VOLUME 3 TECHNICAL SPECIFICATIONS

DIVISION 5 - STRUCTURES

5.4 EXISTING CONCRETE

5.4.1 Description

This work shall consist of the construction of small extensions; reconstruction of

localised defective concrete; rehabilitation of existing concrete facing; reinforcing,
anchoring, tying and nominal stressing together of concrete elements; ground anchors;
and sealing and treatment of structural cracks in various forms of members, all in
accordance with these Specifications and the lines, levels, grades, dimensions and
locations shown on the Drawings and as required by the Engineer.

5.4.2 Materials

5.4.2.1 Concrete

Concrete shall comply with the requirements of Section 5.1 of these Specifications.

5.4.2.2 Reinforcement

Reinforcement shall comply with the requirements of Section 5.2 of these

Specifications.

5.4.2.3 Prestressing Reinforcement

Prestressing reinforcement shall comply with the requirements of Section 5.3 of these
Specifications.

5.4.2.4 Cement Grout and Mortar

Cement grout and mortar shall comply with the requirements of Section 5.1 of these
Specifications.

5.4.2.5 Resin Repair Mortars

Epoxy resins, unsaturated reactive polyester resins or unsaturated acrylic resins

specified on the Drawings and detailed in the Bill of Quantities shall conform to the
requirements of the Manufacturers recommendations or other suitable alternatives,
subject to the approval of the Engineer, where it can be demonstrated that the
proposed alternatives are at least equivalent to the materials proposed.

5.4.3 Construction Methods

5.4.3.1 General

The Contractor shall in due time and as soon as possible present and discuss his
construction proposals and work programmes for nominal extensions to existing
concrete structures; for implementing repairs to existing structural cracks in concrete
structure; for implementing repairs to existing concrete surfaces and for the
rehabilitation of existing defective concrete.

The details of Works shall cover the requirements specified on the Drawings and as
directed by the Engineer at each location. The scope of new Works shall be as
confirmed by the Engineer. The precise extent of all concrete extensions or repairs
shall be jointly surveyed by the Contractor and the Engineer at the commencement of
the Works and the locations of all extensions, repairs or strengthenings shall be
recorded and carefully marked in paint on each structures to permanently identify the
Works to be implemented.

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VOLUME 3 TECHNICAL SPECIFICATIONS
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In locations where existing concrete sections are to be extended or joined, the existing
concrete shall be carefully broken back at the locations where sections are to be
joined. The breaking will be done to ensure the damage to existing concrete is the
absolute minimum. Sufficient concrete will be removed to expose where appropriate the
reinforcement of the existing section. Sufficient reinforcement will be exposed to enable
additional reinforcement to be lapped to the existing steel. The reinforcement will be
carefully cleaned and all loose concrete shall be removed. The existing concrete will be
cleaned of all dust and a construction joint shall be prepared accordingly on the
exposed face to ensure a good feature can be obtained between the new work and the
existing concrete section. Concrete and reinforcement for the construction of the new
section shall conform in all respects to Sections 5.1 and 5.2 respectively.

Defective concrete on the front face of substructure walls such as piers, abutments
etc., particularly adjacent to the water line; and in soffits to beams, slabs and other
superstructures; on the wet faces of main beams and other superstructures shall be
carefully removed in a sequence and in accordance with the strict instructions of the
Engineer. Such works shall be permanently supervised by a technical representative of
the Engineer and the Contractor shall also ensure technical staff are permanently
available on the Site to receive specific instructions. The existing structural integrity of
existing members shall not be impaired during this operation and the Contractor shall
be fully responsible for ensuring strict procedures are followed. Defective concrete on
main structural members shall be carefully and cleanly removed by manual methods
using hammers and chisels to expose the main and secondary reinforcement. This
reinforcement shall be carefully cleaned using wire brushes unless the Engineer gives
alternative instructions. The concrete shall also be carefully broken back and the
surface shall be cleaned of all dust and loose material. The removed defective
concrete shall be replaced by a method proposed by the Contractor that shall be
subject to the approval of the Engineer. In this respect, the Contractor shall propose
and clearly demonstrate that the method he proposes to adopt is capable of giving a
guaranteed facing of concrete that would be equivalent in all respects to the
workmanship standards that would be accepted in new works. Depending on the extent
of the repair works, sprayed concrete or gunite will be allowed provided acceptable
procedures are proposed. Traditional formwork methods with “letter boxes” will also be
allowed for large volume repairs.

Strategic structural cracks on highly stressed structural members such as shear cracks
at scarf joints or shear cracks in beam webs shall be sealed by resin repair mortars.
The Contractor shall ensure temporary access is provided to effectively implement
critical repairs. The final decision of the repair resin will be made on completion of the
inspection immediately prior to undertaking the sealing operation. Initially, cracks will be
cleaned of all dust and debris in accordance with manufacturers recommendations
once the resin to be adopted has been identified. Depending on the method to be
adopted, nipples shall be inserted along the cracks or vacuum impregnation
procedures shall be prepared to enable grout to be effectively injected into the
structural cracks. The Engineer shall assess the effectiveness of crack repairs,
generally on the basis of the quantity of resin injected.

Structural concrete members that exhibit cracking and relative movement may be
anchored or tied in accordance with the Engineer’s instructions. Wingwalls and
abutments shall be tied and anchored at the locations and to the details indicated on
the Drawings and as specified in the Bill of Quantities. Prior to commencing any of the
work, the Contractor shall obtain the approval of the Engineer of the methods to be
adopted for all temporary arrangements. This shall cover the provision of temporary
stages; the proposed drilling methods; proposed safety measures; proposed anchoring
methods and subsequent testing for ground anchors to ensure tie bars are capable of
carrying twice working load; proposed stressing methods and ultimate grouting of
anchor bars. The Contractor shall take instructions from the Engineer on the precise

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VOLUME 3 TECHNICAL SPECIFICATIONS
DIVISION 5 - STRUCTURES

requirements for the provision, installation and anchoring of all tie bars incorporated in
the Works.

5.4.3.2 Workmanship

Repairs and the like to existing concrete shall be constructed as shown on the
Drawings or as may be required, by skilled and experienced personnel well versed in
this type of work. The Contractor shall clearly demonstrate that his workforce proposed
to be used on concrete repair works have a capability to complete this form of work to a
satisfactory standard. Such demonstrations may take the form of pilot repair works not
directly associated with the Works.

5.4.4 Measurement

Concrete Extensions and Repairs shall be measured in either cubic metres or square
metres depending on the form of work ordered, placed and accepted. In computing
quantities, the dimensions of concrete extensions where appropriately shown on the
Drawings for new work and extensions shall be used as the basis for measurement.
Remedial repairs of defective concrete facework and replacement of defective concrete
shall be measured by the area of square metres ordered, marked up and accepted.
The sealing of cracks with resin repair mortars shall be measured by the weight of resin
used in the injection process of cracks ordered to be repaired, marked up and
accepted. The sealing of cracks with cement mortar shall be measured by the
cumulative length of cracks ordered to be repaired, marked up and accepted. The
provision of tie bars and ground anchors, and installation (including fixing, drilling,
grouting in stages, stressing etc.) shall be measured by the weight of bar ordered,
installed and accepted.

No incidental works necessary to perform the repair works shall be measured; the
Contractor shall include in the payment items for all necessary temporary works to
undertake and complete every operation.

5.4.5 Payment

The Work measured as provided above shall be paid for at the Contract unit prices per
cubic metre of concrete or square metre of concrete refacing. Resins used in cracks
shall be paid for at the Contract unit prices per kg of material used. Anchor and tie bars
shall be paid for at the Contract unit prices per tonne of bar used. Concrete cracks
filled with cement mortar shall be paid for at the Contract unit prices per length of crack
required. The rates shall be fully inclusive of all cost of all labour and materials
temporary works and equipment to complete the works in a professional manner.

Pay items shall be:

5/4/1 Modifications to Existing Concrete as Detailed on the Cubic Metre

Drawings and as stated in the Bill of Quantities

5/4/2 Concrete Surface Repair Works (Superstructures) Square Metre

5/4/3 Concrete Surface Repair Works (Substructures) Square Metre

5/4/4 Resin Repair Mortars Kg

5/4/5 Cement Mortar in Cracks Linear Metre

5/4/6 Anchor and Tie Bars Tonne

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