From Surface to Steel: Reinforcing Concrete Columns with Carbon Fiber and Corrosion Protection

This project, completed by Epp Foundation Repair, out of Lincoln Nebraska showcases how a modern surface-applied system can deliver full-depth reinforcement—from external carbon fiber to internal corrosion protection. At an industrial facility in Crete, Nebraska, two concrete support columns were showing signs of surface deterioration and embedded steel corrosion. While still structurally stable, they required proactive reinforcement to ensure long-term durability.

Pre-repair view inside the Smithfield Plant warehouse showing the two deteriorated concrete columns prior to surface preparation and reinforcement.

The Problem

The columns, each 16" x 16", exhibited signs of spalling concrete and visible corrosion in the reinforcement. Traditional repair methods would have required invasive demolition and rebar exposure—adding cost, time, and risk of additional damage. Instead, the team needed a non-invasive approach that could strengthen the structure both externally and internally.

The Solution

Epp Foundation Repair partnered with Structural Reinforcement Solutions to implement a surface-applied carbon fiber system, combined with advanced chemical treatments designed to penetrate deep into the concrete. This approach allowed the crew to stabilize the columns without major disruption or rebar excavation.

Interested in using this system?

Learn more about SRS Carbon Fiber Systems and Surface-Applied Corrosion Inhibitors designed for concrete repair.

The deteriorated concrete column after patching and profile restoration, preparing the surface for c

Crews working at height to patch and repair the concrete column, restoring surface integrity before

First tack coat of epoxy applied to the prepared column surface, ensuring optimal adhesion for CFRP

Contractor applying epoxy to bond carbon fiber reinforcement to the concrete column surface.

Concrete Column Reinforcing: Step-by-Step Repair Process

• Loose concrete removal to expose affected areas

• Application of SRS-4100 Steel Guard, a surface-applied corrosion inhibitor that migrates through the concrete to form a passivating film on embedded steel

• Application of SRS-4000 Concrete Guard to reduce porosity, densify the concrete matrix, and enhance adhesion for patching and carbon fiber

• Patching of deteriorated sections with high-strength repair mortar to restore the original column profile

• Installation of 12" wide SRS-600UNI Carbon Fiber Straps, wrapped horizontally with a 12" lap to provide structural confinement

• Final protective coating over the carbon fiber to complete the system and withstand the facility environment

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Why It Worked

This combined system tackled both visible surface damage and the hidden chemical causes of deterioration. By avoiding traditional rebar exposure and instead applying a corrosion inhibitor, the repair eliminated the risk of creating micro-cracks or activating the anodic ring effect common in invasive repairs.

Key benefits:

• No rebar excavation required

• Surface strengthening and deep corrosion protection in one system

• Fast turnaround with minimal disruption to facility operations

• Long-term durability backed by chemical and composite performance

  
  

Installing carbon fiber wraps to reinforce the column.

Installing carbon fiber wraps to reinforce the column.

Completed column reinforced with carbon fiber wrap.

The Outcome

The repair went smoothly. Epp Foundation Repair mobilized quickly and executed the project with precision. The columns were fully restored and reinforced—ensuring stability and corrosion resistance for years to come.

Interested in using surface-applied systems on your next structural repair?

Explore the full range of carbon fiber and corrosion control products at www.structuralrs.com or call 1-888-292-2592 to speak with our technical team.