DEPARTMENT of INFRASTRUCTURE, ENERGY and RESOURCES, TASMANIA

BRIDGE MAINTENANCE SPECIFICATION

B15 - CONCRETE REPAIRS OCTOBER 2006
Previously MB10
Contents Page
B15.1 SCOPE 2
B15.2 EXTENT OF WORKS 2
B15.3 CONCRETE PREPARATION 2
B15.4 REINFORCEMENT PREPARATION 2
B15.5 FORMWORK 3
B15.6 MATERIALS 3
B15.7 REPAIR 3
B15.8 EXTENSIVE REPAIRS 3
B15.9 CURING 4
B15.10 FAIRING COATINGS 4
B15.11 PROTECTIVE COATINGS 4
B15.12 WORK RECORDS 4
B15.13 PAYMENT 4
Table B 15.1 Concrete Repair Materials 5



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.
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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

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