Kuala Lumpur | February 13, 2026 — At EKG M&E Sdn Bhd, we specialize in the high-precision restoration of industrial cooling infrastructure. This technical update documents a critical refurbishment phase for Cooling Tower No. 4, focusing on the structural reinforcement of the cold water basin through advanced lamination (refibering) techniques.
When a cooling tower reaches a certain age, the integrity of the basin becomes the primary point of failure. Our team was deployed to execute a permanent, watertight solution to eliminate ongoing leakage and prevent structural degradation.
Scope of Work: Infill Dismantling and Cold Water Basin Lamination (Refibering)
The cold water basin serves as the collection point for the entire cooling system. In this unit, several critical issues were identified during our preliminary audit:
Active Hydraulic Leaks: Micro-fissures in the basin floor were causing a continuous loss of treated water, leading to excessive "make-up" water costs.
Seam Degradation: The original joints of the basin had begun to delaminate, compromising the unit's structural stability.
Surface Erosion: Constant exposure to high-velocity water and treatment chemicals had eroded the original protective coating, leaving the base material vulnerable to corrosion.
To achieve a seamless, industrial-grade seal, the project was executed in several technical stages:
Infill Dismantling & Removal: To gain 100% access to the basin floor, our team systematically dismantled the internal infill (fill media). This is a crucial step; attempting to patch a basin with the infill in place often leads to "blind spots" where leaks can persist.
Substrate Preparation: The basin surface was mechanically cleaned and abraded to remove all bio-film, scale, and loose debris. This ensures that the new lamination achieves a chemical and mechanical bond with the existing structure.
Basin Lamination (Refibering): Technicians applied multiple layers of high-grade Fiberglass Reinforced Polymer (FRP) across the entire basin. This process—often called "refibering"—creates a new, secondary shell that is entirely seamless and non-corrosive.
Quality Assurance: Once the lamination was cured, the basin underwent a static water test to confirm 100% watertight integrity before the mechanical components were reassembled.
Zero Water Loss: The new FRP shell provides a permanent barrier, eliminating the need for constant water top-ups and reducing chemical waste.
Structural Reinforcement: The lamination adds significant structural rigidity to the tower base, protecting the building’s mechanical floor from moisture-related damage.
Asset Life Extension: By restoring the basin to better-than-original condition, EKG has effectively extended the service life of this cooling tower by another 10–15 years, significantly delaying the need for a full system replacement.
Based in Selangor, EKG M&E Sdn Bhd is a premier MEP specialist serving the commercial and industrial sectors across Malaysia. We combine advanced material science with meticulous mechanical engineering to keep your facility's cooling systems running at peak reliability.
Is your cooling tower basin showing signs of leakage or structural wear? Contact us today for a professional site audit and a custom-engineered restoration proposal.
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