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Concrete repair

Concrete repair

Chloride attack in the Gulf is not a question of whether, only of when — and of whether you intervene while it is still a repair.

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Concrete in a marine climate fails in a sequence that is entirely predictable. Chloride penetrates the cover. The passive layer on the reinforcement breaks down. The steel corrodes and expands, and the expansion cracks and then spalls the cover away. Once the cover is gone, the corrosion accelerates because the steel is now exposed.

The repair is straightforward when it is caught early and progressively less so afterwards. What makes it go wrong is patching the visible damage without addressing the chloride in the surrounding concrete, which simply moves the corrosion cell to the edge of the patch.

Assessment first

  • Delamination survey by hammer tap or impact echo
  • Cover meter survey and reinforcement location
  • Chloride profiling and carbonation depth testing
  • Half-cell potential mapping where corrosion activity is in question
  • Breakout extent defined by the survey, not by what is visibly spalled

Repair

  • Breakout to sound concrete and behind the reinforcement
  • Reinforcement cleaning, or replacement where section loss exceeds the allowable
  • Reinforcement priming and bond coat application
  • Reinstatement with polymer-modified or flowable repair mortar
  • Structural and non-structural crack injection — epoxy or polyurethane as the condition requires
  • Anti-carbonation and protective coatings to extend the repair life

Where repair is not enough

If the assessment shows the member no longer has the capacity it needs — because of section loss, or because the loading changed — repair restores durability but not strength. CFRP strengthening is how capacity is added back.

Materials: Sika certified applicator, with approvals from Fischer and Fosroc. Repair mortars, injection resins and coatings are specified as a system from a single manufacturer rather than assembled from the cheapest available components.

Standards we work to

  • EN 1504-3
  • EN 1504-5
  • EN 1504-9
  • EN 1504-10
  • ACI 562
  • ICRI 310.2
  • ASTM C1583

Common questions

What clients ask before awarding

Why does patch repair sometimes fail within a year?
Usually because the breakout stopped at the visibly damaged concrete. Chloride-contaminated concrete left at the edge of the patch forms a new corrosion cell against the freshly repaired area — the incipient anode effect. The breakout extent has to be set by chloride profiling, not by appearance.
Do you survey before quoting?
For anything beyond a small, clearly bounded area, yes. Delamination survey, cover meter and chloride profiling define the real extent. Quoting from a visual inspection alone tends to produce a variation rather than a price.
Epoxy or polyurethane injection?
Epoxy for structural cracks that are dry and dormant, where the objective is to restore monolithic behaviour. Polyurethane for cracks that are wet or still moving, where the objective is to seal rather than to bond.
Can you repair and strengthen in the same visit?
Yes, and that is the usual sequence — repair restores durability, CFRP restores or adds capacity. Strengthening is never applied over actively corroding reinforcement.

Send us the drawings. We will tell you what it takes.

BOQ, isometrics, specifications or a full tender package. Acknowledged within one working day, with the machine schedule and programme in the offer.

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