Integrated Inspection Framework for Reinforced Concrete Structures in Petrochemical Plants

Integrated Inspection Framework for Reinforced Concrete Structures in Petrochemical Plants | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Method Article Integrated Inspection Framework for Reinforced Concrete Structures in Petrochemical Plants Mohammed Tajammul Hussain, Mohammed Faisal Ahmed, Mohammed Aadil Ahmed This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7687988/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version 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. Reinforced concrete structures Petrochemical industries Structural inspection Rehabilitation Preventive maintenance Non-destructive testing (NDT) SAP PM Module Risk-based classification Structural integrity Service life extension Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7687988","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Method Article","associatedPublications":[],"authors":[{"id":528978762,"identity":"9b1c6b95-70be-4d1e-9b5f-d7db2849e493","order_by":0,"name":"Mohammed Tajammul Hussain","email":"","orcid":"","institution":"Saudi Chevron Phillips Company","correspondingAuthor":false,"prefix":"","firstName":"Mohammed","middleName":"Tajammul","lastName":"Hussain","suffix":""},{"id":528978764,"identity":"7310405a-d528-4d14-b044-03fb62368382","order_by":1,"name":"Mohammed Faisal Ahmed","email":"","orcid":"","institution":"Saudi Chevron Phillips Company","correspondingAuthor":false,"prefix":"","firstName":"Mohammed","middleName":"Faisal","lastName":"Ahmed","suffix":""},{"id":528978765,"identity":"67f4dce1-543b-4472-842c-062576040879","order_by":2,"name":"Mohammed Aadil Ahmed","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAzklEQVRIiWNgGAWjYHACgwMPDGzq+RkY2EjQklCRliDZQIoWhoQzhxMMDhCrhb/98MYDiW2H84xvJD978KGCQZ5f7AB+LRJn0gqAWtKLzW6kmRvOOMNgOHN2AgFrDuQYALVYM267kWAmzdvGkGBwm4AW+fNvQFqYGTfPSP9GnBaDG0BbEs44J26QyCHSFsMbzwpAgWwsceZNmeSMMxKE/SJ3Pnnzhw8GNnL87enbJD5U2MjzSxPQggACYJUSxCoHAf4DpKgeBaNgFIyCkQQAAbxKCtkibFYAAAAASUVORK5CYII=","orcid":"","institution":"Infineon Technologies","correspondingAuthor":true,"prefix":"","firstName":"Mohammed","middleName":"Aadil","lastName":"Ahmed","suffix":""}],"badges":[],"createdAt":"2025-09-23 02:09:30","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-7687988/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-7687988/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":93452072,"identity":"256471a4-bf47-459d-aa81-12188d19eee9","added_by":"auto","created_at":"2025-10-14 03:50:16","extension":"json","order_by":0,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":5225,"visible":true,"origin":"","legend":"","description":"","filename":"979711c119f14a778939036acfb0ea3b.json","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/7583a670d21f4da3229e1a38.json"},{"id":93451114,"identity":"81ccc6d0-c15b-4168-877c-158d928b12f8","added_by":"auto","created_at":"2025-10-14 03:26:16","extension":"xml","order_by":1,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":33632,"visible":true,"origin":"","legend":"","description":"","filename":"979711c119f14a778939036acfb0ea3b1enriched.xml","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/6984345f47291b91f9fe6694.xml"},{"id":93451223,"identity":"bba6efe9-0bc7-40de-a8b3-697db9849d33","added_by":"auto","created_at":"2025-10-14 03:34:16","extension":"pdf","order_by":3,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":415882,"visible":true,"origin":"","legend":"","description":"","filename":"SpringerNatureIntegratedInspectionFrameworkforReinforcedConcreteStructuresinPetrochemicalPlantsFirstamendment.pdf","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/db083baf4aa94149cc1252ba.pdf"},{"id":93452071,"identity":"a1307d17-f976-42ea-acec-df6ef56e63ae","added_by":"auto","created_at":"2025-10-14 03:50:16","extension":"bst","order_by":4,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":146013,"visible":true,"origin":"","legend":"","description":"","filename":"snapacite.bst","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/4699dc6013d7563fde695956.bst"},{"id":93451119,"identity":"b8367863-5d53-4023-8ef8-2dd76cd5ddf3","added_by":"auto","created_at":"2025-10-14 03:26:16","extension":"bst","order_by":5,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":29828,"visible":true,"origin":"","legend":"","description":"","filename":"snaps.bst","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/a8ff12881f928c14beafac4c.bst"},{"id":93451115,"identity":"dc71579d-31f0-4782-af95-f001b83ca94f","added_by":"auto","created_at":"2025-10-14 03:26:16","extension":"bst","order_by":6,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":35515,"visible":true,"origin":"","legend":"","description":"","filename":"snbasic.bst","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/8f624d47590ae91404e15a96.bst"},{"id":93451117,"identity":"436bf969-b374-482a-ac5a-3e37d9000099","added_by":"auto","created_at":"2025-10-14 03:26:16","extension":"bst","order_by":7,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":33968,"visible":true,"origin":"","legend":"","description":"","filename":"snchicago.bst","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/8047db3be54e05477345ac80.bst"},{"id":93451126,"identity":"69316d7e-8f6e-4905-ab00-bf75fe60c355","added_by":"auto","created_at":"2025-10-14 03:26:16","extension":"cls","order_by":8,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":55857,"visible":true,"origin":"","legend":"","description":"","filename":"snjnl.cls","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/a99736b91096c87475da0239.cls"},{"id":93451116,"identity":"2dfaeae3-0a67-44b9-86f0-8743512ee453","added_by":"auto","created_at":"2025-10-14 03:26:16","extension":"bst","order_by":9,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":64023,"visible":true,"origin":"","legend":"","description":"","filename":"snmathphysay.bst","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/7d25667783f70ec45b62ee5e.bst"},{"id":93451789,"identity":"3097ddf9-6114-4b99-90d7-a0b5d5945613","added_by":"auto","created_at":"2025-10-14 03:42:16","extension":"bst","order_by":10,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":64166,"visible":true,"origin":"","legend":"","description":"","filename":"snmathphysnum.bst","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/2c377534eb1a1406177b0b29.bst"},{"id":93451122,"identity":"205bc2bc-c5d5-44d3-8861-54025123b77e","added_by":"auto","created_at":"2025-10-14 03:26:16","extension":"bst","order_by":11,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":37333,"visible":true,"origin":"","legend":"","description":"","filename":"snnature.bst","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/9f0002e9de72939c7f4d10ca.bst"},{"id":93451128,"identity":"fe4c682a-e1f1-4fd2-a1d9-e9eb0f74035d","added_by":"auto","created_at":"2025-10-14 03:26:16","extension":"bst","order_by":12,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":39951,"visible":true,"origin":"","legend":"","description":"","filename":"snvancouveray.bst","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/7040517861ca503bfcf52d8e.bst"},{"id":93451127,"identity":"69b8098c-deac-4dcd-9942-bf5a4cbc9131","added_by":"auto","created_at":"2025-10-14 03:26:16","extension":"bst","order_by":13,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":40758,"visible":true,"origin":"","legend":"","description":"","filename":"snvancouvernum.bst","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/6eec7bab9691835aaf6e8ab5.bst"},{"id":93451123,"identity":"0795b109-bad2-4228-a417-a394926982cb","added_by":"auto","created_at":"2025-10-14 03:26:16","extension":"xml","order_by":14,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":42193,"visible":true,"origin":"","legend":"","description":"","filename":"979711c119f14a778939036acfb0ea3b1structuring.xml","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/929c1113ffc88fe2b8fde196.xml"},{"id":93451226,"identity":"5dac788b-881b-4f6d-a433-39be82237ee9","added_by":"auto","created_at":"2025-10-14 03:34:16","extension":"html","order_by":15,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":40632,"visible":true,"origin":"","legend":"","description":"","filename":"earlyproof.html","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1/92852726a41ffb7afdc1d7af.html"},{"id":95222824,"identity":"e6d53a4e-b4fd-4bdb-b686-1fd72f76d976","added_by":"auto","created_at":"2025-11-05 16:21:10","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":459264,"visible":true,"origin":"","legend":"","description":"","filename":"SpringerNatureIntegratedInspectionFrameworkforReinforcedConcreteStructuresinPetrochemicalPlantsFirstamendment.pdf","url":"https://assets-eu.researchsquare.com/files/rs-7687988/v1_covered_a1a7b855-1b3f-4072-9131-3a57c47d152d.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"Integrated Inspection Framework for Reinforced Concrete Structures in Petrochemical Plants","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Reinforced concrete structures, Petrochemical industries, Structural inspection, Rehabilitation, Preventive maintenance, Non-destructive testing (NDT), SAP PM Module, Risk-based classification, Structural integrity, Service life extension","lastPublishedDoi":"10.21203/rs.3.rs-7687988/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7687988/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eReinforced 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.\u003c/p\u003e","manuscriptTitle":"Integrated Inspection Framework for Reinforced Concrete Structures in Petrochemical Plants","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-10-14 03:26:11","doi":"10.21203/rs.3.rs-7687988/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"ed2d239a-273a-4495-87a9-59a7f46f42f8","owner":[],"postedDate":"October 14th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2025-11-03T13:08:18+00:00","versionOfRecord":[],"versionCreatedAt":"2025-10-14 03:26:11","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-7687988","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7687988","identity":"rs-7687988","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}