Restoring Structural Integrity & Preventing Future Deterioration in a Tidal Environment

Located on the Atlantic coast in Magnolia, MA, the residence is supported by concrete piers subject to constant tidal and wave activity. Years of saltwater exposure had led to advanced deterioration, including cracking, delamination, rust bleed-through, and loss of concrete integrity.

CFES was brought in to perform structural repairs and apply a long-term protection system to safeguard the foundation from further degradation. The project demanded tidal coordination, corrosion mitigation, and structural reinforcement, all while protecting the marine environment and minimizing disruption to the occupied home above.

Experience always overcomes challenges

CFES was brought in to engineer, design, and implement a permanent structural reinforcement and corrosion protection solution for the degraded concrete piers. The scope involved restoring structural stability, mitigating ongoing saltwater damage, and preventing future deterioration, all within the constraints of tidal activity and environmental sensitivity.

How do you restore severely deteriorated concrete piers in a tidal zone without disrupting the marine environment?
What materials and methods can provide long-term structural strength & corrosion protection under constant seawater exposure?

Inspection and Preparation

CFES implemented a comprehensive approach to inspection and preparation:

Field-verified conditions and assessed delamination across piers P5–P8
Removed fiberglass wrap, contaminated concrete, and embedded iron particles
Water-blasted all pier surfaces at 3000 psi and mechanically scarified to open concrete pores
Surface cleaned and prepared for epoxy bonding and structural reinforcement

Innovative Repair Methods

Advanced materials and techniques were employed to ensure reliable and durable repairs:

Installed Sika FerroGard 670 zinc anodes and corrosion-inhibiting bonding agents
Repaired cracked and spalled areas with polymer-modified mortars (Sika MonoTop 611, Sikatop 123)
Strengthened piers P5–P8 using vertically routed Sika Carbodur rods embedded in Sikadur 30 epoxy
Anchored epoxy-coated reinforcing bars and formed new concrete encasements at the pier bases
Applied SikaWrap Hex 103G carbon fiber wrap system with Sikadur 300 epoxy resin and Sikagard 670W finish coat
Broadcast silica sand for finish bond texture and protection

Key Outcomes

Structural Reinforcement: Damaged piers were repaired and strengthened using a combination of epoxy-coated rebar, carbon fiber rods, and new concrete encasements to restore full load-bearing capacity.
Durable Corrosion Protection: A layered protection system, including zinc anodes, corrosion-inhibiting mortars, and carbon fiber wraps with epoxy coatings was applied to prevent future deterioration from tidal exposure.
Environmentally Safe Execution: Work was coordinated around tidal cycles with full environmental safeguards in place, ensuring marine protection and minimal disruption to the occupied structure.
Extended Foundation Service Life: The integrated repair and protection strategy significantly prolongs the structural integrity and performance of the pier foundation in a harsh coastal environment.