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Carbonbond Structural Systems

Carbonbond Carbon Fiber

Carbonbond is a bi-directional carbon fiber fabric used to strengthen structural elements and laminated using Intech Anchoring Epoxy Resin #400.

The Carbonbond System is an ideal choice for foundation damage of two inches or less in width because they provide maximum stability repair without requiring invasive drilling or excavation in a basement. Woven fiber comes in uni-directional and bi-directional options, allowing for the resistance of movement in one direction or two directions, respectively. The type of carbon fiber for your repair will be dependent upon the severity and characteristic of the offending crack.

An added steel angle at the top of the wall effectively concludes the repair. The finished product can easily be painted over to blend in with the space and contribute to a clean, comfortable living area. This fix is permanent, as carbon fiber repairs require zero maintenance.

Intech's Concrete Repair Solutions

Intech Anchoring Systems offers a proven line of concrete repair solutions, including our Injection Resins and Carbonbond Carbon Fiber Structural System.
  • Carbonbond Repair Kits
  • Epoxy Surface Sealer Side by Side Injector
  • Polyurethane Rigid Foam Side by Side Injector
  • Injection Guns, Ports, Mixer Nozzle, and Retaining Nuts

BI-DIRECTIONAL CARBON FIBER

The Carbonbond Bi-Directional Carbon Fiber system is manufactured to provide support and strength to concrete in all applications. Our Carbonbond System kit includes everything you’ll need, including 32ft long x 12in wide 25 oz. bi-directional carbon fabric, Saturant Epoxy Resin, and all the necessary items for a successful installation. Custom sizes are also available upon request. The Carbonbond Structural System is used as a reinforcement of concrete and block basement walls. In particular, Woven Carbon Fiber straps can prevent damage by providing 10 times the strength of steel to resist soil pressure against basement walls. If desired, the Carbonbond system can be easily painted for an aesthetically pleasing finish.
  • No excavating or drilling as the Carbonbond System installs easily without the need for heavy or noisy equipment.
  • Compared to steel, Carbon Fiber is over 10 times stronger, much thinner (only one-tenth of an inch), and 40 times lighter.
  • Carbonbond repairs are completely maintenance-free because they never will corrode like steel.
  • With the ease of installation, its incredible strength, and the durability of Carbon Fiber, it’s easy to see that no other choice makes sense.

Applications & Benefits

  • Crack Repair
  • Decking Repair
  • Column Repair
  • Foundation Repair
  • Interior Walls
  • Exterior Walls

Commercial Applications

Applications include Concrete columns, walls, bridges, damns, and floor slabs; tilt-up, and masonry walls; parking structures; and steel beams and tanks

Residential Wall Repair

Carbonbond can be utilized in residential applications including basement walls, interior cracks, and exterior foundation walls.

Installation of Carbonbond

Installation can be accomplished with a team of 1-3 members, and only relies on a few simple tools. First, the crack is injected with either epoxy or urethane, depending upon the condition of the fracture, then concealed with carbon fiber strips, which reinforce the wall and prevent further damage. With no welding, digging, or excavating required, the set-up, installation, and cleanup processes are minimally disruptive to the home.

Directions for Use

Prepare the surface, mix epoxies thoroughly and saturate and apply the wraps.

Surface Preparation

The preparation of surfaces to receive the Intech Anchoring Carbon Bond must be given careful attention, as the bonding capability of the epoxy for a given application is primarily dependent on proper surface preparation. Concrete surfaces must be structurally sound and free from contaminants such as dust, oil, or dirt. Surfaces must be shot blasted or mechanically abraded to achieve a minimum 5-mil profile. Remove fins, sharp edges, and protrusions that may trap air behind the installed wrap. Coated surfaces must be mechanically cleaned and abraded with 60-80 mesh sandpaper and approved by the manufacturer before applying adhesive. A calcium chloride test is recommended and hydrostatic pressure must be <5psi before epoxy coatings application. Repair all damaged concrete, spalls, and irregular surfaces and fill uneven surfaces with Intech Anchoring putty mix.

Mixing Epoxy

It is crucial that the epoxy is mixed thoroughly and completely, which is why a mixer is recommended.

WARNING: Epoxies develop heat during mixing and curing. To keep temperature rise to a minimum, a high surface area to volume ratio during mixing is recommended. For manual mixing, each mix volume should be kept to 5 gallons or less. For automated mixing follow the equipment manufacturer’s instructions.

First, mix each component separately. Proportion each component at their specified ratios and mix using a slow-speed drill with jiffy paddle at 400-600 RPM for 3-5 minutes until a consistent color is achieved. No stripes, streaks, or color variation should be visible. Use an up and down motion, scraping the mixing container sides and bottom. Mix no more material than may be applied within the specified pot life of the epoxy.

Dry Lay-Up

  1. Using a roller or sprayer, apply a coat of Intech Anchoring primer onto the prepared surface.
  2. Apply a coat of saturating resin (Intech Anchoring#400) to the still tacky primed surface.
  3. Press the dry fabric (wrap) onto the surface and using a roller, apply pressure to the surface of the fabric to ensure good bonding to the substrate and to roll out any entrapped air before the epoxy sets. Smooth the fabric from the center to the edge to remove air pockets. Good saturation of the fabric is indicated by some epoxy oozing out to the external face of the fabric and wetting the fibers on the external face.
  4. Apply a final coat of saturating resin on top of the fabric using a roller or by using a sprayer (spiked roller can be used to remove any entrapped air).
  5. Apply paint or protective coating if desired while the final resin coat is still tacky. The fully cured resin must be scuffed for optimum bonding to the paint or protective coating When multi-layer wraps are used, each individual layer shall be firmly bedded and adhered to the preceding layer or the substrate before the epoxy on the preceding layer is fully cured and is still tacky.

Wet Lay-Up

  1. Using a roller or sprayer, apply a coat of Intech Anchoring primer onto the prepared surface.
  2. (For applications requiring Tack Coat): Apply the tack coat (Intech Anchoring#4) to the surface using a trowel or putty knife, filling out all pores and leaving a 20-mil thick coating (measured wet) of the tack coat on the surface.
  3. Press the resin-saturated fabric onto the substrate and using a roller applies pressure to the surface of the fabric to ensure good bonding to the substrate and to roll out any trapped air before the epoxy sets. Smooth the fabric from the center to the edge to remove air pockets.
  4. Apply paint or protective coating, if desired while the final resin coat is still tacky. The dry resin must be scuffed for optimum bonding to the paints or protective coatings.

Curing of Wraps

Curing times and temperature for wrap shall be maintained for the designated formulation used, according to the instructions supplied with the epoxy. The cured composite should have a uniform thickness and density and lack porosity.

Procedure Modifications

Due to environmental factors affecting the quality of work, installation procedures may be modified to achieve maximum results. Procedure modifications shall be discussed with and approved by the Engineer of record prior to implementing the modifications.

Conditions to Avoid

  • Do not apply to concrete with temperature outside of application temperature range
  • Do not apply to concrete less than 30 days old
  • Do not apply to concrete with curing or sealing membranes
  • Do not apply to base concrete at a temperature less than 45°F

Benefits of Carbonbond

Installation can be accomplished with a team of 1-3 members and only relies on a few simple tools. First, the crack is injected with either epoxy or urethane, depending upon the condition of the fracture, then concealed with carbon fiber strips, which reinforce the wall and prevent further damage. With no welding, digging, or excavating required, the set-up, installation, and cleanup processes are minimally disruptive to the home.

  • Storage Conditions – Store dry at 40°F-95°F
  • Color – Black
  • Primary Fiber Direction – Bi-Directional
  • Weight Per Square Yard (BC25T) – 25 oz.

Packaging

  • Product – BC25T
  • Description – 25 oz/sq yd Bi-directional
  • Primary Fiber – Carbon
  • Standard Roll Length – 100 yds
  • Available Widths – 50″
  • Roll Sq. Feet – 2000 sq ft
  • Corrosion resistant – minimizing costs and wear
  • Adds only a 1/16 of an inch to the repaired surface
  • Light weight (½ the weight of aluminum)
  • Reduces installation time since heavy equipment and welding is eliminated
  • Low thermal expansion
  • Flexible wrap conforms to any shape
  • Minimal change to structure’s shape, weight and appearance
  • Used for increasing strength, stiffness, fatigue resistance of damaged structures up to, and at times beyond its initial design value
  • Used for shear, confinement or flexural strengthening
  • Minimal disruption and noise
  • Economical
  • Reduces hazards, damage and secondary damage resulting from seismic incidents and falling debris

Contact Intech Anchoring for a Quote

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Tim Comb

President

Tim is the President of Intech Anchoring and has 25 years of experience in the Civil Engineering and Geostructural Industry. Tim has developed extensive industry knowledge by working to support the needs of specialty contractors at each and every business level. Tim’s diverse industry background has given him exposure to a wide variety civil construction projects, ranging from the simplest residential applications to the most complex commercial and industrial projects. Coupled with a highly skilled and educated team, Tim focuses on providing the highest quality products and solutions to Intech Anchoring’s customers in order to consistently exceed expectations.