Project Description

Nyrstar requested a proposal from High Impact Solutions for demolition of the Old Leach Building Cooling Tower. The Project involved demolition of the Cooling Tower and its foundation followed by reinstatement of a new Cooling Tower foundation and installation of Acid Resistant Coatings. Nyrstar also requested that High Impact Solutions manage and direct the installation of the new Cooling Tower, walking platforms and stair case plus the connection of the pump motors.

Reason for engagement

The original Cooling Tower had eroded so severely that the Cooling Tower was constantly leaking. Its foundation had cracked causing electrolyte leakage to the ground water system. As the location of the Cooling Tower is located within 10 meters of the Operating SX Plant, High Impact Solutions was engaged to provide a methodology that would complete the project safely and in a meaningful time frame. As High Impact Solutions are specialists in Project Management and have a specialist Hydro Demolition team, the Hydro Demolition method was chosen to eliminate the potential of sparks and fire hazards around the Operating SX Plant ensuring the safest possible demolition and reconstruction while also allowing the surrounding plant to continue normal operations.

Scope of work

  • Development of Project Methodology
  • Risk Assessment meeting with Nyrstar
  • Assist in Foundation Design
  • Demolition of Original Cooling Tower and Foundation
  • Construct New Foundation
  • Supply and Installation of Metz Acid Proofing Systems
  • Manage and Direct Installation of New Cooling Tower and Walk Platforms
  • Installation of Pump Piping to Motors


  • Civil Construction
  • Robotic Hydro Demolition
  • Excavation, Trenching and Earth Moving
  • Hydro Demolition Lance
  • Concrete and Composite Repair
  • Reinforcement Replacement
  • Structural Strengthening
  • UHP Water Blasting
  • Earth Moving and Preparation
  • Heavy Duty Flooring
  • Plumbing Installation

Key outcomes

As High Impact Solutions developed and executed the methodology for this project it resulted in zero on site incidents and there was no interruption to normal day to day operations to the Nyrstar SX Plant, Leach Plant or Copper Plant. High Impact Solutions have provided a sound structure that is coated in the highest quality Acid Resistant coatings and is no longer causing any environmental hazard through ground water leakage. Nyrstar have applauded how easy it is to clean and maintain the new Cooling Tower suggesting their personnel are very proud of the works High Impact Solutions have accomplished.

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