Working alongside engineering firm Wood, construction partner OCL and concrete specialist Fortress, the Imperial and ExxonMobil teams demonstrated how advanced reinforcement can improve operational efficiency in demanding conditions.

For industrial operators, constructing heavy-load infrastructure in remote locations requires reinforcement that delivers both durability and installation efficiency while addressing logistical challenges and project costs. At the Kearl site, the tunnels must support regular road traffic below while carrying continuous traffic from fully autonomous, ultra-heavy 400-short ton (363-tonnes) Caterpillar 797F haul trucks above. These vehicles are among the largest autonomous trucks operating in an active production environment. Constructing tunnels with traditional steel rebar, which weighs approximately 350 lb (159 kg) per bar, typically requires significant crane equipment and additional handling resources.

To address these challenges, the project selected Proxxima GFRP rebar manufactured by MST Rebar Inc. These Size No. 11 bars weigh approximately 65 lb (29 kg) each and measure up to 36 mm (1.4 in) in diameter — the maximum size permitted under Canadian Standards Association (CSA) code.

Kearl site rebar installation improvements—Proxxima GFRP rebar versus traditional steel:

• Lightweight handing: Simplified on-site handling by transforming a heavy crane-assisted process into a manual two-person lift.
• Logistics and shipping efficiency: The lightweight aspect allowed for maximized truck loads, reducing the overall number of freight deliveries required to reach the remote site.
• Infrastructure performance: Highly resistant to environmental degradation, enabling a longer service life in corrosive environments.

“There’s a big difference between building foundations with steel rebar and Proxxima rebar,” said Bala Swaminathan, Project Manager at Imperial. “Proxxima rebar is much lighter, reduces crane time and reduces construction man-hours.”

Results from the Imperial Kearl Oil Sands site
The completion of this 354-foot (108-meter) tunnel foundation represents one of the largest GFRP rebar applications deployed in Canada. For operators, the project demonstrated the potential to reduce logistics costs, improve construction timelines and support longer-term durability.

The Kearl deployment goes beyond a single successful installation. It demonstrates the potential for advanced composite reinforcement in critical heavy-duty infrastructure applications. Ultimately, the project demonstrates a new path forward for the most demanding projects. ExxonMobil is actively leveraging insights from this project to expand the footprint of Proxxima systems technology, working alongside industry collaborators to usher in a new era of high-performance, cost-effective structural design.

Watch the video below and download the full case study to learn more.