Carbon Fiber Pedestal Repair

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The Rising Importance of Natural Gas in U.S. Energy Production

The U.S. energy landscape is evolving rapidly, and natural gas power plants are playing an increasingly vital role. With over 7,000 power plants operating across the country, the shift toward cleaner energy sources has led to a significant increase in natural gas facilities. In 1993, only 13% of electricity came from natural gas, but that number is expected to climb to 30% by 2030. This trend is driven by abundant natural gas supply, environmental regulations, and the fast construction timelines for these plants. Compared to coal, natural gas emits far less sulfur dioxide and carbon dioxide, making it a more attractive option for energy companies focused on sustainability.

Fixing Corroded Concrete Pedestals at a Southwest Natural Gas Plant

At a natural gas facility in the southwestern U.S., several concrete pedestals support critical power generation equipment. Over time, these pedestals developed small cracks, which were worsened by heat and steam from damaged valves above them. As the cracks expanded, internal rebar began to corrode, leading to further structural damage and concrete loss. The deteriorating condition of the pedestals posed a serious risk to the stability of the entire system.

To address the issue, HJ3’s CarbonSealTM pedestal repair kit was used. The plant's team received thorough training and performed the repairs themselves. The process started with removing loose and damaged concrete, followed by grinding the surface to prepare it for repair. Areas with missing concrete were filled with cementitious grout. A primer was applied, and remaining cracks were injected. Then, carbon fiber fabric soaked in HJ3’s solution was installed, and a chemical-resistant topcoat was added to ensure long-term protection without the need for frequent maintenance.

Compared to traditional concrete patching, the CarbonSealTM system offers a much longer-lasting solution. While standard repairs might require attention every 1–2 years, the carbon fiber system can last up to 20 years. This choice saved the client $150,000. Additionally, the project prevented over 1,000 lbs of concrete and steel from going to landfills and conserved 30,000 gallons of water. It also reduced downtime by nearly a month compared to replacing the pedestals entirely. The repair process also saved 3,000 kWh of energy and one ton of CO2 emissions.

If your facility has cracked or damaged concrete pedestals, consider HJ3’s advanced repair solutions. Contact us today to learn more about how we can help you protect your infrastructure efficiently and sustainably.

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