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The Forth Road Bridge is located in Scotland, connecting Fife and the north east of Scotland with capital city Edinburgh and the south. When the bridge was opened in 1964, it was the fourth longest in the world, and the longest outside the United States, with a main span of 1006 meters between the two towers. In total, the structure is over 2.5km long.

Maintenance to the Forth Road Bridge is ongoing and a large capital programme to strengthen the bridge is also continuing. In 2009 the Forth Estuary Transport Authority (FETA) embarked on a competitive tender process for the Viaduct Bridge Bearing Replacement project, estimated to total £15 million.

The contract is the biggest single contract awarded since the bridge opened. It has involved the replacement of all the mechanical bridge bearings on the Forth Road Bridge’s north and south approach viaducts, which sit at either end of the bridge on each shore, connecting the A90 and M90 with the main body of the suspension bridge. The steel bearings support the bridge deck and enable it to move as required by changes in temperature. The contract also required an extensive overview of the concrete pier condition in conjunction with concrete repair works and the installation of an impressed current CP system.

Freyssinet was chosen to design, supply and install the bridge bearings, and complete associated concrete repair and cathodic protection works on the structure, having demonstrated a successful track record with this type of work.

40No. permanent mechanical bearings were specially designed to BS 5400, and manufactured in Freyssinet Ltd’s factory in Telford in quality controlled conditions that exceed the requirements of BS EN ISO 9001.

Freyssinet also designed and supplied 35No. temporary support bearings and over 100No. hydraulic jacks to meet the requirements of the temporary support and restraint works. In addition Freyssibar, Freyssinet’s own high-tensile pre-stressing bars, was supplied and stressed to assemble and fix the longitudinal restraint frames onto the structure.

Freyssinet were responsible for all the hydraulic jacking and monitoring of the bridge deck to allow removal of the existing bridge bearings. The bridge bearing replacement work by Freyssinet considered also the careful coordination of hydrodemolition works, steel cutting and drilling, and heavy lifting and positioning techniques to all allow the careful and safe positioning of each bearing into an extremely restricted access gap.

The impressed current CP system utilised three anode systems; titanium mesh, titanium ribbon and discreet mixed metal oxide anodes. In addition, galvanic anodes were installed into repairs outside the impressed current zones.

Over 14,000m of titanium ribbon anode strip was installed into the concrete faces of the pier head cross beams and legs to form part of the CP system. Freyssinet introduced an innovative technique that utilised a special chase cut into the concrete using a remote operated wall saw. This cut up to 60m per day without exposing operatives to excessive hand arm vibration or concrete dust.

Corrosion Control Services (CCSL), a sister company of Freyssinet, were involved in the procurement of specialist materials and supplied the necessary specialist site supervision / technical commissioning as required by the contract

The Forth Road Bridge is a category ‘A’ listed structure and consent had to be granted for the works to be carried out. Selection of all repair materials and methods of placement were carefully considered in technical trials prior to the start of the works in order to meet the requirements of the consent.

Freyssinet’s Northern Area Manager, Paul Wood, says “Works have progressed well, and are projected to successfully complete in August 2012, on time and within budget.”

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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 bridge 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 bridge 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.

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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.

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Freyssinet are able to offer a complete solutions package for any concrete structure, no matter how large it may be, and no matter how much it may need in the way of concrete repairs. By using sustainable technologies, Freyssinet are able to do more, but with less materials and energy, which sets them apart from the competition. Freyssinet can offer a full range of integrated concrete enhancement solutions, including: concrete repair, concrete replacement, hydrodemolition, wall sawing and diamond coring.

Concrete repairs are perhaps the most effective way that Freyssinet can prolong the life of your structure. If the concrete shows signs of cracking, if it is spalled, if it has become honeycombed or damaged in any other way, a concrete repair, or in more extensive areas, concrete repairs, may be the answer.

Before any concrete repair work is completed, thorough testing needs to be carried out to assess the true nature of any damage or degradation. Freyssinet are able to offer a comprehensive range of tests to accurately identify and diagnose any problems, before advising on what structural concrete refurbishment is required. These tests can also identify any underlying causes that may need to be addressed, saving additional expense for concrete repairs later on.

Once the appropriate type of concrete repair is identified, a range of techniques are available, including: leak sealing, sprayed concrete, pressure resin injection, vacuum resin injection, or a combination of pressure and vacuum resin injection using epoxy, or patch and thin bond repairs using high quality, modified mortars.

If the concrete is in poor condition, it may be that a concrete repair is not a viable option. Concrete replacement may be necessary, and once again, Freyssinet have a range of solutions available.

Before any replacement can begin, defective concrete will need to be removed. As part of your total Freyssinet solution, removal can be performed by conventional breaking out, or by using hydrodemolition techniques, by Freyssinet’s own in-house team.

Hydrodemolition utilises high pressure water jets, and can be used in small and large areas alike. It can also be used for the removal of coatings, which will then provide an excellent surface for repair materials or new coatings to bond to. This technique reduces the risk of potential harm caused by vibrations, cleans existing steel re-enforcement whilst causing no damage, eliminates dust and debris, and can result in a more efficient programme.

The Freyssinet team have over twenty years of experience in a wide range of hydrodemolition applications. As well as being highly trained and experienced, you can rest assured that they conform with, and adhere to, all the latest health and safety and quality standards of the industry.

Once the old concrete has been removed, Freyssinet will replace this with high performance concretes and mortars.

Concrete repairs and replacement are only part of a wide range of complimentary services offered by Freyssinet. Whether your project involves concrete bridge repair, concrete building repair, or any other kind of concrete structure repair, Freyssinet can offer a holistic package of products and services. Diagnosis, prevention and cure, are all part of the service offered by a company with the reputation, credentials and experience that have secured them landmark projects for the Highways Agency, and many others.

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Freyssinet are in a position to offer clients a wide range of options when it comes to strengthening. Some of the potential applications for the various strengthening techniques include: increasing the floor slab load that is allowed, strengthening of the bridge deck, adding strengthening to new openings, and strengthening columns.

External post tensioning is appropriate when dealing with bridge decks in particular. Along with everything else Freyssinet have to offer is, a complete design and install post tensioning service for any of your existing structures. No matter how big the project may be Freyssinet can meet even the most demanding post tensioning applications. If the bridge structure is a large span box girder, Freyssinet can fit additional post tensioning inside the structure itself. External post tensioning can also be used to upgrade circular storage tanks, or to make them watertight. Tendons fitted to the outside of smaller span structures, are also something offered by Freyssinet.

In existing areas that have a high stress concentration or that may be subjected to bursting forces, pre-stress may need to be introduced. Freyssinet can meet these needs with their own Freyssibar pre-stressing system. This is a comprehensive range of fully threaded, high strength bars that are complimented by extension, coupling and anchoring systems. If you have an over-stressed area of an existing structure, this solution can be an effective remedial action. Freyssibars can also be an excellent option, if you are looking to increase the load carrying capacity of your existing structure with high tensile bars.

If under strength floor slabs or beams are the problem, you may want to consider plate bonding. This is a process where Freyssinet can take appropriately sized steel plates, then bolt them or bond them, with an epoxy adhesive to a structure’s tension zone. By applying this process to the specific area, the load carrying capacity can be increased as required, up to a certain degree.

Another alternative solution offered by Freyssinet is the use of a carbon fibre product called TFC. This reinforced polymer carbon fibre product is manufactured in house by Freyssinet, and can be an outstanding option in the right circumstances. TFC can be particularly useful if the area you need to reinforce has a complex profile, or if clearance height is an issue, such as in a multi-storey car park for example. Other advantages of TFC are that it adds no extra weight to the structure, it is suitable for use in a wide range of temperatures, and it is resistant to UV, fire and shocks.

The correct type of strengthening application is dictated by the structure, its use, its design, and the amount of desired load carrying increase to be achieved. All of these factors require careful consideration, which is why Freyssinet offer a complete design and build service for its clients. Their in-house teams can assist in deciding which is the most appropriate technical and economical solution for your strengthening requirements.

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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.

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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.

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To download the new brochure please click below

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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, concrete structure 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, including concrete bridge repair, 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

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