Case Study: Royal White Cement Domes – From Dereliction to Renewed Industrial Service

Client & Project Overview:

• Client: New Owners of Royal White Cement facility
• Structure: Two Monolithic Domes
• Location: Houston Ship Channel, Texas
• Project Initiation: Inspection Request May 2022; Restoration completed subsequently.

The Challenge: Salvaging Severely Neglected Domes for a New Purpose

In May 2022, Structure Dome Restoration was called to a challenging site on the Houston Ship Channel. Two monolithic domes, silent for years after the property had been left vacant, stood as weathered sentinels. A new owner, envisioning a future for importing and storing cement, faced a critical question: could these heavily deteriorated structures be salvaged, or were they a lost cause?

Our initial inspection revealed the extent of the neglect and the significant pain points for the new owner:

• Complete Airform Loss & Coating Failure: The original PVC airform membrane on both domes was entirely gone. A thin, subsequent coating, applied at some unknown point, had also catastrophically failed.
  
  
• Exposed and Damaged Polyurethane Foam: Large areas of the crucial closed-cell polyurethane foam insulation were directly exposed to the harsh Houston climate (intense UV, humidity, rain, industrial pollutants). This exposure leads to foam degradation, loss of insulative value, and moisture saturation.
  
  
• Significant Blistering (North Dome): The north dome presented numerous large blisters within its exposed foam layer, indicating trapped moisture and delamination, further compromising its integrity.
  
  
• Uncertain Structural Viability: With the primary protective layers gone and foam compromised, the underlying concrete shell’s condition was a major concern.
  
  
• High Cost of Potential Demolition & Rebuild: If the domes couldn’t be restored, the new owner faced the enormous expense and lengthy timeline of demolishing the existing structures and building new storage facilities from scratch.
  
  
• Urgent Need for a Viable Path to Operation: The owner needed a clear assessment and a reliable restoration plan to bring these domes online for their intended cement storage operations.

The situation demanded more than just a repair; it required a comprehensive evaluation of viability and a robust, industrial-grade restoration capable of transforming derelict structures into dependable assets.

The Structure Dome Restoration Solution: Meticulous Preparation & Advanced Restoration

Structure Dome Restoration approached this complex project with a detailed, phased strategy:

1. In-Depth Inspection & Viability Assessment: Our initial visit confirmed the severe degradation but also allowed our experts to assess the underlying structural potential. We provided the new owner with a clear understanding of the challenges and a proposed pathway to salvage the domes.
   
   
2. Intensive Surface Preparation – The Critical Foundation: This was an “enormous amount of preparation,” foundational to the success of the entire project:
   
   • South Dome: The entire exterior, where the airform and old coating had failed, was meticulously scraped relatively smooth. This removed all loose, deteriorated material and created a sound substrate for new applications. Damaged foam sections were identified and prepared for repair.
   • North Dome: The numerous large blisters in the closed-cell foam were carefully cut out, removing all compromised material. These areas were then cleaned and prepped for new foam application.
     
     
3. Specialized Foam Repair & Reinstatement:
   
   • On the South Dome, new polyurethane foam was expertly applied to areas where it was damaged or removed during scraping, ensuring a continuous and properly profiled insulation layer.
   • On the North Dome, the cut-out blistered sections were filled with new, high-density closed-cell polyurethane foam, seamlessly integrated with the existing insulation.
     
     
4. Application of a High-Performance Restoration System: After the exhaustive preparation and foam repairs, a state-of-the-art, industrial-grade restoration system was applied to both domes. This system (e.g., a robust, seamless polyurea or specialized elastomeric coating system) was selected for its:
   
   • Superior Adhesion: Ensuring a tenacious bond to the prepared foam and concrete surfaces.
   • Complete Waterproofing: Creating a monolithic, impenetrable barrier against the Houston Ship Channel’s humid and rainy climate.
   • Extreme Durability: Offering long-term resistance to UV radiation, chemical exposure from the industrial environment, and physical wear.
   • Seamless Finish: Eliminating joints or seams that could become future points of failure.

This systematic approach transformed the severely weathered domes, giving them “new life” and preparing them for their demanding role in cement storage.

The Results & Benefits: Dormant Assets Revitalized for Productive Use

Structure Dome Restoration’s comprehensive intervention delivered significant value to the new owners of the Royal White Cement facility:

• Successful Salvage of Critical Infrastructure: Two domes that might have been considered for demolition were expertly restored, saving the owner immense costs and time compared to new construction.
  
  
• Restoration of Protective Integrity: The new restoration system provides a durable, seamless, and waterproof barrier, protecting the insulation and concrete shell for years to come.
  
  
• Operational Readiness: The domes were made fit-for-purpose, ready to safely and effectively store cement, enabling the new owner’s business operations.
  
  
• Extended Asset Lifespan: The restoration has significantly extended the service life of these structures, turning a liability into a long-term asset.
  
  
• Demonstrated Expertise in Extreme Restoration: This project showcased Structure Dome Restoration’s capability to tackle even the most severely deteriorated monolithic domes and deliver high-quality, lasting solutions.

Have Neglected or Severely Deteriorated Domes? Don’t Assume They’re Beyond Repair. Contact Structure Dome Restoration for an Expert Assessment and Discover How We Can Bring Your Assets Back to Life!