Concrete Foundation Beam Repair Case Study

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Restoring Structural Integrity in Aging Foundations with Carbon Fiber Reinforcement

A Case Study from a Multi-Family Residential Complex in St. Louis, MO

Aging concrete foundations can present serious structural challenges—especially when steel reinforcement embedded within the concrete begins to fail. In a large residential complex consisting of 225 multi-family dwellings in St. Louis, Missouri, extensive foundation damage caused by rebar corrosion threatened the long-term stability of multiple buildings.

Acculift and EcoSpect were tasked with evaluating and repairing this widespread deterioration. Their solution relied on an innovative, cost-effective approach: Carbon Fiber Support (CFS) carbon fiber reinforcement straps.

The Challenge: Rebar Corrosion and Concrete Degradation

The buildings in this residential complex were constructed with poured concrete foundation walls and grade beams supported by concrete piers. At the time of construction, the grade beams were heavily reinforced with steel rebar—a common practice intended to improve strength and durability.

Over time, however, moisture intrusion within the concrete led to corrosion of the embedded steel rebar. As the rebar corroded, it expanded, exerting pressure from within the concrete. This expansion caused the surface of the concrete grade beams to crack, spall, and ultimately fail.

• Concrete degradation extended deep into the 8-inch-thick foundation walls
• Entire sections of grade beams experienced surface blowouts
• In some structures, deterioration affected nearly the entire perimeter foundation

Left unaddressed, this type of damage can compromise load-bearing capacity and lead to costly structural failures.

The Solution: Carbon Fiber Support Reinforcement Straps

To stabilize and strengthen the failing foundations, the project team implemented CFS 12-inch bi-directional carbon fiber reinforcement straps. These high-strength carbon fiber systems were applied strategically to both the interior and exterior foundation walls, based on the extent and location of the damage.

In total, approximately 3,500 linear feet of CFS carbon fiber strapping were installed throughout the residential complex.

Why Carbon Fiber?

Carbon fiber reinforcement offers several key advantages over traditional repair methods:

• Exceptional strength-to-weight ratio
• Corrosion resistance, unlike steel-based solutions
• Minimal impact on existing structures
• Faster installation with less disruption to residents

These benefits made carbon fiber an ideal solution for a large-scale, occupied residential project.

Custom Bracing for Enhanced Structural Support

In addition to reinforcing the degraded concrete, the use of CFS carbon fiber allowed for custom steel bracing to be drilled and tapped directly through the carbon fiber system. This approach ensured the reinforcement was securely anchored into the previously failing foundation walls.

By combining carbon fiber reinforcement with custom bracing, the repair strategy restored structural integrity while maximizing the performance of the existing foundation system.

Results: A Cost-Effective, Long-Term Repair Solution

The carbon fiber reinforcement system successfully stabilized the compromised foundations across the residential complex. The solution addressed both the immediate structural concerns and the underlying cause of the damage—rebar-induced concrete failure—without requiring extensive demolition or replacement.

Key outcomes included:

• Restored strength and stability of foundation walls
• Reduced repair costs compared to traditional methods
• Long-term durability without the risk of future corrosion
• Minimal disruption to residents during installation

Learn More About Carbon Fiber Foundation Solutions

This project highlights how Carbon Fiber Support (CFS) products can provide a reliable, efficient solution for repairing severely degraded concrete foundations caused by rebar corrosion.

For a deeper technical breakdown of this project, including installation details and engineering considerations, view the full case study PDF above.

If you’re facing foundation challenges due to aging concrete or corroding reinforcement, carbon fiber systems may offer the strength and longevity your project requires. Contact us today and let us know how we can help you with your projects!