspection, non-destructive testing (NDT), and laboratory analysis to support decision-making. Findings and repair recommendations are documented within SAP, ensuring traceability and integration with maintenance workflows. The program enhances reliability, mitigates unplanned failures, and extends the service life of civil infrastructure in petrochemical plants. This approach contributes to the body of knowledge by providing a practical, standardized methodology for the inspection, repair, and management of reinforced concrete structures in harsh industrial environments.