Ensuring hydroelectric infrastructures life extension through advanced structural assessment in Malaysia

Malaysia’s power sector continues to place strong emphasis on asset life extension and optimisation of existing generation facilities, particularly in hydropower assets operated by utilities such as Tenaga Nasional Berhad. As demand for energy grows and generation assets are modernised, many stations are being retrofitted with newer, heavier equipment. This shift increases the importance of verifying whether legacy water infrastructure and civil infrastructure can safely accommodate upgraded operational loads without compromising safety or performance.

The key engineering challenge at Sg. Perak centred on a fundamental question: whether existing generator foundations could safely support significantly increased loading from new turbine-generator sets. This was further complicated by limited outage windows, the aged condition of reinforced concrete structures, and the requirement for non-intrusive assessment methods that would not disrupt ongoing operational planning.

The objective of the assessment was to deliver clear, data-driven technical assurance on the condition and capacity of the generator foundations. The scope included identifying any structural limitations or deterioration that could influence upgrade feasibility, while ensuring engineering decisions were supported by robust field data and validated analytical findings.

To achieve this, Applus+ deployed a multi-technique non-destructive testing (NDT) programme tailored to assess both surface and subsurface concrete behaviour. This included Schmidt Hammer testing for surface hardness and indicative compressive strength, Ultrasonic Pulse Velocity (UPV) for internal concrete integrity, Ground Penetrating Radar (GPR) for reinforcement mapping and concrete profiling, concrete resistivity testing for corrosion risk evaluation, and settlement monitoring to detect any structural movement over time. Where required, targeted core sampling was undertaken to validate non-destructive results and strengthen overall confidence in the assessment.

The investigation delivered a comprehensive structural condition profile of the generator foundations. This included verified concrete strength and integrity, identification of potential voids or deterioration zones, detailed reinforcement layout and concrete cover mapping, corrosion risk indicators based on resistivity measurements, and settlement behaviour analysis. The findings were consolidated into engineering reports designed to support refurbishment planning and upgrade decision-making.

The impact of the assessment extended beyond condition verification. It enabled informed engineering decisions regarding generator replacement strategies, reduced uncertainty around structural capacity, supported optimisation of refurbishment planning and cost allocation, and contributed to long-term operational safety and reliability of the hydroelectric assets. The outcome provided a clearer technical basis for progressing modernization works within an ageing but strategically important hydroelectric infrastructure system.

Through this project, Applus+ reinforced its role in supporting the transition of legacy energy infrastructure toward future-ready performance, ensuring that critical foundations continue to meet evolving operational demands with confidence and technical certainty.