QuakeWrap’s Fiber-Reinforced Panels Transform Galveston’s Marine Infrastructure
As one of the busiest ports in the United States, the Port of Galveston, Texas, is an important hub for both commercial and recreational maritime activities. Still, its marine environment poses challenges. When field inspections revealed that about 50 percent of the longitudinal steel reinforcement in the rebar beams supporting concrete structures had been lost to corrosion, the implications extended beyond repair expenses. Structural failures could lead to costly downtimes and environmental hazards. The need for effective corrosion management strategies was urgent.
Strategies for addressing corrosion-damaged concrete structures encompass several techniques, which may be used in combination.
Concrete removal and replacement involves identifying damaged areas, removing deteriorated concrete, cleaning steel reinforcement and placing chloride-resistant concrete. Cathodic protection mitigates corrosion using sacrificial anode CP (where reactive metals corrode instead of steel) and impressed current CP (which applies external current), both of which need regular maintenance and anode replacement. Surface treatments and coatings prevent moisture and chloride ingress by applying sealers (like silanes) to reduce permeability and use protective epoxy coatings. Finally, electrochemical chloride extraction (ECE) uses an electric field to remove chloride ions from steel reinforcement, enhancing concrete longevity with minimal physical work.
Innovative Technique
Dr. Mo Ehsani, president and CEO of Tucson, Ariz.-based QuakeWrap Inc., developed a new repair technique that is a combination of the concrete removal and replacement and surface treatments and coatings methods. The technique was successfully implemented in a major structural repair project at the Port of Galveston.
Ehsani and his products have previously been featured in the pages of The Waterways Journal. Ehsani, centennial professor emeritus of civil engineering at the University of Arizona, is a pioneer in the development of structural applications of fiber-reinforced polymer (FRP) technology and an internationally recognized expert on the subject. His studies focusing on innovative solutions for infrastructure repair and renewal have been published in numerous academic and industry publications. Ehsani is a fellow of the American Society of Civil Engineers (ASCE) and the American Concrete Institute (ACI). A past director of the Arizona Chapter of ACI, Ehsani has served as president of the Structural Engineers Association of Arizona. He is a registered professional engineer in multiple states including Arizona, California, Florida, Maryland and New York.
FRP Advances
Nearly four decades ago, non-metallic fiber reinforced polymer products transformed the repair and strengthening of deteriorating concrete structures, especially in challenging environments like ports. The wet layup technique involves saturating glass or carbon fiber fabrics with epoxy and applying them to concrete.
Ehsani’s FRP system can achieve a tensile strength two to three times greater than steel, making it ideal for reinforcing corroded structures. In addition to strengthening, FRP acts as a durable barrier against corrosion, lasting much longer than traditional paints. Unlike conventional methods, which require smooth surfaces and are difficult to employ underwater, Ehsani’s system—which he trademarks as the SPiRe system—is designed for efficient marine repairs.
Manufactured in Tucson, the SPiRe panels feature a rigid core wrapped in layers of glass FRP, measuring 3/8 inch thick and weighing only 2.2 pounds per square foot. During installation, non-metallic FRP rebar reinforcers are added on-site. The lightweight shells are lifted into position, secured with anchor bolts and filled with non-shrink grout for a solid bond.
Time, Money Savings
This innovative approach saved time and money at the Port of Galveston while providing long-lasting protection against salt spray and corrosion. The Port of Galveston’s facility faced severe corrosion and loss of reinforcing steel due to its low elevation above seawater. Traditional repair methods, like patching with wet layup FRP, were impractical due to limited headroom and high costs.
Initially, timber forms were proposed for concrete pumping, but access challenges made this option expensive. Instead, a cost-effective design-build solution using stay-in-place SPiRe panels was chosen. Custom-sized panels were manufactured in Tucson, with non-corroding glass FRP (GFRP) rebars as tension elements. The installation involved divers positioning the lightweight panels under the beams, supported temporarily and secured with anchor bolts. Non-shrink cementitious grout filled the annular space, ensuring strong bonding between the old and new concrete.
This innovative approach minimized surface preparation, allowing for a rapid and flexible installation that fit the port’s schedule. The panels fully encapsulated the beams, providing protection from seawater and dry-wet cycles. The result was a durable, maintenance-free repair, ensuring the long-term sustainability of the facility.
Ehsani noted that the lightweight design allowed for easy handling, even in challenging access conditions, leading to accelerated installation and reduced labor costs.
“Eliminating the need for cofferdams not only cut costs but also streamlined the project timeline,” he said. “The custom FRP panels effectively addressed corrosion issues while the non-corroding GFRP rebar ensures long-term durability against the harsh marine environment. Client satisfaction was high, with minimal operational disruptions and adherence to budget constraints.”
A Repair Revolution
As the Port of Galveston moves forward with plans to extend the successful repair project, it serves as a beacon of innovation in marine infrastructure, Ehsani said. The introduction of stay-in-place forms made of FRP has “revolutionized” repair techniques, offering a solution that is both sustainable and cost-effective, he said.
“These versatile forms can be tailored to virtually any shape and size using the advanced sandwich construction method, with the option to incorporate non-metallic reinforcing bars as needed,” he said.
The process of Port of Galveston’s construction can be found on YouTube in a video “Repair of Corroded Deck and Girders at the Port of Galveston.”
