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The Rising Importance of Natural Gas Power Plants in the U.S. Energy Mix

With more than 7,000 power plants currently operating across the United States, the energy landscape is rapidly evolving. In recent years, natural gas power plants have seen a significant increase in development and usage. Back in 1993, only 13% of electricity was generated from natural gas, but that number is expected to rise to 30% by 2030. This shift is driven by increased natural gas availability, stricter environmental regulations, and the faster construction timelines for these facilities. Natural gas emits far fewer pollutants like sulfur dioxide and carbon dioxide compared to coal, making it a more attractive option for many energy providers.

Addressing Corrosion on Concrete Pedestals at a Southwest U.S. Natural Gas Plant

At a natural gas facility in the southwestern United States, concrete pedestals play a crucial role in supporting the power-generating equipment. Over time, several of these pedestals developed small cracks, which were exacerbated by heat and steam from damaged valves above them. As the cracks expanded, internal rebar began to corrode, leading to further structural degradation. The loss of concrete on many of the pedestals posed a serious risk to the stability of the entire system.

To address this issue, HJ3's CarbonSealTM pedestal repair kit was used. The plant’s maintenance team received thorough training so they could perform the repairs themselves. The process started with surface preparation, including removing loose and flaking concrete, grinding down surfaces to create a smooth base, and patching areas where concrete had been lost using cementitious grout. A primer was applied, and any remaining cracks were filled. Then, carbon fiber fabric soaked in HJ3’s resin was installed, followed by a chemical-resistant topcoat that offers long-term protection without the need for frequent maintenance.

Compared to traditional concrete repair methods, the CarbonSealTM system provides a much longer-lasting solution. While standard patching might require maintenance within one or two years, the carbon fiber material can last up to 20 years or more. Using this method, the client saved $150,000 in costs. Additionally, the project prevented over 1,000 lbs of concrete and steel rebar from being sent to landfills and saved 30,000 gallons of water. The repair also cut downtime by nearly a month compared to replacing the pedestals entirely. Moreover, the process saved 3,000 kWh of energy and one ton of CO2 emissions.

If your facility has cracked concrete pedestals in need of reliable repair, contact HJ3 today for expert solutions tailored to your needs. We specialize in long-lasting, environmentally friendly restoration that ensures the safety and longevity of your infrastructure.

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