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Carbon Fiber Pedestal Repair
The Expanding Influence of Natural Gas Power Plants in the U.S. Energy Sector
The United States is home to nearly 7,000 operational power plants, and there has been a noticeable increase in the number of natural gas power plants being constructed in recent years. Back in 1993, only 13% of electricity generation depended on natural gas, but projections show that this percentage could reach 30% by 2030. This growth can be largely credited to the rising availability of natural gas, a heightened focus on reducing power plant emissions, and the relatively fast construction timelines for these facilities. Given that natural gas emits significantly lower amounts of sulfur dioxide and carbon dioxide compared to coal, it’s understandable why many energy companies are opting for natural gas power generation.
Addressing Corroded Pedestals at a Southwestern U.S. Natural Gas Facility
At a natural gas processing facility in the southwestern United States, several concrete pedestals were in place to support the power-generating units. Over a dozen of these pedestals had developed small cracks. Heat and steam escaping from malfunctioning valves located above the pedestals worsened the situation, causing the cracks to expand and leading to corrosion of the embedded rebar. As the corrosion spread, the cracks grew larger, resulting in substantial concrete loss across many of the pedestals. The deteriorating condition of the concrete pedestals posed a serious risk to the structural integrity of these support systems.
HJ3's CarbonSealâ„¢ pedestal repair kit was utilized to restore all the affected pedestals. The plant staff received thorough training to perform the repairs independently. The repair work began with the preparation of the pedestal surfaces, which involved removing loose and delaminated concrete. The surfaces were then sanded to eliminate paint and achieve a smooth finish. Areas with missing concrete were filled in with cementitious grout. A primer was applied, and any remaining cracks were sealed using an injection method. Saturated carbon fiber fabric from HJ3 was then installed, followed by the application of a chemical-resistant topcoat designed to provide long-lasting protection without requiring annual maintenance.
Compared to conventional concrete patching, HJ3's CarbonSealâ„¢ system offered a more durable and sustainable solution. The corrosion-resistant and abrasion-resistant properties of carbon fiber ensured that the repairs would last for at least 20 years, whereas concrete patching alone would have required maintenance every 1 to 2 years. By choosing HJ3's CarbonSealâ„¢ system, the client saved $150,000. Additionally, the repair project prevented over 1,000 pounds of concrete and steel rebar from being sent to landfills and conserved 30,000 gallons of water. It also reduced downtime by almost a month compared to replacing the pedestals with new concrete. Furthermore, the repair process saved over 3,000 kilowatt-hours of energy and reduced carbon dioxide emissions by one ton.
If your facility has concrete pedestals with cracks that need attention, feel free to reach out to HJ3 at [insert contact information].
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This article highlights the increasing role of natural gas in the U.S. energy landscape while providing a detailed account of how HJ3's innovative CarbonSealâ„¢ system successfully addressed critical structural issues at a natural gas facility. The combination of cost savings, environmental benefits, and improved durability underscores the value of adopting advanced repair solutions in industrial settings.