Concrete and Steel Repairs at a Mining Facility

This aging mining facility, which had been in operation for over 60 years, faced severe structural deterioration due to the harsh salt mining environment. The constant exposure to moisture from nearby Lake Huron, combined with extreme cold and high chloride levels, led to significant damage across the structure. Walls, columns, beams, and secondary members showed signs of efflorescence, spalling, steel loss, and overall structural degradation.

Concrete and steel repairs

The interior of the mine revealed extensive damage caused by environmental factors. Efflorescence and spalling were widespread, and many steel components had corroded or weakened over time. This kind of damage not only compromised the integrity of the building but also posed serious safety risks.

Interior of mine showing significant efflorescence, spalling, and structural degradation.

The facility’s location near Lake Huron made it particularly vulnerable to heavy storms and high humidity, which accelerated the corrosion process. Salt production created an environment rich in chloride ions, leading to rebar swelling, concrete popping, and further structural weakening.

CarbonSeal carbon fiber on beams and slabs.

This image shows the application of CarbonSeal carbon fiber on beams and slabs, both before and after the topcoat was applied. The system is designed to restore lost strength and provide long-term protection against further damage.

CarbonSeal system installation with topcoat applied to beams, slabs and walls.

The finished CarbonSeal system was applied to beams, slabs, and walls, providing a durable and effective solution for the damaged areas. HJ3 engineered a custom composite fiber system to restore tensile strength and shear reinforcement in critical structural elements, including external walls, targeted columns, and internal supports.

The project successfully repaired and strengthened a total of 9,800 square feet of surface area using 20,000 square feet of carbon fiber. This advanced repair method significantly extended the life of the facility by up to 30 years, ensuring its continued safe and efficient operation.

HJ3's team of experienced engineers specializes in creating tailored structural solutions for challenging environments. Whether you're dealing with corrosion, aging infrastructure, or complex repair needs, we have the expertise to deliver reliable and long-lasting results. Contact us today at 877-303-0453 or email us at [info@hj3.com] to discuss your next project.

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