Concrete and Steel Repairs at Salt Mining Facility

Concrete and Steel Repairs at a Mining Facility

This aging mining facility, located near Lake Huron, had been in operation for over 60 years of salt mining, which led to severe deterioration of its structural components. The constant exposure to moisture from lake storms, combined with the harsh salt production environment, caused significant damage to the concrete and steel structures. Walls, columns, beams, and secondary members showed extensive signs of efflorescence, spalling, steel loss, and overall structural degradation.

Concrete and steel repairs

The interior of the mine revealed visible signs of environmental damage, including heavy efflorescence, spalling, and structural weakening. These conditions were primarily due to chloride ion migration from the salt production process, leading to rebar swelling, concrete popping, and further deterioration of the building’s integrity.

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

As part of the restoration effort, HJ3 implemented a high-performance CarbonSealâ„¢ system to reinforce and repair the damaged areas. This included applying carbon fiber reinforcement to beams, slabs, and walls, significantly enhancing their strength and durability.

CarbonSeal carbon fiber on beams and slabs.

This image shows the CarbonSeal carbon fiber being applied, both before and after the topcoat was added. The system was carefully installed to restore the structural integrity of the facility.

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

The final result was a fully restored CarbonSeal system, with the topcoat applied to beams, slabs, and walls. HJ3 engineered a custom composite fiber system to replace lost tensile strength and shear reinforcement in the external walls, targeted columns, and internal supports. The CarbonSealâ„¢ repair successfully restored the facility's strength, covering 9,800 square feet of surface area with 20,000 square feet of carbon fiber. This advanced solution extended the life of the structure by up to 30 years.

If you're facing similar structural challenges, HJ3’s team of engineers can design custom solutions tailored to your needs. Contact us today to learn more about how we can help protect and strengthen your infrastructure. Call us at 877-303-0453 or email us at [your email address].

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