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Utility Tunnel Concrete Repair

Maple Grove Enterprises was recently called in by a large company in New York to address a utility tunnel in disrepair. The tunnel, constructed nearly 80 years ago, has been badly damaged by water and road salt seeping into the ground and corroding the rebar and support beams. The pressure from the rusted rebar cracks the concrete, resulting in unsafe conditions in the tunnel. Our customer was greatly concerned with resolving this safety issue before it caused damage to the steam lines.

First on our team's agenda was to remove the damaged concrete. They then used a needle scaler to remove rust and scale from the rebar and steel support beams. Using a number of Engineered Resin Solutions (ERS) products, they repaired and then coated the concrete and coated the exposed rebar with epoxy products.

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(Click on any photo for a tour of the concrete repair job.)

Before: Deicing salt leached into the tunnel, corroding the embedded metal rebar and badly damaging the reinforced concrete header. After: We removed the damaged concrete, then used ERS epoxy resin and coating to protect the concrete from further damage. Before: Crumbling tunnel wall due to corrosion of the steel concrete reinforcement. After: The crumbling concrete was removed from the tunnel wall and repaired with ERS Novolite lightweight concrete repair. Before: This photo shows the extent of the damage due to rusted rebar, which reinforces the tunnel's concrete ceiling. After needle scaling the exposed rebar, we applied ERS-80 Rust Stopper, a high-grade resin system with anti-corrosion resistant fillers. During: After coating the rebar, we primed the concrete with ERS-1100 Epoxy Resin, then filled in the damaged area with ERS Novolite epoxy concrete repair. After: Finally, we coated the repaired ceiling area with ERS-2000R Flex Guard ceramic-filled Novolac epoxy coating system. Environmentally friendly ERS-2000R incorporates recycled tire rubber, which provides flexibility and high impact resistance. Before: Badly corroded support beams, which hold the steam lines. During: After using a needle scaler to remove the rust from the steel beam, we applied ERS-80 Rust Stopper to the beam and then built a wood form around its base. During: We encased the steel beam with epoxy mortar made from ERS-1100 Epoxy Resin and pea gravel. After: The support beam is finally coated with ERS-2000R Novolac epoxy coating system.

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