We were instructed by KN Group to carry out works to a highway bridge over a railway in west London. 96 concrete planks formed the bridge deck to the existing structure which we surveyed and made a comprehensive repair schedule. The work consisted of concrete repairs, re-casting replacement of damaged concrete planks, crack injection and coatings.

Once the survey was complete we commenced with the works.

First the concrete planks had to be transported to our depot in Ripley where we carried out concrete repairs to 73 concrete planks.

Due to the nature of the repairs and the time constraints/programme to re-open the bridge we suggested the use of an epoxy repair mortar. Winter weather conditions and temperatures below 5°c would not allow the use of cementitious mortars. The proposed material would reach the same strength of the standard repair mortar within two days opposed to twenty-eight days with the original materials proposed by the clients engineers.

We also pressure injected over three metres length of cracks.

For the replacement planks we made three moulds to cast 13 new planks using a self-compacting micro concrete to encapsulate a steel rebar case.

A final application of a unique water-based product for permanent protection of concrete structures was used on the 96 planks once the repairs and new casts had been completed.

We managed to complete the works well within the set programme and delivered the consignment back to the London site with days to spare.

"A successful structural repair project needs more than just a good contractor"

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