Case Study: Carbon Fiber Repair On Horizontal Rebar Crack

Recent Rhino Carbon Fiber Repair On Rebar Crack In Residential Garage Slab

A homeowner contacted SEALED after noticing two spots of cracked and flaking concrete along the west facing exterior of his two-car garage.

Removal of mulch and simple excavation with hammer and chisel revealed that the actual damage was continuous for the length of the slab for 24’ and that rusted rebar was visible at several points connected by narrow cracks.  Approximately 50 lbs of concrete was removed from the edge of the slab.

The exposed sections of rebar (approx 10’ total) were encapsulated with a recommended high viscosity two-part epoxy mixed with fine sand.  This treatment was allowed to cure for 18 hours.

Subsequently, SEALED dug a trench from the bottom of the cedar siding extending down 14” to accommodate the width of the 13” carbon fiber fabric.  Approximately 250 lbs of dirt and mulch was removed for later use.

The entire surface was cleaned with a 4 – 1/2” angle grinder and a steel brush to remove paint and dirt.  Then the voids and cracks were filled and smoothed even with the original surface with hydraulic concrete.

SEALED then applied the first coat of Rhino Epoxy Adhesive and spread it with a putty knife.  We placed the first of five – 5’ sections of overlapping Rhino Carbon Fiber Strap with a horizontal weave against the surface of the slab.  Since the strap is being deployed sideways, the horizontal weave actually goes up and down over the crack.

We subsequently applied the second coat of Rhino Epoxy Adhesive using hands and a wide putty knife as squeegees, ensuring that the Carbon Fiber Strap was fully extended horizontally and that the fibers were placed in tension over the crack vertically.  We repeated this process along the entire length of the garage

The finished job pending paint and replacement of dirt and mulch.

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