Carbon Fiber Reinforced Polymer (CFRP)

Carbon fiber reinforced polymer (CFRP) is a composite strengthening system made of high-strength carbon fibers bonded to concrete with structural epoxy. Once installed, the fabric or strips work with the existing structure to carry added loads. CFRP is used on buildings, bridges, parking garages, marine structures, and industrial facilities where the original reinforcement no longer meets load requirements.

CFRP closes the gap between a structure’s existing capacity and the loads it now needs to carry. Common uses include change of use projects, increasing flexural, shear, and axial capacity, reducing deflection by adding stiffness, and establishing composite action in beams and girders. It can be applied as a fiber wrap on columns or as plate reinforcement on beams, slabs, and walls.

No. CFRP is designed to supplement the original reinforcement, not replace it. The system adds strength where the existing structure falls short, while the original steel and concrete continue to do their part. This is why the condition of the existing concrete and reinforcing steel is evaluated before any CFRP design is finalized.

Yes. A proper CFRP installation requires a structural analysis and stamped design plans from a licensed engineer. The design should follow ACI 440 guidelines, which cover the materials, layout, and number of fabric layers needed for the project. Epoxy Design Systems installs CFRP to the engineer’s specifications and works with owners, engineers, and architects throughout the project.

Installation starts with surface preparation. The concrete is abrasive grit blasted or hydro blasted to a rough texture, and pull-off tests must show a tensile strength above 200 psi to confirm a sound substrate. Epoxy primer and putty are applied to promote adhesion and fill irregularities. The CFRP fabric or strips are then placed, rolled, and encapsulated in epoxy resin using the ACI 440 modified dry method.

Carbon fiber wrap strengthens concrete, but it does not fix damaged concrete on its own. Spalls, cracks, and corrosion must be repaired before CFRP is applied so the system bonds to a sound surface. Our team often pairs CFRP with structural concrete repair, crack injection, or spall repair to restore the concrete first and then add the needed capacity.

Yes. After the CFRP system has fully cured, the surface can be coated for UV protection or fireproofing. The right coating depends on whether the installation is exposed to sunlight, located in an occupied building with fire rating requirements, or used in a harsh industrial or marine environment. Coating requirements are typically included in the engineer’s design.

Cost depends on the size of the area being strengthened, the number of fabric layers in the engineered design, the amount of concrete repair needed before installation, access to the work area, and any required coatings. Because every structure is different, Epoxy Design Systems prices CFRP projects after reviewing the design and site conditions. Request a quote to have our team review your project.