TECHNICAL SUBMISSION

SECTION C PART 2

PROJECT SPECIFICATION
SECTION 5: CONCRETE

PART 16 MISCELLANEOUS
16.6

REPAIR OF CONCRETE

16.6.1

General
Delete paragraphs 1 and 2 and substitute with the following:

The extent and nature of the defects in the concrete shall be established in
accordance with Part 13 of this Section 5 for new concrete or following an inspection
jointly undertaken by the Engineer and the Contractor where existing concrete is to
be refurbished. Typical details to be noted during this inspection are:
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
(m)
(n)

Crack less than 0.5 mm

Crack greater than 0.5 mm
Surface staining
Crazing
Surface honeycombing
Extensive honeycombing
Local spalling
Voids greater than 10 mm deep
Voids greater than 15 mm deep
Exposed reinforcement
Significant spoiling
Displaced cracks greater than 5 mm
Any other notable defect
Any area that is beyond refurbishment

If remedial works are required the Contractor shall submit a detailed method
statement identifying the specific materials to be used and the sequence of activities
for the repair to the Engineer for approval. No work shall commence until the
method statement has been approved. The method statement shall include but not
necessarily be limited to:
(a)

Material Details:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)

Manufacturer
Product name
Application procedure
Primers required
Method of application
Special precaution required
Technical details and properties
References or case studies of previous applications of a similar
nature
Guarantees applicable to the use of the product in the locations to be
repaired.

IA 12/13 C 057 ST
C2/S5/42
Construction and Upgrade of Rayyan Road
Project 7: Contract 1
West of New Rayyan R/A to East of Bani Hajer R/A

February 2013

TECHNICAL SUBMISSION
SECTION C PART 2
(b)

Installation:
(i)
(ii)
(iii)
(iv)
(v)
(vi)

16.6.2

PROJECT SPECIFICATION
SECTION 5: CONCRETE

Details of temporary scaffolding

Details of formwork
Method of mixing
Method of placing
Equipment to be used
Method of supporting and protecting existing plant and equipment.

Honeycombing or Spalling
Delete paragraph 1 and substitute with the following:

Where there is honeycombed concrete or concrete damaged by physical forces

such as impact that has caused spalling, the concrete shall be replaced using a high
strength free flowing cementitious micro-concrete. This section also applies to
damage caused by gases and chemicals, notably hydrogen sulphide and chlorine.

16.6.5

Repair Methodology
Include after paragraph 3 the following:
The preferred method is high pressure water jetting specifically developed for
cleaning concrete. Light mechanical breakers may be used but the use of heavy
breakers shall not be allowed.
Delete paragraph 4 and substitute with the following:

Water jetting equipment shall be capable of using an entrained abrasive to aid

cutting and cleaning. Only potable water shall be used. Provision for protecting the
rest of the structure shall be made.
Delete paragraph 8 and substitute with the following:

Exposed reinforcement shall be blast cleaned using grit or water to Swedish

Standard SIS 05 5900 Sa 2.5 (near white metal). Two coats of zinc based primer
shall be applied making sure that the back face of the steel is also coated. Time
between coats shall be as the manufacturers instructions.
Delete paragraph 9 and substitute with the following:

Reinforcement damaged during the removal of concrete or eroded by chemical

attack shall, if required by the Engineer, be repaired or replaced. Concrete breakout
along the reinforcement shall continue a minimum of 100 mm past the point where
non-corroded reinforcement is reached, or as directed by the Engineer. Unless
otherwise directed by the Engineer, primary tension or compression reinforcement
which displays a reduction in diameter due to corrosion of more than 10% shall be
supplemented by reinforcement of size suitable to make up the reduction. Such new
reinforcement shall be lapped with the existing sound bars for a distance of 600 mm
in either direction.
Delete paragraph 16 and substitute with the following:

IA 12/13 C 057 ST
C2/S5/43
Construction and Upgrade of Rayyan Road
Project 7: Contract 1
West of New Rayyan R/A to East of Bani Hajer R/A

February 2013

TECHNICAL SUBMISSION
SECTION C PART 2
16

PROJECT SPECIFICATION
SECTION 5: CONCRETE

The formwork shall be inspected by the Engineer and, if approved, filled with clean
water which demonstrates that the formwork is grout-tight and saturates the
prepared concrete surfaces. The existing concrete shall be saturated with potable
water for a period of not less than 24 hours. Where formwork is not used saturation
shall be by spray. The formwork shall then be completely drained and resealed.
Add new paragraphs 25, 26, 27 and 28 as follows:

25

Where mortar is used for repair polymer modified mortar shall be mixed in a high
shear pan-type mixer for the minimum time necessary to produce the required
consistency. Free fall mixers may cause air entrainment and shall not be allowed.
For quantities of less than 10 kg, hand mixing may be used.

26

The mortar shall be applied by trowel over tacky bond coat in layers not exceeding
the thickness recommended by the manufacturer. Each layer shall be surface
scored, coated with bonding agent and allowed to take up its initial set prior to the
application of subsequent layers. If sagging occurs due to the applied layer being
too thick, the material shall be completely removed and fresh mortar re-applied at a
reduced thickness.

27

Any fine hair cracks which develop around the perimeter of the repaired area shall
be sealed after 28 days by cement grout gauged with a suitable acrylic emulsion.

28

Repairs which do not adhere and display a hollow sound when tapped with a light
hammer shall be broken out completely and repeated.

IA 12/13 C 057 ST
C2/S5/44
Construction and Upgrade of Rayyan Road
Project 7: Contract 1
West of New Rayyan R/A to East of Bani Hajer R/A

February 2013