Sprayed Concrete Repairs

Sprayed concrete has a wide application range due to its adaptability, flexibility versatility of application, high structural integrity and physical properties and favourable economics.

Sprayed concrete repair is commonly used for:
  • Strengthening and repair of existing concrete structures
  • Reinstatement of concrete on vertical or overhead surfaces
  • Soffits or brick barrel arch structures of railway bridges
  • Organic, curved or multi-faceted structures
  • Cathodic protection – encapsulation / overlay to CP management systems
  • Motorway bridge abutments and soffits
  • Half joint replacement or repair
  • Columns and concrete support beams
  • Replacement of defective or spalled concrete
Chesterfield - Sprayed concrete repairs to half joint of motorway bridge abutment wall, steel float finish.

The sprayed concrete method of concrete repair requires a high degree of mechanisation and well trained nozzle operators to be effective. All GSSL personnel are trained to national standards (SCA – Sprayed Concrete Association and NVQ 2 minimum) together with training in robotic spraying for shotcrete works.

The removal of the defective areas of concrete, preparation of the exposed steel reinforcement and concrete reinstatement has to be done correctly for the repair to be durable and have structural integrity. GSSL have the capacity, and trained workforce to cover all these preparation requirements in- house.

Hydro-demolition is often the preferred option for concrete removal on larger scale concrete repair work projects, and GSSL have long standing working relationships with reliable outsourced partners for this option.

Before: Cathodic protection sprayed concrete overlay works – New Elvet Bridge - Durham<br />
After: Cathodic protection sprayed concrete overlay works – New Elvet Bridge - Durham<br />
The advantages over conventional concrete repair methods are:
  • Application of sprayed concrete repair without any formwork/shuttering
  • High impact bonds to existing substrates
  • Higher daily outputs compared to hand applied concrete repair mortar
  • Increased depth of repair and fewer layers = monolithic concrete repair
  • Superior encapsulation of steel reinforcement
  • Lower material wastage due to drop outs and delamination during application
  • Rapid set times to allow early load bearing and reduce wait times

Successful sprayed concrete repair requires the combination of many aspects of modern concrete technology particularly concrete admixture chemistry, combined with modern materials handling technology.

Before: M1 underpass bridge – sprayed concrete repairs and additional thickenessing works, Derbyshire
After: M1 underpass bridge – repair and additional thickenessing works, Derbyshire

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The increasing demands for cost-effectiveness and the protection of health and the environment mean that sprayed concrete has been in continuous development for the last few decades with a proven track record.
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