Process Structures
Process Structure Design, Assessment & Life‑Extension
Specialist Design, Assessment & Life‑Extension of Industrial Process Structures
Process structures are critical to the safe and reliable operation of industrial, chemical, energy and COMAH facilities. Arthian provides design, assessment, remediation and strengthening of steel and concrete process structures, ensuring they remain safe, compliant and operational throughout their lifecycle.
Our engineers support clients with new design, modification, corrosion management, PFP‑related deterioration, and life‑extension strategies grounded in robust structural engineering and asset‑integrity principles.
What Are Process Structures?
Process structures include the steelwork, platforms, pipe supports, access systems and reinforced concrete elements that support plant, equipment and process lines. They must withstand:
- Static and dynamic loads
- Thermal expansion
- Vibration
- Chemical exposure
- Fire protection requirements
- Long‑term corrosion and fatigue
Arthian delivers whole‑life engineering solutions that keep these structures safe and functional.
Our Process Structure Engineering Services
Arthian provides a complete end‑to‑end service covering:
New Process Structure Design
We design steel and reinforced‑concrete process structures for:
- Pipe racks and pipe bridges
- Access platforms, walkways and stairs
- Equipment support structures
- Modular process units
- Elevated pipe gantries
- Structural frames for process equipment
Designs follow Eurocodes, CDM, and site‑specific safety and operational requirements.
Structural Assessment & Condition Surveys
We provide detailed inspections and modelling to understand structural condition and risk:
- Visual, intrusive and specialist inspections
- Load capacity checks and structural modelling
- Fatigue, deformation and stability assessments
- Corrosion and deterioration mapping
- Prioritised, regulator‑aligned reporting
This aligns with best practice for asset inspections and lifecycle planning.
Corrosion Under PFP (Passive Fire Protection)
Corrosion under PFP (CUF) is one of the most common—and most dangerous—failure mechanisms affecting steel process structures. CUF occurs when moisture becomes trapped beneath fireproofing systems, leading to hidden corrosion and section loss.
Industry evidence highlights:
- CUF is frequently associated with aged, weathered or damaged PFP systems
- PFP degradation can arise from mechanical damage, process changes, or environmental exposure
- Inspection and repair of PFP is a legislative requirement for safety‑critical elements
- CUF must be identified, risk‑ranked and remediated using tested, verified repair systems
Our Corrosion Under PFP (Passive Fire Protection) Engineering Services
Arthian provides a complete CUF management approach:
- PFP condition surveys and defect categorisation
- Corrosion detection using NDT, UT, radiography and intrusive checks
- Risk‑based prioritisation of defects
- Engineering assessment of section loss and structural capacity
- Specification of PFP repair systems with verified fire‑resistance performance
- Replacement, reinstatement and upgrade of PFP systems
- Corrosion‑resistant detailing and improved access for future inspection
We design solutions that restore both fire performance and structural integrity.
Extension of Life: Remediation & Strengthening Design
Ageing process structures often suffer from corrosion, fatigue, reinforcement loss, or outdated design standards. Extending their life is frequently more sustainable and cost‑effective than replacement.
- Industry guidance shows that life‑extension is achieved through:
- Diagnostic engineering to identify root causes of deterioration
- Structural remediation using advanced materials
- Strengthening systems such as CFRP to restore or increase load capacity
- Integrated corrosion protection strategies for long‑term durability
Our Life‑Extension Services
- Structural remediation design (steel and concrete)
- CFRP strengthening for beams, slabs, columns and connections
- Steel plate bonding and section enhancement
- Resin injection and concrete repair design
- Temporary propping and staged construction design
- Cathodic protection and corrosion‑management strategies
- Fire protection upgrades and reinstatement
Our approach ensures assets remain safe, compliant and operational—often with minimal downtime.
Our Process Structures Services, continued…
Modification, Upgrade & Brownfield Integration
We support complex brownfield projects involving:
- New loads on existing structures
- Process changes and equipment upgrades
- Integration of new pipework or platforms
- Structural alterations and cut‑and‑carve works
- Temporary works and construction sequencing
Our engineers ensure modifications are safe, buildable and aligned with operational constraints.
Process Structure Asset Management
We provide long‑term asset‑integrity support:
- Lifecycle modelling and deterioration forecasting
- Risk‑based prioritisation and investment planning
- Inspection strategies aligned with regulatory requirements
- Strengthening and remediation roadmaps
This aligns with Arthian’s wider asset‑management framework.
- Multidisciplinary civil, structural and asset‑integrity expertise
- Strong track record on industrial, chemical and COMAH sites
- Experience in corrosion, PFP deterioration and remediation
- Clear, practical design documentation
- Fast mobilisation for urgent structural issues
- Whole‑life engineering approach
Request a Process Structure Assessment or Design Proposal
If you need support with new design, CUF management, remediation or life‑extension of process structures, our engineers can help. Contact us today.