Concrete repairs to return the area back to its original structural strength and to protect any exposed reinforcement steel to prevent corrosion.
A thorough tap test was conducted across the entire affected concrete surface to identify areas of delamination.
The repair areas were carefully measured and marked. The boundaries were clearly defined to ensure the removal of all damaged concrete, extending slightly beyond the affected zones.
Delineation cuts were made 20mm deep along the perimeter of each marked repair area using a concrete saw. These cuts provided a clean boundary to guide the removal of damaged concrete and to minimise further damage.
Using a jackhammer, the damaged concrete was mechanically broken and removed. The process was continued until the first layer of reinforcement steel was exposed, ensuring the complete removal of all deteriorated material.
After the damaged concrete was removed, the exposed steel reinforcement was cleaned using a combination of wire brushes, grinders, and sandblasting. This cleaning process removed any rust, debris, or contaminants, ensuring a clean surface for bonding the repair materials.
The exposed steel reinforcement was examined for any damage. Sections with more than 20% loss of diameter due to corrosion were replaced with new reinforcement steel, following proper installation and tying techniques to ensure structural integrity.
Fosroc Nitoprime Zincrich was applied to all exposed reinforcement steel to protect against further corrosion. The primer was applied evenly, ensuring full coverage as per the manufacturer’s guidelines.
A prime coat of Nitobond HAR was applied to the concrete substrate to enhance bonding between the existing concrete and the repair material. The primer was applied according to the manufacturer’s recommendations, ensuring the proper curing time was observed before proceeding.
Both Fosroc Renderoc HB40 and Renderoc LA55 were used for the repair. The patches were poured with LA55 and the smaller patches were packed with HB40.
The repaired areas were covered with plastic wrap to retain moisture and ensure proper curing. The curing process was maintained in accordance with the manufacturer’s instructions to allow the repair materials to achieve their full strength.
Once the repairs had cured, they were inspected for any imperfections.
This systematic approach ensured the successful completion of the concrete repair, restoring the integrity and longevity of the structure.
