Cracked Brick Support Column Repair with Carbon Fiber

When a critical brick support column at an operating glass manufacturing facility began showing significant cracking and deterioration, replacement was not a practical option. The column supported a furnace capable of holding more than 300 tons of molten glass, making structural reliability—and a rapid repair schedule—essential.

Structural Reinforcement Solutions (SRS) worked with the facility's engineering team to develop a carbon fiber strengthening system that could fully encapsulate and confine the existing masonry column while minimizing disruption to plant operations.

The Challenge: Strengthening a Critical Masonry Support Column

The project took place at the historic Owens-Illinois glass manufacturing facility in Zanesville, Ohio, where glass has been produced since 1929.

A brick support column associated with one of the plant's glass furnaces had developed significant cracking and required structural reinforcement.

This was not a structural element that could simply be taken out of service for an extended repair.

At full capacity, the furnace held more than 300 tons of molten glass, placing substantial demands on the supporting structure. The repair also had to fit within an extremely tight plant schedule.

SRS was contacted on a Wednesday. After reviewing the conditions with the facility's engineers, a repair plan was developed and the contractor mobilized the following day.

The carbon fiber installation needed to be completed before tank loading began on Friday.

Why Carbon Fiber Was Selected For Brick Column Repair

Traditional repair approaches involving major demolition or reconstruction would have created significant challenges in an active industrial environment.

Instead, SRS developed a strengthening approach based on full carbon fiber encapsulation of the existing brick column.

The system utilized SRS-600UNI unidirectional carbon fiber to provide confinement around the masonry column.

Unlike conventional steel reinforcement, externally applied CFRP adds very little weight or profile to an existing structural member. The material can also conform to existing structural geometry, making it particularly useful for rehabilitation projects where access, downtime, and demolition must be minimized.

For this project, the goal was to create continuous confinement around the deteriorated masonry column while retaining the existing structural element.

Preparing the Existing Brick Column

Successful carbon fiber strengthening begins with the substrate.

Before CFRP could be installed, voids and uneven areas in the existing brick surface were filled and leveled with repair mortar.

Creating a properly prepared surface is critical because the carbon fiber system must develop a continuous bond with the existing structure.

Once the masonry substrate was prepared, the column was ready for installation of the CFRP strengthening system.

Full CFRP Encapsulation with SRS-600UNI

The repair design called for the column to be fully encapsulated using SRS-600UNI Carbon Fiber.

The unidirectional carbon fiber reinforcement was installed around the column to provide confinement. Individual wraps were overlapped to create continuous reinforcement around the structural member.

Once installed with the compatible SRS epoxy system, the carbon fiber and resin work together as a fiber reinforced polymer composite.

The resulting system provides high-strength reinforcement while adding minimal weight and cross-sectional size to the existing structure.

This makes CFRP particularly useful for strengthening structural members in industrial facilities where traditional enlargement or steel reinforcement may interfere with equipment, access, or ongoing operations.

Performance Requirements for an Industrial Environment

Material performance was particularly important because of the conditions surrounding an operating glass furnace.

The selected SRS carbon fiber system had testing to address glass transition temperature requirements under AC125 and carried a Class A fire rating.

These considerations helped ensure that the strengthening system was appropriate for the demanding conditions of the application.

The project demonstrates an important principle of structural carbon fiber repair: CFRP should be treated as an engineered strengthening system, not simply as fabric applied to a damaged surface.

Existing conditions, loads, substrate preparation, fiber orientation, overlap requirements, environmental exposure, and material properties all need to be considered when developing the repair.

Rapid Structural Strengthening with Minimal Disruption

One of the most significant aspects of the Owens-Illinois project was the speed at which the repair needed to be evaluated and implemented.

From the initial call on Wednesday to contractor mobilization on Thursday and installation ahead of Friday's scheduled tank loading, the project required close coordination between SRS, the facility's engineers, and the installation contractor.

The completed CFRP system allowed the existing brick support column to be strengthened without the extensive demolition and reconstruction that a conventional repair could have required.

For an operating industrial facility, minimizing downtime can be just as important as the structural repair itself.

Carbon Fiber for Masonry and Column Strengthening

Although CFRP is commonly associated with reinforced concrete strengthening, engineered carbon fiber systems can also be used for certain masonry rehabilitation applications.

Depending on the structure and design requirements, CFRP may be considered for:

• Cracked masonry columns

• Concrete column confinement

• Industrial support structures

• Masonry wall strengthening

• Seismic reinforcement

• Structural members requiring additional confinement

• Deteriorated structures where demolition needs to be minimized

Every project is different, and the appropriate reinforcement configuration should be determined based on the existing structure and required performance.

Have a Column or Masonry Strengthening Project?

Structural damage does not always require demolition or replacement.

SRS works with contractors, engineers, facility owners, and project teams to develop carbon fiber strengthening solutions for concrete, masonry, and other structural applications.

If you have a cracked or deteriorated column, submit your project information through the SRS Project Review process. Photos, dimensions, drawings, and existing structural information can be reviewed to help determine the appropriate materials, repair approach, and technical support for your project.

Get all the details in our case study at www.structuralrs.com