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S & SUBSOIL DRAINAGE SYSTEMS VOLUME IV- TECHNICAL SPECIFICATIONS

TORMWATER SPECIFICATION
STORMWATER

9 CONCRETE REPAIR (SECTION 03500)


9.1 Part 1 General
9.1.1 Scope and General Requirements
A. This section of the specification gives the requirements for concrete repair.
B. The repair system to be utilized for a particular area or member will be subject to a
trial demonstration as designated by the Engineer and will generally be as follows:
C. Epoxy fillers shall be utilized to fill small cavities and pinholes on all concrete

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surfaces to receive epoxy coating.
D. Epoxy and cementitious repair mortars shall be utilized for small surface repairs.
E. Shotcrete, concrete and micro concrete shall be used for large, deep repairs.

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F. Cracks up to 0.3mm wide shall be filled with an epoxy filler or epoxy crack injection

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resin.
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G. Cracks or joints which are leaking shall be injected with a polyester resin.
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9.1.2 Related Documents
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A. The following sections of the specification shall be read in conjunction with this
section.

Section 01300-Submittals.

Section 01400 -Quality control.

Section 01600-Materials and equipment.

Section 03100 -Concrete formwork

Section 03200 -Concrete reinforcement.

Section 03300 -Cast in place concrete.

Section 03600 -Concrete protection and waterproofing systems.

9.1.3 Standards
A. All activities relating to this section of the specification shall comply with the following
or approved equal standards.

ACI 506 Guide to shotcrete.

ACI 506.2 Specification for shotcrete.

ACI 506.3 Guide to certification of shotcrete nozzlemen.

ACI 506.4 Guide for the evaluation of shotcrete.

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ACI 548.1 Guide for the use of polymers in concrete.

ASTM C157 Standard test method for length change of hardened hydraulic-
cement, mortar and concrete.

ASTM C881 Standard specification for epoxy resin base bonding systems
for concrete.

ASTM C1202 Standard test method for electrical indication of concrete’s


ability to resist chloride penetration.

BS 1881 Testing Concrete

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BS 4449 Steel for the reinforcement of concrete. Weldable reinforcing
steel. Bar, coil and decoiled product. Specification

BS 4551
C - Mortar. Methods of test for mortar. Chemical analysis and

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C physical testing.

BS 4652 Specification for zinc rich priming paint (organic media).


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BS 6319-2 Testing of resin and polymer/cement compositions for use in
construction. Method for measurement of compressive
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strength.

BS 6319-3 Testing of resin and polymer/cement compositions for use in


construction. Methods for measurement of modulus of
elasticity in flexure and flexural strength.

BS 6319-7 Testing of resin and polymer/cement compositions for use in


construction. Method for measurement of tensile strength.

BS 6744 Stainless steel bars for the reinforcement of and use in


concrete. Requirements and test methods.

ISO 17660-1 & 2 Specification for metal arc welding of steel for concrete
reinforcement.

BS EN 1542 Products and systems for the protection and repair of concrete
structures. Test methods. Measurement of bond strength by
pull off.

BS EN 12390-3 Testing hardened concrete. Compressive strength of test


specimen

CIRIA R092M Reinforcement connector and anchorage methods.

ISO 9000 Quality management systems.

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Submittals
9.1.3.1 Products and Materials Approval

1. In order to verify compliance with the specification the Contractor shall submit
information for all products and materials used in the Works to the Engineer for
approval sufficiently in advance of their use in accordance with the Contract
programme allowing for ordering and approval times. Reference shall also be made
to Section 01600 of the specification on products and materials approval. Information
to be submitted shall comprise but not necessarily be limited to:

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Repair materials.

a. Manufacturers name.

b. Suppliers name.

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c. Product name (if applicable).
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d. Product description.
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e. Manufacturer’s technical data.
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f. Manufacturers guarantee

g. Manufacturer’s statement that the material is suitable for the intended


purpose.

h. Mix design.

i. Test results or certificates.

j. Storage instructions.

k. Application instructions.

l. Product health and safety requirements.

m. Endorsements of previous long term successful usage.

Once materials have been approved, substitution will not be permitted unless
otherwise agreed by the Engineer.

9.1.3.2 Method Statements

1. The Contractor shall submit method statements to the Engineer for approval 4 weeks
in advance of commencing the trial and demonstration repairs specified in Clause
3.03 in accordance with Section 01300 of the specification. These shall comprise but
not necessarily be limited to:
2. Procedures for surface preparation and application of repair materials for all concrete

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repair methods including reinforcement cleaning and coating.


3. Procedures for mixing and application of shotcrete.
4. Procedures for crack injection.
5. Procedures for coating application.
6. Statements shall, if relevant, address at least the following points.

a) Description of problem.

b) Description of how the proposed materials will prevent a recurrence of


the problem.

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c) The projected life of the repair.

d) Identification of the expertise and skills required to perform the repair.

e) Identification of the workforce with the required expertise and skills.


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f)
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Pre works precautions and planning.

g) Safety arrangements.
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h) Substrate preparation.
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i) Work schedules.

j) Materials application plan with descriptions and methods.

k) Equipment and tools.

l) Finishing operations.

m) Removal of debris and cleaning.

n) Quality control forms and schedules.

o) Inspection and approval forms.

p) Measurements techniques and methods.

q) Records and forms list and samples.

r) Acceptance by material manufacturers.

s) CV’s of qualified supervision staff.

t) Material, location and sample labeling system.

u) Scheduling and project management report format.

7. The Contractor shall follow the approved method statements. No change to the
method statements shall be allowed unless otherwise approved by the Engineer.
Proposals for revisions to the method statements shall be submitted for the

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Engineer’s approval. The Engineer may require to alter the work sequence and
method statement if he deems it necessary or if the Contractor has made omissions,
deviated from the proposed plan or caused damage deliberately or accidentally to
sound structures.
8. The Contractor shall bear all costs in the latter event.

9.1.3.3 Drawings

1. The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity in accordance with Section 01300 of the specification.

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These shall comprise but not necessarily be limited to:
2. Drawings of repair areas showing the location, size, depth and proposed repair
method.

9.1.3.4 Mock Up
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1. Provide a mockup of each type of proposed concrete repair method as directed by
the Engineer for the Engineers approval.
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2. Mock up shall be of sufficient size to illustrate repair method, colour and texture of
repair surface.
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9.1.3.5 Progress Reporting

1. The Contractor shall submit a detailed and summary work schedule showing all
activities to be carried out for the Engineers approval.
2. The Contractor shall submit to the Engineer daily progress reports. The progress
report shall include a description of activities carried out, materials delivered and
used on site, test results, safety records, problems encountered and the approved
solutions.
3. Weekly reports shall be submitted to include but not be limited to an updated work
schedule reflecting the actual progress of the works, a summary statement of the
salient points in the daily progress reports and dated photographs comprising a set of
negatives and 150mm X 100mm prints

9.1.4 Quality Control


A Prior to dispatch of any product and/or material from source the Contractor shall
notify the Engineer in writing in sufficient time to allow the Engineer the opportunity
to inspect and test the product and/or material prior to delivery in accordance with
Section 01400 of the specification.
B Products and materials shall be from a manufacturer/supplier that operates a quality
system, which is registered to ISO 9000 series or approved equal.

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C To allowthe Engineer to inspect the Works the Contractor shall give the Engineer a
minimum of 24 hours notice of carrying out the following activities on site:

a. Removal of areas of defective concrete.

b. Commencement of surface preparation.

c. Repair of reinforcement.

d. Application of repair method.

e. Application of final protective coating.

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D Only specialist contractors thoroughly familiar with concrete repair techniques shall
carry out the work.
E The Contractor shall appoint a QA/QC Engineer approved by the Engineer. The

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QA/QC Engineer shall be conversant with the aims of quality control, the materials

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being used in the contract and the levels of workmanship required.
F The Contractor shall be responsible for all testing as specified and shall supply the
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Engineer with the test results immediately after completion of the tests. Cost of all
testing including those for trial purposes shall be borne by the Contractor.
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G The level of quality and workmanship required and that will be imposed on the work
is high. The Contractor shall ensure that materials, systems and skilled personnel
are sourced with the level of quality and workmanship required of the works.
H Cost of testing carried out which is not in accordance with the specification or of
unapproved items shall be borne by the Contractor.
I Samples shall be taken, and testing shall be conducted, in locations and at intervals
stipulated by the Engineer. The Engineer shall witness all sampling and testing
unless he decides otherwise.
J All samples shall be properly labelled and secured at site and accompanied by the
Engineer during transportation to the testing laboratory.
K All repair works shall be carried out in the presence of the Engineer unless prior
agreement otherwise is obtained from the Engineer.
L The Contractor shall keep a daily record of the maximum and minimum ambient
temperature and relative humidity in the application areas.
M The number, frequency and selection of tests prescribed in the documents and the
Engineer’s study is a reflection of the depth of inquiry and the quality expected of the
respective works and shall be binding on the Contractor. Depending on
circumstances, the Engineer may require additional tests to be conducted to satisfy
himself on material, workmanship or adequacy of the repair.
N Existing structures, machinery or devices associated with the repair areas such as
pipelines, pumps, chambers shall not be damaged during the repair period. The

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Contractor shall take all precautions to safeguard these. Any damage shall be made
good to its original condition at the Contractors own cost.
O All damage caused by in-situ destructive testing shall be repaired using the
approved materials and to the Engineer’s satisfaction.

9.1.5 Delivery, Storage and Protection


A. Delivery, storage and handling of products and materials shall be in accordance with
the manufacturers recommendations, Section 01600 of the specification and the
following provisions:

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B. Delivery, storage and handling shall at all times be performed in a manner to avoid
product damage.
C. Store materials on a flat level area and raised above the ground on timber bearers.
D. Where product manufacturer recommends storage under controlled temperatures,
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the Contractor shall provide an enclosed, insulated cool store maintained at the
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proper temperature at all times.
E. If stored outside, store materials under opaque cover and out of direct sunlight at all
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times. Maintain a free flow of air around the materials at all times.
F. Bulk mixed shotcrete shall be suitably stored on polythene sheets and kept covered
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with additional sheets to provide complete protection as directed by the Engineer


and be used within 3 days unless otherwise agreed by the Engineer.
G. The Contractor shall visually inspect all products upon delivery to site and report any
damage to the Engineer.

a. Any products damaged during delivery, storage and handling shall be


marked by the Contractor and set aside.

b. Proposals for repair of any damaged products shall be submitted in writing


to the Engineer for approval.

c. Any damaged products deemed unsuitable for repair by the Engineer shall
be removed from site and replaced.

d. All products shall be clearly labeled with date of manufacture and shelf life
or date of expiry. Any expired products shall be removed from site.

9.1.6 Warranty
A. The manufacturer and the Contractor shall jointly guarantee the completed repairs
to be free from defects in materials and workmanship for a period of 10 years from
the date of completion of the Works.
B. The Contractor shall furnish the Engineer with the manufacturer’s guarantee and
warranty certificates for all materials and components used.

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C. If the concrete repairs are found to be defective during the warranty period, the
manufacturer and Contractor shall replace and/or repair the concrete to the
satisfaction of the Engineer.

9.2 Part 2 Products


9.2.1 Epoxy Fillers
A. Epoxy fillers shall be two component solvent free epoxy resin compounds, suitable
for repair of small activities, pinholes, offsets or imperfections.
B. All fillers shall be special purpose products manufactured in premeasured quantities

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for easy site mixing.
C. Bonding agents and ancillary products shall be as recommended by the
manufacturer, unless otherwise directed by the Engineer.

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D. Epoxy fillers shall meet the requirements of ASTM C881, Type 1, Grade 3, classes

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B and C.
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9.2.2 Epoxy Repair Mortar
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A. Epoxy repair mortar shall be a two-part epoxy resin mortar suitable for use in the
climatic conditions prevailing in Abu Dhabi with regard to pot life, useable life of
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freshly mixed components and curing.


B. Mortar shall be packaged in pre-measured quantities for easy site mixing.
C. Bonding agents and ancillary materials shall be as recommended by the
manufacturer.
D. Mortar shall have a minimum compressive strength of 50N/mm2 at 7 days when
tested in accordance with BS 6319-2.
E.
F. Mortar shall have a minimum tensile strength of 10N/mm2 at 7 days when tested in
accordance with BS 6319-7.
G. Mortar shall have a rapid chloride penetration of 1000 coulombs maximum when
tested in accordance with ASTM C1202.

9.2.3 Cementitious Repair Mortar


A. Cementitious repair mortar shall be a single component general purpose concrete
reinstatement mortar exhibiting the following characteristics.
B. Low permeability to provide good protection against carbon dioxide and chloride
penetration.
C. Excellent bond to the concrete substrate.
D. Shrinkage compensated.
E. Pre bagged to overcome site batched variations requiring only the site addition of

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potable water.
F. Contains no chloride admixtures.
G. Bonding agents and ancillary materials shall be as recommended by the
manufacturer.
H. Minimum compressive strength of 28N/mm2 at 28 days when tested in accordance
with BS 6319-2.
I. Rapid chloride penetration of 1000 coulombs maximum when tested in accordance
with ASTM C1202.

9.2.4 Polymer Modified Cementitious Repair Mortar

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A. Polymer modified cementitious repair mortar shall be a single component
lightweight polymer modified concrete reinstatement mortar exhibiting the following
characteristics.
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B. Lightweight formulation to allow high build.
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C. Low permeability to provide good protection against carbon dioxide and chloride
penetration.
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D. Excellent bond to the concrete substrate.
E. Shrinkage compensated.
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F. Pre bagged to overcome site batched variations requiring only the site addition of
potable water.
G. Bonding agents and ancillary materials shall be as recommended by the
manufacturer.
H. Contains no chloride admixtures.
I.
J. Minimum compressive strength of 40N/mm2 at 28 days when tested in accordance
with BS 6319-2.
K. Rapid chloride penetration of 1000 coulombs maximum when tested in accordance
with ASTM C1202.

9.2.5 Shotcrete
A. Pre-bagged shotcrete shall be a single component cementitious material suitable
for dry or wet mix applications with the properties given in Table 9-1 below.

B. A suitable approved fibre shall be added to the shotcrete to reduce crack


propagation.

a. The use of fibre shall be strictly in accordance with the manufacturer’s


instructions and as approved by the Engineer.
b. Prior to the approval of shotcrete the Contractor shall carry out trials mixes in
the presence of the Engineer.

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Table 9-1:– Shotcrete Properties


Property Test Method Value
Max aggregate size - 12.5mm
Min compressive strength BS 4551-1 40 N/mm2 at 28 days
Min flexural strength BS 6319-3 10 N/mm2 at 28 days
Min tensile strength BS 6319-7 5 N/mm2 at 28 days
Water absorption BS 1881 < 2%
Drying shrinkage ASTM C157 < 300 microstrain at 7 days
< 500 microstrain at 28 days
Rapid chloride penetration ASTM C1202 1000 coulombs max

C. Bulk mixed shotcrete compliant with the recommendations of ACI 506.2 may be

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utilized in lieu of pre-bagged shotcrete, if approved by the Engineer.

D. Aggregates shall meet the requirements in Section 03300 of the specification


except as modified hereunder.
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E. The combined grading shall be within the limits given in Table9-2 below unless
otherwise agreed by the Engineer.
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Table 9-2:– Shotcrete Aggregate Grading
Sieve Size (mm) Percent Passing
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12.5 100
9.5 90-100
4.75 70-85
2.36 50-70
1.18 35-55
0.6 20-35
0.3 8-20
0.15 2-10

F. Suitable approved fibre shall be added to the shotcrete to reduce crack


propagation.

a. The use of fibre shall be strictly in accordance with the manufacturer’s


instructions and as approved by the Engineer.

b. Prior to the approval of shotcrete the Contractor shall carry out trials
mixes in the presence of the Engineer.

G. Minimum cement content shall be 415 kg/m3.

a. Type of cement shall be ASTM Type I, unless otherwise approved by


the Engineer.

b. Shotcrete shall have the properties given in Table 9-1 above.

c. The temperature of the mix shall not be more than 32ºC.

d. Where applicable shotcrete shall comply with the ACI 506, ACI 506.2,

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ACI 506.3, ACI 506.4 and ACI 548.1.

e. Prior to the start of the work each nozzle man will be subject to
certification by the Engineer in accordance with ACI 506.3

f. The Contractor has to spray shotcrete in to the approved moulds for


cutting cores. Cores shall be taken as directed by the Engineer for the
specified tests.

g. The Contractor shall be allowed to start the works only after the
Engineer has approved the materials mix design, nozzlemen and the

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site procedure including mixing procedure.

h. The finished surface shall be smooth, free from voids, cracks,


honeycombing, and suitable for the application of surface coatings or

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other finishes as applicable.

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9.2.6 Concrete
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A. Requirements for C40/10 concrete shall be in accordance with Section 03300 of the
specification.
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9.2.7 Micro-Concrete
A. Shall be supplied as a pre-bagged special purpose product requiring only the
addition of a pre-determined volume of water at site to produce a mix of predictable
performance.
B. Micro-concrete shall be a single component, shrinkage controlled, free flowing
concrete without segregation of the materials with the properties given in Table 9-3
below.
Table 9-3:– Micro-Concrete Properties
Property Test Method Value
Min compressive strength BS 4551 60 N/mm2 at 28 days
Min flexural strength BS 6319-3 9 N/mm2 at 28 days
Min tensile strength BS 6319-7 5 N/mm2 at 28 days
Water absorption BS 1881 < 2%
Drying shrinkage ASTM C157 < 300 micro strain at 7 days
< 500 micro strain at 28 days
Rapid chloride penetration ASTM C1202 1000 coulombs max

C. Bonding agents and ancillary material shall be as recommended by the repair


material manufacturer, unless otherwise directed by the Engineer.

9.2.8 Epoxy Lining Mortar


A. Epoxy lining mortar shall be a heavy duty, high strength, durable, chemical and
abrasion resistant trowel-applied epoxy resin lining mortar with the physical

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properties given in Table 9-4 below.


Table 9-4:- Epoxy Lining Mortar Properties
Property Test Method Value
Compressive strength BS 6319-2 70 N/mm2
Flexural strength BS 6319-3 28 N/mm2
Tensile strength BS 6319-7 12 N/mm2
Density - 1750 kg/m3

9.2.9 Concrete Coating Systems


A. Coating systems for concrete shall comply with the requirements of Section 03600

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of the specification.

9.2.10 Reinforcement
A. Reinforcement shall comply with the requirements of Section 03200 of the
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specification.
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9.2.11 Coating to Reinforcement
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A. Coating to reinforcement shall be a single component zinc epoxy primer meeting
the requirements of BS 4652 Type 2 with a minimum zinc content of 85% dry film.
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9.2.12 Epoxy Crack Injection Resins


A. Epoxy crack injection resins shall be two part epoxy resins suitable for use in the
climatic conditions prevailing in Abu Dhabi with regard to pot life and curing and
shall be generally used for structural repairs

B. The resin and hardener shall be pre-packaged.


C. Resins shall have a minimum compressive strength of 70 N/mm2 at 7 days when
tested in accordance with BS 6319-2.

9.2.13 Polyester Crack Injection Resins


A. Polyester crack injection resins shall be two part polyester resins suitable for use
in the climatic conditions prevailing in Abu Dhabi with regard to pot life and curing
and shall generally be used for stopping water leakage.
B. The resin and catalyst shall be pre-packaged.
C. The end product shall be a foam, gel or solid according to the specific repair
requirement as agreed by the Engineer.

9.3 Part 3 Execution


9.3.1 Condition Survey

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