A significant portion of the concrete infrastructure that facilitates everyday life in America—critical structures like bridges, dams, docks, piers, columns, and beams—was constructed decades ago. Originally designed for a 40 to 50-year life span, many structures are nearing 50 to 60 years old and still in operation.
Most infrastructure is approaching its maximum designed service life: 50 years. For example, more than half of America’s bridges were built in the 1980s or before, making them 40+ years old. Water and sewage pipe are in the same situation, approaching 45+ years old on average.
Factors like substantial population growth place strain on transportation networks, public utilities, and coastal infrastructure that are already handling three, four, and five times their original design capacities.
As this infrastructure continues to age, budget limitations across local, state, and federal jurisdictions frequently hinder full-scale replacement projects. Asset owners are searching for reliable solutions that are safe and cost-effective to extend the lives of critical systems.
Advantages Of Carbon Fiber Composites for Engineered & Non-Engineered Repairs
Carbon fiber composite systems have emerged as a proven solution for both engineered and non-engineered concrete repairs. Their advantages are especially compelling when compared to conventional strengthening options such as heavy steel members or full rebuilds, which are usually very costly.
Several benefits of carbon fiber reinforcement of critical concrete structures are listed below:
High strength-to-weight ratio (especially when compared to heavy steel reinforcements)
Lightweight and easy to maneuver in confined or elevated spaces
Exceptional load-bearing capabilities for structural applications
High stiffness for reinforcement of load-bearing elements
Superior adhesion to concrete substrates
Excellent resistance to corrosion, chemicals, and environmental degradation
Rapid installation times that minimize disruption
Significant cost savings compared to complete replacement or large-scale rebuilds
These advantages position carbon fiber systems as an ideal solution for both engineered and non-engineered repair applications.
Engineered Carbon Fiber Repairs
Engineered repairs are required when a custom solution must be designed for a degraded structure. This includes strengthening bridge columns, restoring damaged structural beams, or rehabilitating slabs with compromised reinforcement ability.
Engineered solutions require careful analysis to ensure that the composite reinforcement provides sufficient strength and stiffness. This typically involves advanced engineering techniques, including finite element analysis (FEA), to simulate loading conditions and verify the adequacy of the reinforcement design.
These engineered repairs using composites are an excellent alternative to large, heavy steel retrofits or full-scale reconstruction. By using carbon fiber composites, asset or facility owners and supervisors can restore, maintain, or enhance overall integrity while reducing the project’s duration and minimizing disruption.
Non-Engineered Carbon Fiber Repairs
Not all concrete repairs demand full engineering analysis, especially where a history of successful preventative repairs can inform best practices moving forward. In many situations, carbon fiber composites can be applied to mitigate signs of degradation, including spalling, cracking, or early-stage delamination to prevent additional damage—or even catastrophic failure—later on. Specifically, non-engineered repairs stabilize the structure’s condition and halt further costly deterioration.
Examples of non-engineered carbon fiber repairs can include sealing or reinforcing non-load-bearing walls, piers, or dock elements, or performing preventative maintenance on aging concrete structures exposed to aggressive environments. These types of repairs can and often do structurally reinforce the asset being repaired. They preserve and extend the longevity and service life of the structure.
Case Studies of Carbon Fiber Reinforced Concrete
Beam Repair at Federal Courthouse Repair
Two concrete beams at a federal courthouse building in Houston, Texas, were badly damaged from exposure to water and wind. To provide structural reinforcement, an engineered approach was used to repair the beams. A structural engineer determined the correct thickness of carbon fiber to provide the required strength to withstand the bending movement of the beam.
The repair consisted of seven layers of unidirectional carbon fiber composite followed by two layers of bidirectional fabric.
Concrete Floor Repair with Composites
In a separate project, the cooling tower at the top of the urban power station needed a reinforced solution. The concrete flooring was experiencing severe leaking. To combat the problem, the facility used a Kevlar-reinforced composite and covered the floor with bidirectional composite fabric and an immersion-grade epoxy system for concrete repairs.
Concrete Column Repair for Condo Association
In this project, the condo building manager was challenged by a degraded column located near a waterway. The rebar in the column started to corrode from exposure to the water after the concrete was damaged from age and a boat collision. The building needed a solution that was structurally reinforcing but quick to install and avoided full replacement.
Advanced FRP recommended a solution that included repair putty to fill the void between the concrete and the wrapped carbon fiber composite sleeve. The repair could accommodate the compressive load on the column, even if the concrete and rebar continued to degrade. The putty and composite system was installed in less than two days.
Selecting A Partner: Exploring the Partnership between Advanced FRP & Industrial Process Design (IPD)
Executing composite reinforcement projects successfully often requires collaboration between multiple parties, including material specialists and qualified engineering partners. For engineered carbon fiber repairs, Advanced FRP’s capabilities are complemented by its engineering partner, Industrial Process Design (IPD).
This unique partnership with Advanced FRP Systems ensures that critical concrete infrastructure repairs are both technically sound and economically feasible, with attention paid to safety factors, regulatory requirements, and long-term performance.
By leveraging the combined expertise of Advanced FRP Systems and IPD, infrastructure owners can confidently approach concrete repair projects with solutions tailored to meet both immediate needs and long-term reliability goals.
About Advanced FRP Systems
Advanced FRP has performed extensive testing, including both subscale property verification and large-scale destructive testing on our composite reinforcement systems. The coating and composite manufacturer provides a range of reinforcement options suited to the infrastructure industry, including bi-directional composites, uni-directional composites, high modulus systems, and impact-resistant systems. As a provider with a proven track record in providing durable, high-performance solutions, Advanced FRP is a trusted advisor for a variety of repair and maintenance needs.
Please contact us with questions about your next maintenance project.
About Industrial Process Design (IPD)
IPD provides a full suite of engineering activities for energy system design and field support services. Its engineers, designers, and project managers combine knowledge of industrial infrastructure with cutting-edge technology to develop solutions for structural, mechanical, electrical, and energy challenges.
Using Carbon Fiber Reinforcement For Concrete Infrastructure: Engineered Vs. Non-Engineered Applications
A significant portion of the concrete infrastructure that facilitates everyday life in America—critical structures like bridges, dams, docks, piers, columns, and beams—was constructed decades ago. Originally designed for a 40 to 50-year life span, many structures are nearing 50 to 60 years old and still in operation.
America’s Low-Scoring Infrastructure Report Card
The American Society of Civil Engineers rated America’s infrastructure at an overall score of “C” on the 2025 report. Of the items scored:
Most infrastructure is approaching its maximum designed service life: 50 years. For example, more than half of America’s bridges were built in the 1980s or before, making them 40+ years old. Water and sewage pipe are in the same situation, approaching 45+ years old on average.
Factors like substantial population growth place strain on transportation networks, public utilities, and coastal infrastructure that are already handling three, four, and five times their original design capacities.
As this infrastructure continues to age, budget limitations across local, state, and federal jurisdictions frequently hinder full-scale replacement projects. Asset owners are searching for reliable solutions that are safe and cost-effective to extend the lives of critical systems.
Advantages Of Carbon Fiber Composites for Engineered & Non-Engineered Repairs
Carbon fiber composite systems have emerged as a proven solution for both engineered and non-engineered concrete repairs. Their advantages are especially compelling when compared to conventional strengthening options such as heavy steel members or full rebuilds, which are usually very costly.
Several benefits of carbon fiber reinforcement of critical concrete structures are listed below:
These advantages position carbon fiber systems as an ideal solution for both engineered and non-engineered repair applications.
Engineered Carbon Fiber Repairs
Engineered repairs are required when a custom solution must be designed for a degraded structure. This includes strengthening bridge columns, restoring damaged structural beams, or rehabilitating slabs with compromised reinforcement ability.
Engineered solutions require careful analysis to ensure that the composite reinforcement provides sufficient strength and stiffness. This typically involves advanced engineering techniques, including finite element analysis (FEA), to simulate loading conditions and verify the adequacy of the reinforcement design.
These engineered repairs using composites are an excellent alternative to large, heavy steel retrofits or full-scale reconstruction. By using carbon fiber composites, asset or facility owners and supervisors can restore, maintain, or enhance overall integrity while reducing the project’s duration and minimizing disruption.
Non-Engineered Carbon Fiber Repairs
Not all concrete repairs demand full engineering analysis, especially where a history of successful preventative repairs can inform best practices moving forward. In many situations, carbon fiber composites can be applied to mitigate signs of degradation, including spalling, cracking, or early-stage delamination to prevent additional damage—or even catastrophic failure—later on. Specifically, non-engineered repairs stabilize the structure’s condition and halt further costly deterioration.
Examples of non-engineered carbon fiber repairs can include sealing or reinforcing non-load-bearing walls, piers, or dock elements, or performing preventative maintenance on aging concrete structures exposed to aggressive environments. These types of repairs can and often do structurally reinforce the asset being repaired. They preserve and extend the longevity and service life of the structure.
Case Studies of Carbon Fiber Reinforced Concrete
Beam Repair at Federal Courthouse Repair
Two concrete beams at a federal courthouse building in Houston, Texas, were badly damaged from exposure to water and wind. To provide structural reinforcement, an engineered approach was used to repair the beams. A structural engineer determined the correct thickness of carbon fiber to provide the required strength to withstand the bending movement of the beam.
The repair consisted of seven layers of unidirectional carbon fiber composite followed by two layers of bidirectional fabric.
Concrete Floor Repair with Composites
In a separate project, the cooling tower at the top of the urban power station needed a reinforced solution. The concrete flooring was experiencing severe leaking. To combat the problem, the facility used a Kevlar-reinforced composite and covered the floor with bidirectional composite fabric and an immersion-grade epoxy system for concrete repairs.
Concrete Column Repair for Condo Association
In this project, the condo building manager was challenged by a degraded column located near a waterway. The rebar in the column started to corrode from exposure to the water after the concrete was damaged from age and a boat collision. The building needed a solution that was structurally reinforcing but quick to install and avoided full replacement.
Advanced FRP recommended a solution that included repair putty to fill the void between the concrete and the wrapped carbon fiber composite sleeve. The repair could accommodate the compressive load on the column, even if the concrete and rebar continued to degrade. The putty and composite system was installed in less than two days.
Selecting A Partner: Exploring the Partnership between Advanced FRP & Industrial Process Design (IPD)
Executing composite reinforcement projects successfully often requires collaboration between multiple parties, including material specialists and qualified engineering partners. For engineered carbon fiber repairs, Advanced FRP’s capabilities are complemented by its engineering partner, Industrial Process Design (IPD).
This unique partnership with Advanced FRP Systems ensures that critical concrete infrastructure repairs are both technically sound and economically feasible, with attention paid to safety factors, regulatory requirements, and long-term performance.
By leveraging the combined expertise of Advanced FRP Systems and IPD, infrastructure owners can confidently approach concrete repair projects with solutions tailored to meet both immediate needs and long-term reliability goals.
About Advanced FRP Systems
Advanced FRP has performed extensive testing, including both subscale property verification and large-scale destructive testing on our composite reinforcement systems. The coating and composite manufacturer provides a range of reinforcement options suited to the infrastructure industry, including bi-directional composites, uni-directional composites, high modulus systems, and impact-resistant systems. As a provider with a proven track record in providing durable, high-performance solutions, Advanced FRP is a trusted advisor for a variety of repair and maintenance needs.
Please contact us with questions about your next maintenance project.
About Industrial Process Design (IPD)
IPD provides a full suite of engineering activities for energy system design and field support services. Its engineers, designers, and project managers combine knowledge of industrial infrastructure with cutting-edge technology to develop solutions for structural, mechanical, electrical, and energy challenges.