Instant Concrete Road Repair Solution

INTRODUCTION
The Durability of road structures depends on the quality of its
maintenance & minor renovations. Maintenance keeps the roadway safe,
provides good driving conditions & prolongs the life of the pavement,
thus protecting the road investment.

Currently in India more than 2000 km of concrete road is in the

operation since last few years. Most of the projects completed by NHAI,
MSRDC and other state government authorities. Though the quality &
procedural aspects, specifications / guidelines clearly mentions in IRC,
MoRTH, but still we observes that various minor cracks, potholes and
joints edge spalling in the PQC due to various factors which requires
maintenance. Maintenance includes the prompt sealing of cracks &
filling of potholes to prevent water entering through the surface.

Repairs and rehabilitation of concrete roads are required to have a

smooth riding quality as well as avoid inconvenience causing to the
vehicles. We need to have a durable repair products to avoid of cost of
various factors like :

a) Diverting the traffic for repairs

b) Inconvenience to the traffic
c) Repeatedly cost of repairs by using conventional methods.
 REQUIREMENT OF THE PRODUCT FOR REPAIRS OF
CONCRETE SURFACE

1) Resistant to abrasion and weather conditions.

2) Skid resistance, non-reflective finish with colour matching with
concrete
3) Fast setting so that repaired patch can accept traffic in as little as
one hour.
4) Resistance to deicing chemicals & various industrial chemicals
5) Jet fuel and other fuel resistance like petrol, diesel, oil and grease.
6) Good bond between concrete and steel, Impermeable.
7) Flexible enough to accommodate anticipated expansion and
contraction.
8 ) Ultra-violet Resistance, User friendly and pain table.
9) Manufacturer of the material should have the good track record &
experience in such kind of repair products.
10) Economical

CONVENTIONAL METHODS OF REPAIR CONCRETE

STRUCTURES
Though we have developed our specifications and guidelines to lay the
PQC up to the international standards, but now considering the
deteriorating conditions of the concrete roads, we have to develop the
good specifications and proper guidelines / application systems to repair
and rehabilitation of concrete surfaces permanently.
Currently following are the various conventional methods we are using
for the repairs of concrete road.
1) Repair by fast setting water based cement compound
2) Repair by epoxy mortar, which is non-UV Resistance material.
3) Repairs of PQC by laying bituminous concrete or bitumen in the
cracks & potholes.
4) Other conventional methods

NEXT GENERATION FAST SETTING COMPOUND

DELPATCH

In 1983, The D.S. Brown Company introduced Delcrete TM

Elastomeric Concrete. The rigid, yet flexible connection DelcreteTM
provided between steel and concrete soon made it the premier solution
for bridge and highway spall repair as a permanent repair solution for
high performance pavements, which would offer minimum downtime
and, at the same time, limit exposure of work crews to traffic.

D.S. Brown engineers formulated DelpatchTM Elastomeric Concrete

from the original DelcreteTM product. DelpatchTM a new generation of
elastomeric concrete has two main uses. First, it is an excellent patching
material for cracks and spalls on airport runways and highways. Second,
Delpatch TM provides an easy to use solution in retrofitting airport
runways with lighting & bridges with expansion joints.
Delpatch vs Others

Description Epoxy based Cementatious Material Delpatch – Polyurathan Based

Material Material

 Technical properties:

Compressive Strength 60 N/mm2 Max 55 N/mm2 in 28 80 N/mm2 in one days

days time.

Flextural Strength 20 N/mm2 5.5 -

Tensile Strength 10 N/mm2 - 13.44 N/mm2

Impact resistance Poor poor very good Impact resistance

Flexible Poor poor It can deflect up to 10%, and will
regain its original shape
Abrasion resistance Yes Up to some extent very good abrasion resistance.
  Practicle:

Curing Doesn’t required curing Curing by water is must, otherwise it Doesn’t required curing by
by water develops cracks water
Time required to 6 – 16 hours 12 – 24 hours After one hour
allow traffic
Paintable Yes Yes Yes
UV resistance Poor good Very good
Water impermeability Good poor Very good

 Economy :

Rate per ltr or Kgs. Initial cost will be Cheaper than epoxy Initial cost will be slightly
cheaper, higher
Life cycle cost Will be high as need to Will be too high as need to repair Life cycle cost will be
repair frequently frequently cheaper
A. Existing condition before repair:
After construction of PQC, various cracks has developed due to various
reasons like

a) Settlement of the sub-base

b) Surface cracks due to high wind-velocity during laying of PQC
c) Late initial cut of PQC

We have found that various major potholes, cracks and joint spalling at
various junctions of Jogeshwari Vikhroli Link Road, Mumbai and at
Mumbai international airport wherein contractor or government authorities
are unable to repair by epoxy, as epoxies are not UV Resistant or by
cementatious material and also they are unable to hold the traffic for
conventional repairs.

Following are the few photographs shows deteriorating concrete surfaces

and cracks, which requires repair on priority basis to avoid further damage
to take place.

Conclusions:
We can conclude with the recommendation of Delpatch should be the
material which can be used for such kind of repairs which are critical and
important.
This material can be used for following repairs and rehabilitations of:

1. Concrete roads & patches including underpasses

2. Expressways, aprons of airports, where we can not hold the traffic
for the sake of repairs of the deterioted patches
3. Nosing wheel areas, where the loads expected more than 150 – 200
tonnes per 2 sq.ft. Area
4. Replacing the expansion joints – which we can complete in one
night, actually such kind of practices adopted in US, and other part
of the world, where replacement of expansion joint is essential but at
the same time, contractor does not have the permission to hold the
traffic for longer time.
5. Heavy Industrial floors, shop floors.
6. Light conduits to put lights on the runways.
7. All the surfaces exposed to the sunlight.
8. A top surface of spillways, bucket area of Dams, where water
pressure is more, & surface is exposed to sunlight.