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Structural Reinforcement Using Carbon Fiber: A Copper Mine Case Study

Carbon Fiber Beam and Slab Repair

Problem: Copper mining facilities endure accelerated degradation due to constant exposure to vibrations, moisture, and chemicals. The concrete beams and ceiling slabs at a century-old copper plant's concentrator building faced severe degradation, including corrosion, de-lamination, and concrete spalling. Dangerous through-holes had developed in the ceiling slabs, endangering the safety of the facility.

Design Scope: The scope of this structural reinforcement project included 2 beams and 3 ceiling slabs, requiring 960 square feet of carbon fiber. Severe damage affected the entire length and width of the beams and slabs, with substantial through-holes in the ceiling slabs due to extreme corrosion.

Installation: Prior to applying the CarbonSeal™ carbon fiber system, deteriorated concrete was meticulously removed using pressure washers and hand tools. Exposed rebar underwent thorough cleaning, and missing concrete was expertly patched. The patented CarbonSeal™ bi-directional carbon fiber fabric was then applied to the beams and slabs, complemented by uni-directional carbon fiber on the bottoms of each beam. A protective urethane topcoat was added to prevent future corrosion, and weep holes were drilled into the beams after the system had fully cured.

Conclusion: The comprehensive beam and slab reinforcement was completed within a swift 10 days. By choosing carbon fiber reinforcement over complete replacement, the mine not only saved nearly $150,000 but also prevented over 1,000 lbs of steel and concrete from potentially ending up in landfills. Additionally, this structural repair endeavor prevented almost a ton of carbon dioxide emissions and saved more than 30,000 gallons of water by eliminating the need to manufacture replacement steel and concrete.

If you're involved in mining and require structural reinforcement, or seek more information about HJ3's cutting-edge carbon fiber solutions, don't hesitate to reach out. Contact us at info@hj3.com or call 1-877-303-0453.

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