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Copper Mine Beam and Slab Repair

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The beams and ceiling slabs at this mine were severely degraded.

Structural Reinforcement Using Carbon Fiber: A Copper Mine Case Study

Carbon Fiber Beam and Slab Repair

Challenge: In the heart of a long-standing copper mining operation, structural integrity was under threat. The aging concentrator building faced relentless environmental stress—constant vibrations, high moisture levels, and exposure to corrosive chemicals. Over time, the concrete beams and ceiling slabs deteriorated significantly, leading to serious safety concerns. Cracks, delamination, and concrete spalling were widespread, with dangerous through-holes forming in the ceiling slabs that posed a real risk to workers.

Project Scope: The reinforcement project focused on two critical beams and three ceiling slabs, covering a total area of 960 square feet. The damage was extensive, affecting the entire structure of the beams and slabs. The ceiling slabs, in particular, had suffered from deep corrosion, creating large voids that compromised their strength and stability.

Installation Process: Before applying carbon fiber solutions, we first removed all damaged concrete using pressure washers and manual tools. Exposed rebar was thoroughly cleaned, and missing sections were carefully repaired. Then, we applied HJ3’s patented CarbonSeal™ bi-directional carbon fiber fabric to reinforce the beams and slabs. For added strength, uni-directional carbon fiber was used on the bottom surfaces of the beams. To protect the system from future corrosion, a durable urethane topcoat was applied, and weep holes were drilled into the beams after curing was complete.

Results: The entire project was completed in just 10 days, demonstrating the efficiency of carbon fiber reinforcement. By choosing this method over full replacement, the mine saved nearly $150,000. Additionally, the project prevented over 1,000 lbs of steel and concrete from being discarded, reduced carbon dioxide emissions by almost a ton, and saved more than 30,000 gallons of water by avoiding the need for new materials.

If you're involved in mining and need reliable structural reinforcement, or want to learn more about HJ3's advanced carbon fiber solutions, contact us today. Reach out via email or call us at 1-877-303-0453.

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Dangerous through-holes had developed in the ceiling slabs between the 3rd and 4th floors.

The concrete had de-laminated, exposing inner steel rebar to the mine's corrosive atmosphere.

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HJ3's protective urethane topcoat prevents future corrosion.

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