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There are almost 7,000 operational power plants in the United States today, and recent years have seen an increase in natural gas power plant construction. While only 13{f00316eaeff19fc4d3daa6454136ee4db9a0ad1868aa2a79e58a2db09827821d} of electricity generation came from natural gas in 1993, projections estimate that natural gas generation will climb to 30{f00316eaeff19fc4d3daa6454136ee4db9a0ad1868aa2a79e58a2db09827821d} by 2030, doubling the projected outputs of renewable and nuclear energies. This increase in natural gas plants is said to be a result of an increase in the supply of natural gas, increasing focus on power plant emissions, and short construction times for natural gas plants. Considering the lowered sulfur dioxide and carbon dioxide emissions output of natural gas as compared to coal, natural gas power plants are quickly becoming the power-generator of choice for many energy companies in the country.


At a natural gas facility in the southwest United States, a series of concrete pedestals support the power-generating units. More than a dozen of these pedestals had developed minor cracks. Broken valves above the pedestals released heat and steam, which expanded the cracks, corroding the internal rebar. As the rebar bloomed, the cracks expanded, causing concrete loss on many of the pedestals. The concrete was so deteriorated that if not addressed soon, the integrity of the supporting pedestals would have been threatened.
Pedestals Support the Power-Generating Units at this Facility


The CarbonSealTM pedestal repair kit restored all of the pedestals. HJ3 provided thorough installation training, as the power plant wished to perform the repair themselves. First, the surface of the pedestals was prepared by chipping away loose and delaminated concrete. The surface was ground to rid it of any paint and smooth the concrete, and areas with concrete loss were patched with cementitious grout. Primer was then applied, and all remaining cracks were injected. HJ3’s carbon fiber fabric was saturated and installed, and then protected by a chemical-resistant topcoat, which prevents the need for yearly repair.
Cracked Pedestal
A Trained Installer Applies CarbonSeal Fabric
Pedestals Wrapped With HJ3’s CarbonSeal System


HJ3’s CarbonSealTM system provided a long-term solution compared to traditional concrete patching; the chemical, corrosion, and abrasion-resistant qualities offered by carbon fiber eliminate the need for repair for at least 20 years, while concrete patching alone would have required maintenance in 1 or 2 years. Because HJ3’s CarbonSealTM system required no rental for scaffolding or other expensive equipment, and required no new concrete to be poured, the client saved $150,000. Furthermore, the repair prevented more than 1,000 lbs of concrete and steel rebar from going to landfills, saved 30,000 gallons of water, and almost a month of downtime versus replacing the pedestals with new concrete. More than 3,000 kWh of energy and one ton of CO2 emissions were also spared in the repair. If you have concrete pedestals that are cracked and need repair, contact HJ3 at info@hj3.com