CONCRETE REPAIR AND STRENGTHENING OF EXISTING STRUCTURE

MATERIALS

1. FORMWORK

Formwork shall be timber or other materials, which produce the specified finish. Materials used as formers
for profiled formwork, chamfers, splays, rebates and other features shall be such that they produce the same
finish as the main formwork.
Plywood for formwork shall have a close, uniform grain and the edges shall be sealed with
barrier paint, polyurethane varnish or other impermeable materials. Plywood sheathing to
formwork shall not be subjected to more than nine uses, irrespective of the use of one or both
faces of such sheathing.

2. REINFORCEMENT

Steel reinforcement shall be plain round steel or deformed high yield steel bars or hard
drawn steel wire fabric to BS 4483:2005. Dowel bars and replacement reinforcements shall comply in all
aspects with the Specifications.

3. PRIMERS

The primer shall be in accordance with the recommendations/ instructions of the manufacturer
of the approved proprietary repair mortar.
(i) Rust Inhibitors: unless otherwise approved, rust inhibitors shall contain titanium dioxide as
the pigment in a modified aliphatic was binder.
(ii) Cement Based Reinforcement Primer shall be approved polymer modified cement based
corrosion resistance primers.
(iii) Epoxy Based Reinforcement Primers shall be approved two components epoxy resin
supplied in pre-weighed quantities. The primer shall be used before the expiry of its shelf
life and pot life. It shall also have a pot life suitable for repair application as in the opinion
of the Architect.
Where zinc rich primers are required they shall contain zinc dust as pigment in epoxy resin
binder.

4. BOND COATS

It shall be all in accordance with the recommendations/instructions of the manufacturer of the

proprietary repair mortar
(i) Cement based bond coats shall be approved blend of cementitious materials incorporating
a polymer emulsion. The bond coat shall be all in accordance with the recommendations/
instructions of the manufacturer of the approved proprietary repair mortar.
(ii) Epoxy based bond coats shall be approved two component materials based on epoxy resin.
(iii) Acrylic based bond coats shall be approved single component materials based on an
acrylic polymer or copolymer emulsion.

5. CEMENT

Unless otherwise specified, it shall be ordinary Portland cement complying with BS EN 197-
1:2000. The quality, delivery, storage and testing of cement shall comply in all aspects with the
Specifications.
6. SAND

For mortar, it shall be medium grade natural sand complying with BS EN 12620:2002+A1:2008
and shall pass the 2.36mm sieve size. The chloride content of the sand, expressed as chloride
ion content, shall not exceed 0.1% by weight of dry sand. The sand shall be suitable for the
approved repair mortar mix.

7. WATER

It shall comply in all respects with the provisions of the Specifications.

8. ADMIXTURES AND ADDITIVES

Admixtures and additives for use in any type of mortar may be approved if there is any specific
benefits to the fresh mortar and provided that no adverse effects to the hardened mortar shall be made all as
in the opinion of the Architect. Such benefits may include
plasticity, adhesion to substrate, cohesion or alteration to setting time. Where appropriate
admixtures shall comply with the requirements of BS EN 934-3:2003, BS EN 480-4:2005, BS
EN 480-2:2006, BS EN 480-5:2005, BS EN 480-6:1997, BS EN 480-10:1997, BS EN 480-
8:1997, BS EN 934-2:2009, BS EN 480-1:2006, BS EN 480-12:2005, BS EN 480-11:2005, BS
EN 934-6:2001, BS BS EN 934-2:2009 or other appropriate standards.

9. CURING COMPOUNDS

Curing compounds shall have a minimum curing efficiency of 75 percent. After the application,
the curing compound shall become stable and impervious to evaporation of water from the
surface of the repair mortar within 60 minutes after the application. They shall not react
chemically with the repair mortar to be cured and shall not crack, peel or disintegrate within
three weeks after application.
Curing compound shall be applied strictly in accordance with the manufacturer’s instructions.
Curing compounds shall not be used when a further layer of repair mortar is to be applied or
when they may affect the adhesion of subsequent coatings or finishes as in the opinion of the
Architect

REPAIR STRUCTURE CONCRETE AND MORTAR

Repair concrete shall be a mixture of cement, sand, water, primer, bond coat, curing compound, admixtures and
additives (where approved) in approved proportions. The repair mixture shall be high build; suitable for
overhead work and is capable of achieving a minimum thickness of 40mm per layer. The components of the
repair mixture, except water or pre-batch gauging liquid, shall be supplied in single-batch sized container.

The constituent materials for each system proposed shall be from the same manufacturer.
The materials shall be in strict accordance with the manufacturer’s instructions and the
Specifications.

DOWEL BARS

Dowel bars shall be type 2 deformed bars as specified in BS 8110-1:1997; BS 8110-2:1985; BS

8110-3:1985.

DOWEL BARS GROUT

Grout for dowel bars installation shall be an approved product based on epoxy resin or polyester. The grout shall
have non-shrink properties and shall undergo its initial set in less than 2 hours. For all applications except
downhand holes, the grout shall be thixotropic with a high viscosity at the time of application.

WORKMANSHIP

PROPOSAL OF REPAIR MIXTURE SYSTEM (RMS)

The RMS proposed shall be in accordance with the properties and characteristics stated in the
Specifications. The following information shall be provided in the contractor’s proposal:

(i) Mix proportions.

(ii) Cement content, admixtures and additive content, water/cement ratio and aggregate/
cement ratio of repair mortar.
(iii) Source of aggregate, cement and admixture and additives.
(iv) Application procedure including mixing procedures, substrate preparation, rust cleaning,
application of primer and bond coat, repair mortar application and curing regime.

BREAKING OUT AND PREPARATION OF CONCRETE SUBSTRATE

For any concrete strengthening area required, the perimeter of the patch area shall be cut
by saw or diamond cutting.
Any damage to existing reinforcement (especially where embedded in existing concrete) and to
adjacent elements of the building shall be minimized. The exposed concrete surfaces against
which repair mortar on concrete is to be placed shall be roughened to expose the aggregate
and to remove all loose materials.
Adequate shoring and propping shall be provided.

PREPARATION OF REINFORCEMENT
Replacement reinforcement shall be clean to the same standard as specified for the remaining
reinforcement unless otherwise directed by the Architect.
All weld slag shall be removed by hammer and chisel.
After breaking out and preparation of reinforcement, the reinforcement and concrete substrate
shall be brushed with a dry brush to remove all loose dust and dirt.

REQUEST FOR INSPECTION OF WORKS

Immediately after completion of breaking out, preparation of concrete substrate and
reinforcement, we shall submit notice in good time to the Architect for
approval of workmanship. The submitted notice shall also serve as Record of Repairs.
Upon receipt of the notice, the Architect shall inspect the workmanship of all the
patches concerned and give instructions for further improvement of workmanship, if any, or
give approval to proceed with the application of primer, bond coat, repair mixture and curing
agent, if any.

PRIME COAT FOR REINFORCEMENT

The reinforcement shall be primed as soon as possible for cleaning. The reinforcement shall be
free from moisture, rust, oil and other contamination before priming. Primer shall be applied in strict
accordance with the manufacturer’s instructions.

BOND COAT FOR CONCRETE SUBSTRATE

Bond coats shall be applied to the concrete substrate and the primed reinforcement as soon as
possible after the reinforcement primer has cured sufficiently as specified in the manufacturer’s
instructions. 100% coverage shall be achieved but care shall be taken to avoid covering too
large an area at any one time to ensure the repair material is applied during the open time of
the bond coat. The concrete surfaces to which the bond coat are to be applied shall be thoroughly
wetted down for about 20 minutes to achieve saturation, except for epoxy based bond coat.
The bond coat shall be applied in strict accordance with the manufacturer’s instructions.

BATCHING AND MIXING OF REPAIR MIXTURE

Dry mixing ingredients for repair mixture shall be weight batched, unless exceptional approval for
volume batching is given by the Architect. Liquid ingredients shall be volume batched or separately
weight batched.
Mixing shall be carried out in an approved mechanical pan mixer with means to provide folding
and tumbling of the constituents materials in accordance with the manufacturer’s instructions
so that all constituent materials are uniformly dispersed throughout the mixture.

APPLICATION OF REPAIR MIXTURE

Repair mixture shall be placed so as to produce a dense homogeneous mass and to avoid
sags. Where voids are found in repair mortar, none of them shall have:
(i) for void immediately adjacent to the reinforcement:
(a) Any linear dimension greater than 3mm measured away from the reinforcement;
(b) Any linear dimension greater than 6mm measured along or around the reinforcement
provided that primer has been properly applied; and
(c) The product of all 3 linear dimensions greater than 27 mm³.

(ii) for void at any other location:-

(a) any linear dimension greater than 20mm;
(b) the product of any 2 linear dimension greater than 200 mm²; and
(c) the product of all 3 linear dimensions greater than 800 mm³.

The repair mixture shall be placed in thickness not less than 10mm unless otherwise
recommended by the manufacturer. Where more than one coat of repair mortar is to be applied,
the timing of surface preparation to former coat and application of new coat shall be in accordance
with the manufacturer’s specifications.
Where practical, soffits board or side form shall be used. Cover to reinforcement of at least
10mm shall be provided. Displace bars shall be tied back to achieve the specified cover.

CURING OF REPAIR MIXTURE

The repair shall be properly cured by the method as recommended by the manufacturer.

INSTALLATION OF DOWEL BAR AND GROUTING

Holes for the installation of dowel bar into existing concrete shall be frilled with a rotary percussive
drill to sizes and depths shown on drawings provided. The hole shall be air blown by a pneumatic
device to clean out debris and dusts. The dowel bar grout shall be placed in the deeper end of the
hole in order to avoid the entrapment of air.
The dowel bar shall be inserted into the grouted hole to the grouted length required. If flow is
not displaced from the hole then the dowel must be removed and further grout shall be inserted
in the hole. The installed bar should be given a 1/2 turn and then turned back to the original
position and left undisturbed for 2 hours or as recommended by the manufacturer of the grout..
During curing no further grout shall flow from the hole.

QUALITY TEST - PULL-OUT TEST

The adhesive strength of the repair shall be determined by pull-out testing at 7 days after
repairing as follows upon request by the Architect whenever he considers the repair area is not
satisfactory.

A suitable metal plate shall be glued to the cored surface and this attachment shall be pulled
with increasing tensile force using a specially calibrated device until failure occurs. The force
needed to cause failure shall be examined and the mode of failure reported as either adhesive
(at the concrete/repair interface) or cohesive (within the parent concrete or repair mortar). The
core shall be immediately coloured photographed to show the core and failure surface in close
up against a contrasting background all to the approval of the Architect.

Any repair where cores indicate delaminating voids or other imperfections shall be opened up
and repaired again or further tested at the discretion of the Architect. Coring for specimens shall be
carried out generally in accordance with requirements of BS 1881.

The proposed wall adhesive shall be able to meet the minimum standard of performance
(adhesion strength of 0.4N/mm2 minimum for concrete/rendering interface) after application
on site. Such performance shall be proven by Pull-out Tests to be conducted on site by an
approved independent laboratory in accordance with an endorsed procedure with reference to
the relevant BS standards.

Determination of adhesion concrete to concrete in accordance to BS EN 12636:1999. Pull-out

tests are compulsory test and shall be carried out by the contractor at a rate of one per 50 m² of
repaired surface area, in positions selected by the Architect to check compliance
with the Specification.

Should the pull-out test fail to meet the Specification, all repair patches of the 50 m² of patch
repair surface area represented by the pull-out test shall be deemed not to comply with the
Specification