Freyssinet is awarded further contracts under HA Framework
Freyssinet Limited has recently been awarded three further contracts within the Highways Agency Area 9 &10, Construction Management Framework.
The works, which commenced on site in March 2012, include:
• A40 Bridstow Bridge – Concrete repair, cathodic protection, bearing refurbishment and joints
• M50 Queenhill Viaduct Phase 3 – Concrete repair, cathodic protection and drainage works
• M50 Pendock Sledge and Queens Arms – Concrete repair, cathodic protection and joints
The CMF is a collaborative approach to maintaining £75billion worth of assets for HA in these areas over the next 4 years. It consists of a number of different contractors from different specialist areas who work together to deliver network improvement and maintenance schemes on the all purpose trunk road and motorways in Highways Agency Area 9 and 10, which covers much of the West Midlands and North West.
Freyssinet Ltd, and their sister company Corrosion Control Services Ltd (CCSL), both form part of the CMF, having been selected for their skills and experience in concrete structure repairs and concrete corrosion prevention techniques.
To date Freyssinet Ltd and CCSL have completed six other contracts under the CMF agreement:
• AC5/AC7 Gravelly Hill – Concrete repair, bridge bearing replacement works and cathodic protection
• Oldbury Viaduct – Cathodic protection
• M6 Rayhall Viaduct – Concrete repair and cathodic protection
• M50 Kempley Road Bridge – Concrete repair
• M5 Northway Decks – Concrete repair and deck strengthening
• Bromford Viaduct – Concrete repair and cathodic protection
The CMF contract is different to the traditional sub contract relationship. It is based on partnering, encouraging open working relationships and providing opportunity to develop and share innovative practices.
Freyssinet complete concrete repair works at Harlech Swimming Pool
In 2007, the future of Harlech swimming pool in Wales, which was built in the 1970s, was in doubt when Gwynedd Council decided it could no longer afford to run it. A community company set up to save Harlech swimming pool from closure was established, and in 2010 they were handed the keys to the pool, and had secured grants from the lottery and Welsh Government to fund essential refurbishment works.
In July 2011 Freyssinet were appointed to carry out condition surveys of the swimming pool crawl duct walls and soffits to establish the scope and quantum of repair required to the concrete surfaces. The survey undertaken included a 100% sounding survey of the service void swimming pool elevations and soffits, a cover meter survey to establish reinforcement density and continuity testing to estimate the extent of electrical bonding that may be required during concrete repair to make the reinforcement compatible with electrochemical repair techniques.
Results of the survey found there to be deteriorating reinforcement steel within the crawl duct walls and soffit, along with areas of cracked and spalling concrete. Freyssinet put forward a solution of concrete repair and the installation of a cathodic protection (CP) system, appointing their sister company Corrosion Control Services Limited (CCSL), specialists in concrete corrosion prevention, to provide the design and specification for the CP system.
The perimeter crawl ducts where the works were to be carried out were classified as confined space, therefore, careful planning, correct equipment and monitoring as well as competent certified personal was all essential to complete the project in a safe manner.
Repair works commenced in December 2001 and the project was completed in two stages. Initially, Freyssinet broke out all delaminated and spalled concrete, then tested and ensured continuity of the reinforcing steel and completed concrete repairs.
The concrete repair areas were then allowed to cure prior to the installation of the ZLA “sticky zinc” galvanic CP system. The locations of zinc were marked out on the walls and soffit, and small pockets were broken out to allow for studs to be welded to the reinforcement and then electrically connected to the ZLA.
The works were completed in January 2012 to the satisfaction of the client. It is hoped that the successful refurbishment of the swimming pool, along with a new climbing wall and cafe will increase revenue and ensure the building can remain open.
Structural Enhancement Specialists
Concrete deterioration is mostly caused by the combination of reinforcement corrosion which has been made worse by a surrounding concrete suffering from a reduction of alkalinity. The principle instigators of this form of deterioration can be carbonation and chloride attack. Carbonation can be caused by carbon dioxide that exists in the atmosphere, whilst chloride attacks are most likely the result of marine aggregates, de-icing salts or seawater. To minimise the effects of these elements, some form of concrete corrosion prevention is required.
To address the challenge of concrete corrosion prevention, there are several structural enhancement techniques to look at. These techniques include cathodic protection, coatings, grout injection, resins and wax injection. Freyssinet have been using these techniques for over thirty years, so you know that you are in good hands.
Cathodic protection is a concrete corrosion prevention technique that can be used where patch repairs are likely to be unsuccessful. Situations where cathodic protection may be the best form of concrete corrosion prevention are where there are sufficient amounts of chlorides in untreated areas of adjacent and untreated concrete. Cathodic protection may also be the best course of action where carbonation has managed to get behind the reinforcement layer.
The process of cathodic protection is achieved by passing a small amount of electric current through the reinforcement layer and offers several advantages over other concrete corrosion prevention techniques that can be used. Being a continuous process, it not only stops the existing corrosion; but also prevents further corrosion attacking the structure at a later date. There is also no need for any reapplication, it can be used on very badly damaged concrete, protects against both carbonation and chloride and can be adjusted and controlled through constant monitoring. Furthermore, it is a more economical alternative form of concrete corrosion prevention than concrete replacement. Cathodic protection is especially well suited to marine and motorway structures, which are highly susceptible to corrosion.
To prevent chemical attack whilst providing waterproofing, with limited maintenance costs and a long life expectancy; coating treatments are the answer. Freyssinet can provide clients with an extensive and full range of coatings to inhibit corrosion, provide anti-carbonation, waterproof and resist chemicals.
Void filling solutions can be applied using the injection of resins and grouts in both structural and non-structural applications. The latest vacuum assisted grouting technology, resin and polyester epoxy is used along with both high and low pressure injection equipment to deal with fine cracks within reinforced concrete structures. A wide range of different injection techniques are employed by Freyssinet’s teams of highly trained specialists. Whatever the problem, you can be assured that they have the expertise, experience and equipment to do the job.
For the full range of treatment work, from post-tensioning to ground anchors, more often now Freyssinet find it better to use wax injection, rather than more traditional grouts. The two major benefits for wax are its properties as a modern semi-solid bonding substance make it, more corrosion resistant, and a more flexible bonding agent to work with than traditional grouts. No matter how big the job, Freyssinet can provide the equipment needed, whether it’s a project needing 2 litre ‘top hat’ caps, or a 2000 litre application.
Freyssinet Complete Further Works Under Highways Agency Framework
Freyssinet Limited are continuing to work successfully in collaboration with other specialist contractors under the Highways Agency Area 9 & 10, Construction Management Framework.
The CMF is a collaborative approach to maintaining £75billion worth of assets for HA in these areas over the next 4 years. It consists of a number of different contractors from different specialist areas who work together to deliver network improvement and maintenance schemes on the all purpose trunk road and motorways in Highways Agency Area 9 and 10, which covers much of the West Midlands and North West.
Bromford Viaduct is one of a number of viaducts forming the Midland Link Motorway Viaducts (MLMVs). There are 21km of elevated motorway comprising 1200 no. cross beams and 3600 no. columns, constructed between 1969 and 1972.
During the mid 1980s corrosion started to occur due to de-icing salts leaking through deck expansion joints onto cross beams. Initial preventative measures, such as placing gutters beneath the expansion joints, were implemented during the mid – late 1980s and repair works in 1990. Concrete repair and cathodic protection schemes have been on-going to the present day based on calculated intervention dates for each cross beam. Repair Contract 153 (R153) commenced in January 2011 and comprises of 8 no. cross beams. With Amey acting as Principle Contractor, Freyssinet Limited was appointed as a specialist contractor within the Highways Agency Area 9 &10 CMF.
The scope of works involved removing sections of concrete to be repaired by saw cutting and hydrodemolition, undertaken by Freyssinet’s own in-house hydrodemolition team. Repairs were carried out as necessary to reinforcement steel, and the areas re-instated using flowable concrete, with some beams repaired under a supported condition.
Cathodic protection to 2 no. beams involved the installation of Galvanic (Sacrificial) anodes, whilst the remaining 6 no. beams had an Impressed Current Cathodic Protection (ICCP) system installed. The ICCP was designed as a 3 no. zone system; zone 1 to the shear walls being a ribbon mesh primary anode with a spray applied conductive overlay, zone 2 to the beam top and upper section of the beam sides being a ribbon mesh anode with non-conductive repair mortar overlay, and zone 3 to the lower section of beam sides, beam soffit and top of columns being a similar system as zone 2.
Technical issues which prevented supporting steel work being erected to underside of 2 no. cross beams threatened to cause delays to the programmed works, and Freyssinet’s installation of the CP system in particular. Successful cooperation between all parties resolved this situation, and the works were re-sequenced to enable Freyssinet to begin installation works ahead of programme by utilising concrete curing periods where there was no other activity taking place in the work area.
The designers also re-sequenced concrete repair works so that as far as practical, whichever half of each beam needing least repair was concentrated on in initial repair stages and would be complete in advance of the other half of beam, freeing up nearly 50% of CP installation work to be done before completion of concrete repairs. This method was applied to all beams where programmed work extended beyond Christmas 2011.
Utilising Freyssinet’s own in-house hydrodemolition team contributed to the success of the new programme. Where concrete surface hydro-prep was required for overlay material, the team was able to mobilise immediately, taking advantage of short durations of concrete curing time, all the time pulling back the programme.
The cathodic protection on R153 was commissioned with performance verification taking place 45 days after ‘switch-on’ in early December 2011.
Successful cooperation between all parties resulted in the programme being pulled back to mid December 2011, offering the client savings in terms of both time and money.
New Repair & Strengthening Brochure
With their Repairs Division continuing to expand and adapt within the current market Freyssinet Limited have taken the opportunity to update their Repair and Strengthening Brochure and promote the wide range of products and services that they are able to offer to their clients.
To download the new brochure please click below
Forthcoming Exhibitions
Freyssinet Limited invites you to come and discuss their wide range of products and services and ways in which we can support you at every stage of your structural enhancement project.
22-23 February 2012
UK Concrete Show, Ricoh Arena, Coventry
Freyssinet Limited will be exhibiting at Stand M13 of Europe’s best specialist concrete show, which brings the industry together, under one roof, to see and hear about all that’s new in concrete.
Freyssinet offers a full range of concrete repair and maintenance techniques providing clients with a “one stop” contracting service for all their repair requirements. Freyssinet assures clients of impartial advice with regard to repair material selection from the widest range of sources. The types of structure successfully repaired include bridges, buildings, car parks, and industrial structures. Freyssinet is a member of the Concrete Repair Association, Corrosion Prevention Association, Institute of Corrosion and Sprayed Concrete Association.
Freyssinet is recognised by the British Standards Institute to ISO 9001:2008, OHSAS 18001:2007 and ISO 14001:2004. We have a large in-house design department, and directly employ a highly trained, well motivated, experienced, and safety conscious workforce.
Assessment
Accurate identification of the type, severity and extent of problems affecting a structure are crucial in determining the underlying causes, and in developing effective and economic repair solutions. Freyssinet offers a comprehensive range of testing and reporting to allow clients to identify an appropriate repair strategy.
Concrete Replacement
Where concrete is in poor condition, or strengthening is required, replacement is often the only viable option. Freyssinet offer removal both by conventional breaking and hydrodemolition, with subsequent replacement using high performance repair concretes and mortars.
Concrete Repair
A wide range of techniques are available for repairing spalled, cracked, damaged, and honeycombed concrete including: modified mortars for patch and thin bond repairs; pressure and vacuum injection using epoxy, polyester, and cementitious grouts; and sprayed concrete.
Coatings
Freyssinet offer a full range of coatings.
Complementary services
Freyssinet undertake concrete repair as part of a wider range of complementary services that includes: cathodic protection and chloride removal, strengthening, parapet replacement, deck refurbishment, bearing replacement, jacking and sliding, plate bonding and carbon fibre bonding, retrofit steelwork installation, slab joint replacement, and external post-tensioning.
The UK Concrete Show is aimed at all concrete industry professionals, with over 100 exhibitors and 30 seminars the show is the biggest it’s ever been, totalling 6000m2 of all that’s best in concrete products, tools, systems and technology.
To reserve your place and for further information please click here
27-28 March 2012
Bridges 2012: Home & Away, The Midland Hotel, Manchester
Freyssinet origins are as a specialist in bridge construction and the manufacture of bridge bearings and our knowledge and expertise in this area remain unparalleled. Years of experience in the design, construction, testing and monitoring of structural systems have equipped Freyssinet Limited with exceptional insight and resources in the field of repair and strengthening. Our extensive track record of bridge work illustrates our capabilities to complete projects both large and small, and always to the highest standard. Traditionally our main area of work has been on highway structures, but Freyssinet have also been actively involved in the rail sector both as specialist civil engineers and structural enhancement professionals.
Services available include:
• Complete refurbishment as main contractor
• Bridge Jacking and Bearing Replacement
• Concrete Repair
• Concrete Coatings
• Cathodic Protection
• Strengthening / Retrofitting
• Post tension tendon regrouting
• Cable stay maintenance, replacement or repair
• Expansion Joint Replacement / Repair
Now in its 20th year, “Bridges” remains the leading event for highway authority bridge engineers and their private sector partners, and continues to act as the definitive forum for all issues relating to bridge management and maintenance, policy, strategy and funding.
To reserve your place and for further information please click here
Foreva® repair solutions: improve, preserve and secure your structures
The ageing of structures generates a growing need for renovation, heightened by the increasing stringency of regulatory requirements. As an extension of its new-build business, over 30 years Freyssinet has developed expertise and know-how in structural repair with its exclusive solutions marketed under the Foreva® label.
Foreva® is a collection of exclusive solutions using products developed in industrial partnerships and implemented by Freyssinet teams. The Foreva® solutions portfolio covers both structural repair technologies (external prestressing, shotcrete, carbon fibre reinforcement, injection, levelling, etc.) and chemical and electrochemical repair techniques (realkalisation, chloride ion extraction, reinforcement protection, waterproof coatings, cathodic protection, etc.).
Foreva® solutions help extend the service life of structures and have numerous areas of application:
• bridges and civil engineering structures
• buildings
• water civil engineering structures
• industrial structures
• old buildings
• tunnels
For a range of materials:
• concrete
• steel
• wood
• masonry
With Foreva®, Freyssinet puts its know-how at your service and supports you at all stages of your projects, from help with initial diagnosis through to choosing the right solution to execute the works.
New Foreva® solutions are always being developed and the range of products and solutions continues to grow.
Click here to veiw the Foreva® brochure.
Concrete Bridge and Highway Structure Repairs, Strengthening and Hydro-Demolition
Freyssinet Limited is an expert provider of concrete bridge repairs and structural concrete refurbishment. Owing to their experience and excellent track-record in bridge and highway structure repair and all aspects of concrete repair, the Highways Agency and numerous Local Authorities are regular clients.
Coatings
Pore-lining impregnants are often applied to bridges exposed to chlorides before they are opened to traffic. However, when the level of chloride reaches reinforcement depth the coating will not stop corrosion and permanent concrete bridge repairs will need to be done.
Patch Repairs
Patch concrete repairs have historically been the conventional method of concrete bridge repair. However, this method requires the removal of undamaged (but chloride-contaminated) concrete which is otherwise in sound condition. In addition, patch repairs inevitably increase the corrosion in surrounding areas of concrete.
Electro-chemical Cathodic Protection (CP) – Concrete Corrosion Prevention
The Cathodic Protection method does not require the removal and replacement of chloride-contaminated, but otherwise sound, concrete. This significantly cuts concrete quantities and reduces on-site working time, minimising the cost of concrete repairs to bridges and highway structures.
Hydro-demolition for Bridge and Highway Structure Repair
As part of its forward-thinking approach to structural concrete refurbishment, Freyssinet offers clients the advantages of hydro-demolition concrete removal by their own in-house teams.
Efficient Concrete Removal Hydro-demolition is a high-pressure, water-jetting technique for the efficient removal of both damaged and sound concrete. It can be used with equal effectiveness on small areas of localised damage, for extensive concrete repairs preparation and for removing existing concrete coatings. Hydro-demolition is an excellent preparation for concrete repairs, leaving a perfect bonding surface for new coatings and all types of concrete repair material.
Advantages of Hydro-demolition for Bridge and Highway Structure Repair Hydro-demolition offers a number of important advantages in comparison to conventional concrete removal methods used in concrete bridge repairs and other concrete structures e.g. jackhammer removal.
• Eliminates all dust and debris
• Cleans existing reinforcing steel
• More efficient process reducing on-site programme
• No damage to reinforcing steel
• No hand-arm vibration injuries
• No vibrations ensures no cracking or micro fractures in the structure
• Surfaces are prepared perfectly to key-in new concrete and receive mesh overlay
Experienced Team The Freyssinet Limited hydro-demolition team is highly trained with more than 20 years of solid experience in hydro-demolition applications including concrete bridge repairs and all types of concrete structures.
Health, Safety and Quality The hydro-demolition team wears the latest TST PPE, including 2000 bar-rated bib and brace, TST safety gaiters to cover safety wellington boots and TST waistcoats.
Freyssinet Limited is an Accredited Full Member of the Water Jetting Association – with a representative on the Technical Committee. All of their work is carried out with rigorous adherence to the Water Jetting Association’s Code of Practice.
Hydro-demolition is an important component of Freyssinet Limited’s unique, one-stop service for concrete bridge and highway structure repairs. Other services include:
• Bearing replacement
• Carbon-fibre strengthening
• Cathodic protection
• Coatings
• Concrete repairs
• Core drilling
• Grit blasting
• Jacking
• Wall sawing
Comprehensive Range of Freyssinet Services for Durable Concrete Repair and Refurbishment in Scotland
Freyssinet Limited has been providing first-class structural concrete repairs in Scotland and the rest of the UK for more than 30 years, offering a comprehensive range of structural concrete refurbishment and long-term repair techniques depending on the type of structure, the type of damage and the extent of concrete deterioration.
Concrete Bridge and Concrete Building Repair in Scotland
Freyssinet is a specialist bearing manufacturer producing standard and customised bearing design for concrete bridge repairs. If required, prior to bearing replacement, inspection and testing is carried out by our experts in Scotland. Freyssinet’s expert services include every other aspect of a high quality concrete bridge repair.
The range of techniques available for concrete bridge and concrete building repairs in Scotland includes:
• Modified mortars for patch and thin-bond repairs
• Pressure and vacuum injection using epoxy, polyester and cementitious grout
• Sprayed concrete – both wet- and dry-sprayed concrete structural repairs
• Expert hydrodemolition concrete removal
Hand- and machine-applied concrete repair mortar is appropriate for structural and non-structural concrete repairs. Hand application is suitable for small-scale concrete repairs and sprayed concrete is used on large-scale structural concrete refurbishment.
Strengthening
Freyssinet offers a range of highly effective strengthening techniques for structural concrete refurbishment in Scotland to prolong the life-span of existing structures or allow a change of use. These high-grade concrete structure repairs include:
• Column strengthening,
• Bridge deck strengthening
• Raising allowable floor slab loads
• Strengthening around new openings
External post-tensioning
This method is especially suitable for concrete bridge strengthening and Freyssinet offer an expert in-house design and installation service of supplemental post-tensioning to existing structures. Additional tendons can be fitted within the structure or externally depending on the size of the bridge. External post-tensioning is also a highly effective concrete structure repair technique for upgrading circular storage tanks in Scotland and the rest of the UK.
Plate bonding
Plate bonding is carried out by Freyssinet to provide an excellent strengthening method for under-strength beams and floor slabs.
Freyssibar high-strength bars
Freyssibars are versatile, high-strength bars used to introduce pre-stress into existing areas which are subject to bursting force or high stress concentrations. For example, concrete structure repair to bridge deck diaphragms, anchorage regions and column heads. In addition, Freyssibars provide a significant increase in load-carrying capacity and are a suitable alternative to plate bonding.
FRP Composites
Freyssinet also offers TFC®, a carbon-fibre product developed by the Freyssinet Group. TFC® has numerous strengthening applications for concrete structural repairs in Scotland. For example, beam strengthening, column-wrapping, reinforcement around new openings and floor slab strengthening.
Freyssinet One-stop Design and Build Service
Strengthening techniques required for concrete bridge and concrete building repairs demand careful consideration of the existing and desired loading regimes to assess what strengthening methods are viable and to facilitate a technically appropriate, cost-effective design. Freyssinet has a highly-qualified and experienced team available to offer clients a comprehensive design and build service for concrete repairs in Scotland.
Innovative Techniques
Innovative Cathodic Protection (CP), Chloride Migration and Re-alkalisation are modern techniques which have been used with success in hundreds of structures worldwide. Furthermore, electro-chemical methods have been approved by the Highways Agency for use in concrete corrosion prevention in Scotland and the rest of the UK. Chloride Migration is available as a technique for structural concrete refurbishment in Scotland, providing an excellent concrete corrosion prevention treatment. Re-alkalisation is the newest method for carbonated concrete structures in Scotland and worldwide.
Freyssinet Limited is a forward-thinking and highly experienced company, offering technically sound and cost-effective concrete repair and structural concrete refurbishment techniques in Scotland and the UK.
The Freyssinet Solution: Innovative Concrete Corrosion Prevention
Freyssinet Limited is able to offer clients a comprehensive, one stop service for the design and installation of concrete corrosion prevention systems.
In partnership with their sister company Corrosion Control Services Limited (CCSL), Freyssinet install permanent cathodic protection systems for the continuous protection of concrete structures exposed to chloride contamination or carbonation.
CCSL provides expert assessment, design and component supply and Freyssinet undertake the installation, associated concrete repairs and application of coatings. This provides clients with an integrated service supervised by one named contact, offering both time and cost savings for clients who would otherwise need to organise and oversee several sub-contractors. In this way, overall responsibility for the success of each concrete corrosion prevention project is clearly defined.
The Problems
Reinforcement corrosion is the major element causing concrete deterioration and requiring structural concrete refurbishment. Good quality concrete creates a high alkaline setting for steel reinforcement, but if the level of alkalinity diminishes, the steel becomes increasingly susceptible to corrosion.
Corrosive rust formation increases the volume of the reinforcement until the expansive force becomes sufficient to cause the surrounding concrete to crack and spall. There are two main causes of the type of severe concrete deterioration that requires extensive structural concrete refurbishment and long-term concrete corrosion prevention treatment:
1. Carbonation The process of carbonation occurs when atmospheric CO2 dissolves in moisture forming carbonic acid. The acid progressively penetrates and reacts with concrete, decreasing the pH value. When the contamination penetrates as far as the reinforcement layer, the steel is de-passivated and starts to corrode. Freyssinet can assist in halting this carbonation damage by applying re-alkalisation and structural concrete refurbishment methods.
2. Chloride Contamination De-icing salts, marine aggregates and sea water are common sources of chlorides. When chlorides manage to penetrate to the reinforcement layer, they attack the steel aggressively, starting corrosion. The rate of progression of carbonation and chloride contamination depend on:
• Quantity of CO2 present in the atmosphere/chlorides on the concrete surface
• Concrete permeability/density
• Concrete moisture content
Cracked or poor quality concrete in need of widespread structural concrete refurbishment will deteriorate more rapidly. Freyssinet are able to halt the corrosion process and provide concrete corrosion prevention by the application of innovative electro-chemical cathodic protection.
The Freyssinet Solution
Conventional patch repairs to damaged concrete are unlikely to provide successful concrete corrosion prevention when carbonation has penetrated behind the reinforcement layer or where there is severe chloride contamination in the surrounding, untreated concrete.
Freyssinet carries out cathodic protection as a long-term concrete corrosion prevention technique, which works by passing a small electric current through the reinforcement. This innovative method has been used in several hundred successful concrete corrosion prevention repairs around the world and offers a number of important advantages over other structural concrete refurbishment techniques:
• Continuous concrete corrosion prevention stops corrosion and prevents future attack
• Permanent solution that never requires re-application
• Highly effective even on severely damaged concrete
• Effective against both carbonation and chloride attack
• Effectiveness can be controlled and monitored – economically and simply
• Conservation of large areas of contaminated but sound concrete
• Shorter on-site work duration
• Reduced need for temporary propping
• More cost-effective than complete replacement
• Perfectly suited to marine structures and highways with recurrent contamination
One-stop service provider
Concrete corrosion prevention and structural concrete refurbishment are becoming increasingly necessary to deal with the cracking and spalling problems of ageing stone and masonry-clad buildings with steel frames.
Freyssinet is a leading provider of a comprehensive range of concrete repair and maintenance techniques – able to offer a one-stop contracting service for all concrete repairs and structural concrete refurbishments.
Owing to an outstanding track-record in all aspects of concrete repair, The Highways Agency and various Local Authorities are valued clients. Freyssinet offers valuable, impartial advice on the selection of the best methods and high-quality materials for individual projects and their experts are always available to discuss your requirements.