This Specification sets out the requirements for the preparation and reinstatement of damage to mass or reinforced concrete. The Contractor shall determine whether temporary shoring or propping is required for any concrete repairs, and submit proposals to the Superintendent for approval. Where damage results from carbonation of the cover concrete, the extent of repair shall be confirmed during preparation.
This Specification sets out the requirements for the preparation and reinstatement of damage to mass or reinforced concrete. The Contractor shall determine whether temporary shoring or propping is required for any concrete repairs, and submit proposals to the Superintendent for approval. Where damage results from carbonation of the cover concrete, the extent of repair shall be confirmed during preparation.
This Specification sets out the requirements for the preparation and reinstatement of damage to mass or reinforced concrete. The Contractor shall determine whether temporary shoring or propping is required for any concrete repairs, and submit proposals to the Superintendent for approval. Where damage results from carbonation of the cover concrete, the extent of repair shall be confirmed during preparation.
B15 - CONCRETE REPAIRS October 2006 B15.1 SCOPE This Specification sets out the requirements for the preparation and reinstatement of damage to mass or reinforced concrete. B15.2 EXTENT OF WORKS The area of repair shall be as detailed on the drawings, as specified elsewhere or as defined on site by the Superintendent. Where damage results from carbonation of the cover concrete, the extent of repair shall be confirmed during preparation by the application of phenolphthalein solution to remove all carbonated concrete over the defined area of repair. Where damage results from the delamination of cover concrete, the extent of repairs shall be confirmed after preparation of repair works to ensure that all delaminated cover concrete has been removed. The Contractor shall determine whether temporary shoring or propping is required for any concrete repairs, and submit proposals to the Superintendent for approval. B15.3 CONCRETE PREPARATION Preparation for concrete repairs shall be undertaken using high-pressure water blasting, at a pressure in excess of 140 MPa (20,000 psi) to avoid creating micro cracks. Before high pressure blasting, the perimeter of the areas to be repaired shall be cut to a depth of 10 mm. Featheredges shall not be permitted. All damaged, carbonated, delaminated or otherwise unsound concrete shall be removed within the extent of works until sound concrete is reached. Where concrete has been damaged by impact, the minimum depth of preparation shall be 40 mm. Where reinforcement is exposed, or the remaining cover is negligible, breaking out shall continue to expose the full circumference of the reinforcement and to a further depth not less than 20 mm. Care shall be taken to ensure that the removal of concrete does not result in damage to reinforcement or other embedments such as conduits or sockets. The prepared surface shall be shaped so that there is no entrapment of air or moisture during application of repair material. The prepared concrete surface shall be sound and clean and free of loose particles, dust and debris. B15.4 REINFORCEMENT PREPARATION Where exposed reinforcement is sound or shows signs of corrosion it shall be mechanically cleaned of rust and loose millscale. If the structural capacity of the reinforcing is compromised by the extent of corrosion or pitting then the diameter of the reinforcement shall be measured after preparation and, as directed by the Superintendent, the reinforcement cut out and replaced, or additional bars added. Where bars are replaced, full strength butt welds, using backing plates are required. Reinforcement damaged during preparation shall be repaired or replaced, as directed by the Superintendent. Reinforcement used in repairs shall comply with the requirements of AS 4671. Exposed reinforcement shall be coated with Zinga prior to flash rust occurring. The Zinga shall be applied by brush to ensure that all surfaces of the reinforcement, including hidden surfaces, are coated. Any rust that cannot be removed shall be stabilised with Resene 167 pre-prime and then coated with Zinga prior to rebuilding of the concrete section. DIER SPEC B15 2 of 5 B15 - CONCRETE REPAIRS October 2006 B15.5 FORMWORK Where required, formwork shall be provided in accordance with AS 3610. Formwork shall be securely fixed to withstand the hydraulic pressures of the repair material. Fixing of the formwork shall not compromise the durability of the structure. Facing of the formwork shall be selected so that the finish of the repaired area matches that of the surrounding concrete. An appropriate release agent shall be applied to the formwork. Where repair material is introduced into the repair by hydrostatic pressure or pumping, the entry point for the feed point shall be at the lowest point of the formwork. Where necessary, provision shall be made for controllable inspection ports to prevent air entrapment and to enable the extent of flow of the repair material to be assessed. B15.6 MATERIALS Concrete repair materials and associated primers shall be supplied by the one manufacturer, and shall be shrinkage compensated polymer modified cementitious materials. The materials listed in Table B 15.1 are acceptable; the use of other products is subject to approval by the Superintendent, with the chosen materials listed in the Contract Management Plan. B15.7 REPAIR Repairs shall not be undertaken when the ambient temperature is below 5 o C, 5 o C on a falling thermometer, or above 35 o C. Preparation, application of bonding agent, recoating, and machine mixing shall be in accordance with the manufacturer's instructions. Water shall be measured with graduated measuring equipment. The repair material shall be pre- bagged and added to the quantity of mixing water prescribed by the material manufacturer. Full bag mixes only shall be permitted. Retempering, remixing and the addition of water to restore the workability of the repair material shall not be permitted, and any unsuitable material shall be rejected. Repair material shall be applied taking particular care to pack behind and between reinforcement. The required depth and profile of repair shall be achieved by building successive wet on wet layers. If sagging occurs, the material must be completely removed and the void filled by two or more successive layers, or by providing formwork. B15.8 EXTENSIVE REPAIRS Conventional pre-mixed concrete shall be used for any extensive repairs as detailed in this Specification or on the drawings. Preparation shall be in accordance with this Specification, except that impact methods may be used for bulk concrete removal. Concrete shall be Grade 32S for inland locations and Grade 50S within 1 km of the coast, tidal estuaries or other bodies of salt water, in accordance with Specification B10, Supply of Concrete, unless otherwise specified. Reinforcement shall be placed at the locations detailed in the Specification or as shown on the drawings. Splicing to the existing structure shall be by full penetration butt-welding or by laps in accordance with AS 5100 Bridge Design Code. Supply and placement of reinforcement and concrete shall comply with Specification B11, Reinforced, Prestressed or Mass Concrete. DIER SPEC B15 3 of 5 B15 - CONCRETE REPAIRS October 2006 B15.9 CURING Repaired areas shall be fully cured, by moist curing, for not less than seven days. Surfaces are to be continuously wet when moist curing is used. The Superintendent may approve the use of a curing agent when continuous moist curing is not feasible. B15.10 FAIRING COATINGS A fairing coating shall be applied when required by this Specification for architectural reasons, or to provide protection against further carbonation or chloride ingress. The extent of application shall be as specified or as directed by the Superintendent. All surfaces shall be free of oil, grease, loose particles, decayed matter, moss or algal growth, curing compounds, laitance and surface contamination. Cleaning shall be in accordance with specification R54, Road and Bridge Cleaning. Treatment, including wetting, priming, mixing, application and curing, shall be in accordance with the manufacturer's instructions. B15.11 PROTECTIVE COATINGS When required, a protective coating shall be applied in accordance with specification B23 Penetrating Sealers and Coatings to protect concrete against carbonation and chloride ingress. Any blowholes or substantial pitting shall be repaired with a fairing coat in accordance with this Specification. B15.12 WORK RECORDS Further to Specification G1 daily records shall be kept of the following: Stability of Structure Reinforcement Surface Finish Materials - Generic Types, Brand Names and Batch Numbers Temperature Records Curing regime B15.13 PAYMENT Payment for concrete repairs shall be at the items as listed in the Schedule of Rates. Payment shall include the provision of all plant, labour and materials required for traffic control, access, scaffolding, shoring and propping, formwork, preparation, repairs, curing and the disposal of any debris DIER SPEC B15 4 of 5 B15 - CONCRETE REPAIRS October 2006
Table B 15.1 Concrete Repair Materials
EPIREZ FOSROC Degussa SIKA Concrete Primer EPIPATCH PRIMER NITOBOND AR/HAR BARRA EMULSION AC MONOTOP 610 Steel Primer Resene 167 pre-prime over coated with Zinga cold galvanising Resene 167 pre-prime over coated with Zinga cold galvanising Resene 167 pre-prime over coated with Zinga cold galvanising Resene 167 pre- prime over coated with Zinga cold galvanising Concrete Repairs Shallow EPIPATCH RENDEROC S Barra Mortar HS MONOTOP 610 High build, overhead EPIPATCH HB RENDEROC HB Barra Mortar HL MONOTOP 615 HB Large scale, congested, reinforcement RENDEROC LA EMACO S66 Rendering, fairing RENDEROC FC BARRA 80 MONOTOP 620 Curing CONCURE CR MASTERKURE 410 TILTSEAL Protective Coating ENVIROBLOCK NITOCOTE DEKGUARD BARRACRYL D