Overhead Slab Reinforcement in Wisconsin

Carbon Fiber System Replaces Compromised Steel in Garage Basement Ceiling

The Challenge

A Wisconsin basement located beneath a garage was experiencing severe deterioration of its overhead concrete slab. The steel rebar reinforcement had corroded significantly, weakening the structural integrity of the slab and raising serious safety concerns.

The Solution

Basement Repair Specialists of Appleton, Wisconsin, were brought in to deliver a structural repair that would not only stop the deterioration—but also restore long-term strength. The project was completed in three key phases:

1. Steel Treatment & Removal
   The exposed rebar was assessed, and a rust inhibitor was applied to salvageable steel. Any reinforcement that could not be preserved was carefully removed to eliminate future risks.

2. Cementitious Void Filling
   Holes were drilled through the garage floor above, and a cement-based mixture was injected to re-encapsulate the damaged slab. On the basement side, plywood forms were braced in place with 4x4 posts to support the mixture during the curing process.

3. Carbon Fiber Reinforcement with ReGrid
   To restore lost tensile strength, Fortress Invisibeam® straps were installed across the slab. The system was anchored into adjacent foundation walls using Fortress carbon plate anchors, ensuring proper load transfer and preventing future slab failure.

Additionally, a vertical crack in the wall was repaired using Fortress Crack Stitches and epoxy injection to reinforce and seal the area.

The Outcome

With the damaged steel removed and replaced by ICC-certified carbon fiber technology, this overhead slab is now structurally sound and protected against future failure. The repair not only restored performance—it upgraded the slab using materials over five times stronger than steel, without the need for major demolition.

Why It Matters

Overhead slab failures are complex and potentially dangerous. This project demonstrates how ReGrid carbon fiber technology can restore and even exceed the original strength of compromised concrete structures—without the cost or disruption of full replacement.

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