Copper Mine Beam and Slab Repair

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Structural Reinforcement Using Carbon Fiber: A Copper Mine Case Study

Carbon Fiber Beam and Slab Repair

Problem: In a century-old copper plant, the structural integrity of the concentrator building was under serious threat. The concrete beams and ceiling slabs had suffered extensive damage due to constant exposure to harsh conditions like vibrations, moisture, and chemical corrosion. This led to severe issues such as rebar exposure, delamination, and even dangerous through-holes in the ceiling slabs, creating a major safety hazard for workers.

Design Scope: The project involved reinforcing 2 beams and 3 ceiling slabs, requiring a total of 960 square feet of carbon fiber. The damage was widespread, with significant structural weaknesses across the entire surface of the elements. The ceiling slabs had developed large voids due to extreme corrosion, making them unstable and unsafe.

Installation: Before applying the carbon fiber solution, we first removed all deteriorated concrete using pressure washers and manual tools. Exposed rebar was cleaned thoroughly, and missing sections were carefully repaired. Then, we applied HJ3's patented CarbonSealâ„¢ bi-directional carbon fiber fabric to the beams and slabs, with additional uni-directional carbon fiber on the bottom of each beam for added strength. A protective urethane topcoat was added to prevent future corrosion, and weep holes were drilled into the beams once the system had fully cured.

Conclusion: The entire reinforcement process was completed in just 10 days, significantly faster than traditional methods. By choosing carbon fiber over full replacement, the mine saved nearly $150,000 and avoided over 1,000 lbs of steel and concrete from being discarded. Additionally, this approach helped reduce carbon dioxide emissions by almost one ton and saved more than 30,000 gallons of water by eliminating the need to produce new materials.

If you're working in the mining industry and need reliable structural reinforcement solutions, or if you want to learn more about HJ3’s advanced carbon fiber systems, reach out today. Contact us at or call 1-877-303-0453.

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