Standard Technology

Title: Standard for Eskom Power Unique Identifier: 240-144332407

Stations Concrete Remedial
Work
Alternative Reference Number: N/A

Area of Applicability: Engineering

Documentation Type: Standard

Revision: 1

Total Pages: 18

Next Review Date: February 2024

Disclosure Classification: CONTROLLED

DISCLOSURE

Compiled by Approved by Authorised by

………………………………….. ………………………………….. …………………………………..

C. Radford Q. Cai G. Macintosh
Engineer Structural Design Chief Engineer Structural Structural Design CoE
CoE Design CoE Manager (Acting)

Date: …………………………… Date: …………………………… Date: ……………………………

Supported by CTC

…………………………………..
G. Dudenska
CTC Chairperson

Date: ……………………………

PCM Reference: 240-53573084

SCOT Study Committee Number/Name: SC10f
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CONTENTS
Page
1. INTRODUCTION ...................................................................................................................................................... 4
2. SUPPORTING CLAUSES ........................................................................................................................................ 4
2.1 SCOPE .............................................................................................................................................................. 4
2.1.1 Applicability................................................................................................................................................ 4
2.2 NORMATIVE/INFORMATIVE REFERENCES .................................................................................................. 4
2.2.1 Normative .................................................................................................................................................. 4
2.2.2 Informative ................................................................................................................................................. 5
2.3 DEFINITIONS .................................................................................................................................................... 5
2.3.1 Disclosure Classification ........................................................................................................................... 5
2.4 ABBREVIATIONS .............................................................................................................................................. 5
2.5 ROLES AND RESPONSIBILITIES .................................................................................................................... 5
2.6 PROCESS FOR MONITORING ........................................................................................................................ 5
2.7 RELATED/SUPPORTING DOCUMENTS ......................................................................................................... 5
2.8 DOCUMENTATION REQUIRED ....................................................................................................................... 5
3. IDENTIFICATION OF CONCRETE DETERIORATION MECHANISMS ................................................................. 5
3.1 DEFECTS IN CONCRETE ................................................................................................................................ 5
3.2 REINFORCEMENT CORROSION .................................................................................................................... 6
4. AVAILABLE REMEDIAL ACTIONS FOR DIFFERENT DETERIORATION MECHANISMS ................................. 6
4.1 PREPARATION PRIOR TO REMEDIAL ACTION ............................................................................................ 6
4.1.1 Substrate preparation ................................................................................................................................ 6
4.1.2 Reinforcement preparation ........................................................................................................................ 6
4.2 GENERAL.......................................................................................................................................................... 7
4.2.1 Deterioration mechanisms and possible remedial actions ........................................................................ 7
4.3 SURFACE PROTECTION REMEDIAL METHODS .......................................................................................... 9
4.3.1 General ...................................................................................................................................................... 9
4.3.2 Surface impregnation and coating ............................................................................................................ 9
4.3.3 Crack repair ............................................................................................................................................... 9
4.3.4 Applying membranes ................................................................................................................................. 9
4.3.5 Cladding .................................................................................................................................................... 9
4.3.6 Hydrophobic impregnation ...................................................................................................................... 10
4.4 CONCRETE REPAIR REMEDIAL METHODS ............................................................................................... 10
4.4.1 Hand applied mortar ................................................................................................................................ 10
4.4.2 Re-casting concrete elements ................................................................................................................. 10
4.4.3 Spray concrete or mortar ......................................................................................................................... 10
4.4.4 Increase cover by adding additional concrete or mortar ......................................................................... 11
4.4.5 Protective coatings .................................................................................................................................. 11
4.4.6 Corrosion inhibitors ................................................................................................................................. 11
4.4.7 Repair method where certain there is no more movement in the structure ............................................ 12
4.4.8 Repair method Cracks on horizontal surfaces where there is movement in the structure ..................... 12
4.4.9 Repair method Cracks on vertical surfaces when there is movement in the structure ........................... 12
4.4.10 Converting cracks to joints .................................................................................................................... 12
4.4.11 Cracks on horizontal surfaces where there is no movement ................................................................ 13
4.4.12 Cracks on vertical surfaces where there is no movement .................................................................... 13
5. SELECTION OF REMEDIAL ACTION METHODS FOR DIFFERENT DETERIORATION MECHANISMS......... 13
6. REMEDIAL ACTION FOR CONCRETE EXPANSION JOINTS ............................................................................ 15
7. REPAIR MATERIALS REQUIREMENTS .............................................................................................................. 15
8. FORMWORK REQUIREMENTS............................................................................................................................ 15
9. EQUIPMENT REQUIREMENTS ............................................................................................................................ 15

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10. CURING REQUIREMENTS ................................................................................................................................. 16

11. PERSONNEL REQUIREMENTS ......................................................................................................................... 16
12. AUTHORISATION ................................................................................................................................................ 17
13. REVISIONS .......................................................................................................................................................... 18
14. DEVELOPMENT TEAM ....................................................................................................................................... 18
15. ACKNOWLEDGEMENTS .................................................................................................................................... 18

TABLES
Table 1: Summary of deterioration mechanisms and available remedial actions ........................................................ 7
Table 2: Remedial actions categories and methods .................................................................................................... 8
Table 3: Selection guideline for concrete repair for deterioration due to defects in concrete .................................... 13
Table 4: Selection guideline for concrete repair for deterioration due to reinforcement corrosion............................. 14

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1. INTRODUCTION
Under normal conditions concrete can give a long service life if designed and constructed correctly. A
large number of concrete structures at Eskom Power Stations are deteriorating or have been damaged
and require remedial measures to reinstate the concrete structures’ safety, serviceability and integrity to
the original design. The deterioration may be a result of inadequate design, workmanship, materials
used, poor maintenance, environment, service life, insufficient cover to reinforcement and loads applied
to structures.
This document addresses the identification of the different deterioration mechanisms, and their
subsequent defects as well as the available remedial actions pertaining to each deterioration defect. This
document provides a standard for selecting the required remedial action and the suggested methodology
for executing each remedial action.
The document also provides requirements for repair materials, formwork, equipment, curing and
personnel for all concrete remedial works across Eskom Power Stations.

2. SUPPORTING CLAUSES

2.1 SCOPE
The document provides details of the Standard for Eskom Power Station’s remediation of concrete
defects. The document does not include deteriorated concrete that requires further specialist
investigations. This document includes other National, Regulatory and Eskom standards and guidelines
that should be adhered to. This standard is applicable but not limited to all concrete structures that need
remedial work, except structural defects that require specialist assessment.

2.1.1 Applicability
This document shall apply throughout Eskom Holdings Limited Divisions.

2.2 NORMATIVE/INFORMATIVE REFERENCES

Parties using this document shall apply the most recent edition of the documents listed in the following
paragraphs.

2.2.1 Normative
[1] ISO 9001 Quality Management Systems.
[2] 240-53113685 Design Review Procedure
[3] 240-56364545 Structural Design and Engineering Standard
[4] 240-107981296 Constructability Assessment Guideline
[5] 36-681 Generation Plant Safety Regulation
[6] SANS 2001-CM2 Construction works Part CM2: Strip footings, pad footings and slab-on-the-
ground foundations for masonry walling
[7] SANS 2001-CM1 Construction works Part CM1: Masonry walling
[8] SANS 2001-CC1:2012 Construction Works Part CC1: Concrete Works 2012-05-18 (Structural)
[9] SANS 2001-CC2:2007 Construction Works Part CC2: Concrete Works 2007-03-30 (Minor works)

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2.2.2 Informative
[10] 240-86973501 Engineering Drawing Standard – Common Requirements

2.3 DEFINITIONS
Definition Description
Hydrophobic Impregnation Treatment of concrete to produce a water repellent surface
Impregnation Treatment of concrete to reduce surface porosity
Expansion joint Material placed in the joints between concrete slabs to protect the
slabs from cracking when they contract and expand as the
temperature changes
Concrete Reinforced Concrete, Mass Concrete and Sprayed Concrete

2.3.1 Disclosure Classification

Controlled disclosure: controlled disclosure to external parties (either enforced by law, or discretionary)

2.4 ABBREVIATIONS
Abbreviation Description
CoE Centre of Excellence
CPP Condensate Polishing Plant
SANS South African National Standards
TDS Technical Data Sheet

2.5 ROLES AND RESPONSIBILITIES

It is the role of the Power Station and CoE to ensure that the repairs and monitoring are executed in
accordance with this standard.
It is the role of the Contractor to conduct the works in accordance with the details that are provided in
this document.

2.6 PROCESS FOR MONITORING

Not Applicable

2.7 RELATED/SUPPORTING DOCUMENTS

Not Applicable

2.8 DOCUMENTATION REQUIRED

Method statements and TDS shall be submitted for acceptance to Eskom prior to commencement of any
concrete repairs.

3. IDENTIFICATION OF CONCRETE DETERIORATION MECHANISMS

Concrete deterioration can be categorised into two main mechanisms, defects in the concrete and
reinforcement corrosion.

3.1 DEFECTS IN CONCRETE

Deterioration due to defects in concrete can be visually identified through the following:

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 Cracks
 Spalling
 Delamination
 Disintegration and degradation;
 Surface abrasion.
 Honey combing.
 Low strength.
 Chemical Reaction.

3.2 REINFORCEMENT CORROSION

Deterioration due to reinforcement corrosion can be visually identified through the following:
 Carbonation induced corrosion
o Surface stains
o Uniform corrosion on steel reinforcement.
 Chloride induced corrosion
o Pitting corrosion on steel reinforcement with distinct cathode and anode sites.
 Cracking
 Spalling.

4. AVAILABLE REMEDIAL ACTIONS FOR DIFFERENT DETERIORATION MECHANISMS

4.1 PREPARATION PRIOR TO REMEDIAL ACTION

4.1.1 Substrate preparation

Prepare all concrete substrates in accordance with the following guidelines unless otherwise stated:
 Areas to be repaired shall be clearly marked.
 All areas to be repaired shall be cleared and cleaned removing all loose material, dust and free
water. Unless otherwise specified.
 Areas to be repaired shall be saw-cut and/or chipped to a minimum of depth of 10mm in a
rectangular shape or until sound concrete is reached.
 Repair edges in water retaining structures shall be dove-tailed.
 A bonding agent shall be applied prior to applying repair products. The bonding agent shall be
applied immediately prior to applying the repair product ensuring a wet on wet bond.
 Repairs areas shall be protected from wet or windy conditions and direct sunlight.

4.1.2 Reinforcement preparation

Prepare reinforcement in accordance with the following guidelines:
 Prior to any remedial action where reinforcement is exposed remove all tie wires, scour away
corrosion mortar/concrete and any other loose material.

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 Use a steel wire brush, air pressure or water jetting to clean reinforcement. If the structural integrity
of the rebar has been compromised the affected bars should be removed and replaced. Or additional
rebar added and tied to the remaining rebar.

4.2 GENERAL
Damaged or deteriorated structures can be repaired in many different ways, as new technologies are
continuously developed. The choice of repair depends on the type of deterioration, the possible root
cause and the remaining service life of the structure (Refer to Table 1). The types of defects can be
categorized as either defects in the concrete or deterioration caused by reinforcement corrosion.

4.2.1 Deterioration mechanisms and possible remedial actions

Each defect shall be assessed and classified as either deterioration due to a defect in the concrete or
deterioration due to reinforcement corrosion. The available remedial action for each defect observed on
site can then be selected once the possible root cause has been identified (Table 1).
Table 1: Summary of deterioration mechanisms and available remedial actions

Deterioration Defects observed Possible root cause Available remedial

mechanism during visual action
inspection
Defects in concrete Cracks, Spalling, Mechanical: Impact,  Concrete
Delamination, Settlement, seismic, Restoration
Disintegration, and vibration, Increased
Surface abrasion load, explosion,
Cavitation, inadequate
design or construction
Chemical: Alkali-  Protection
aggregate reaction, against ingress
aggressive  Control
environment, biological Moisture
activities,
 Increase
resistance to
chemicals
Physical: Freeze-thaw,  Restore
Thermal expansion, passivity
Shrinkage, Erosion,  Control anodic
Wear areas
Reinforcement Uniform corrosion, Carbonation of  Restore or
corrosion Pitting corrosion, Stress concrete, Inadequate preserve
corrosion, cracking, cover, cracking. passivity
spalling.  Control Anodic
areas
Corrosive contaminants  Cathodic
control
 Cathodic
protection
 Control of
anodic areas

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Deterioration Defects observed Possible root cause Available remedial

mechanism during visual action
inspection
 Restore or
preserve
passivity
Stray currents  Increase
resistivity

For each Remedial action selected in Table 1: Summary of deterioration mechanisms and available
remedial actionsthere are several available methods see Table 2 ‘Remedial action method’. Each of
these remedial action methods are further explained in the respective sections in this document.

Table 2: Remedial actions categories and methods

Remedial Action Remedial Action method

Protection against ingress: Reduce or prevent  Surface impregnation
ingress of harmful liquids, vapour, gas and/or  Surface coating
biological agents.
 Crack repair
 Converting cracks to joints
 Applying membranes
Physical resistance: Increase concrete resistance to  Surface impregnation
physical or mechanical damage  Coatings
Resistance to chemicals: Protect concrete surface  Applying membranes
from chemical attack
Moisture control: Maintain the moisture content in  Hydrophobic impregnation
the concrete within a specified range.  Surface coating
 Sheltering/cladding
Concrete restoration: Restore the deteriorated  Hand applied mortar
concrete to original design  Re-casting concrete elements
 Spray concrete or mortar
 Replacing concrete elements (Pre-cast)
Cathodic control: Create conditions in which  Reduce oxygen at surface by saturating
cathodic areas of reinforcement cannot have an or applying a surface coating
anodic reaction
Restore passivity: Create chemical conditions which  Increase cover by adding additional
restores the surface of reinforcement to a passive concrete or mortar
condition
Control Anodic areas: Create conditions which  Paint reinforcement with coatings which
make it impossible for potentially anodic areas of contain active pigments
reinforcement to corrode.  Paint reinforcement with barriers coatings
 Apply penetrating corrosion inhibitors to
surface or in repair concrete or mortar

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4.3 SURFACE PROTECTION REMEDIAL METHODS

4.3.1 General

4.3.2 Surface impregnation and coating

Surface impregnation is the process of applying products to concrete surfaces which reduces and
strengthens the surface. The pores and capillaries are filled blocking the concrete pores, thus preventing
ingress of harmful substances.

Surface coating is the process of improving the concrete surface resistance to external agents.

Only approved surface coating and impregnation products may be used and applied in accordance with
the repair material section in this document.

The selection of coating products shall take into account structures subject to temperature fluctuations,
vibration or inadequate joints. The coating material shall accommodate dynamic and thermal movement.

Surface impregnation and coatings shall be executed in accordance with the following methodology:

 Prepare substrate in accordance with section 4.1.1of this document.

 Ensure the area is dry prior to applying surface impregnation products, unless otherwise specified on
the product Technical Data Sheet (TDS).
 An approved concrete surface impregnation or coating product shall be used.
 All impregnation products should be based on an epoxy resin; ensure a good bond to smooth
surfaces and achieve a penetration depth of 5mm.
 All surface impregnation products should be applied and cured in accordance with product
application manual.

4.3.3 Crack repair

All cracks with a width greater than 0.2mm needs to be properly repaired.
Concrete with surface cracks smaller than 0.3mm can be repaired with a waterproof crack bridging
coating. Refer to the Impregnation and coating section of this document for the remedial methodology.

4.3.4 Applying membranes

Where necessary a pre formed or liquid membrane may be applied to horizontal and vertical surfaces to
protect concrete surface form attack or ingress from external agents.
Repair methodology:
 Prepare substrate in accordance with section 4.1.1of this document
 Pre-formed membranes shall be applied and fastened to the surface according to the product TDS
 Liquid membranes shall be applied according to the product TDS by either a spray on application of
hand application.

4.3.5 Cladding
Where a concrete surface is exposed to deterioration through weathering, a suitable panel or membrane
shall be installed to protect the structure protect the structure from deterioration.

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4.3.6 Hydrophobic impregnation

Hydrophobic impregnation is the treatment of concrete surfaces to produce a water repelling surface. All
concretes structures subject to deterioration through water ingress shall be coated with a hydrophobic
impregnation product.

Repair methodology:
 Prepare substrate in accordance with section 4.1.1of this document
 Clean and dry area prior to application of products;
 All products used shall not fill the surface pores and capillary network, but should line the entire
concrete surface;
 All products shall be applied and allowed to cure according to the product Technical Data Sheet.

4.4 CONCRETE REPAIR REMEDIAL METHODS

4.4.1 Hand applied mortar

For smaller areas, not requiring formwork, mortar shall be applied by hand. A hand float shall be use to
achieve the desired surface finish.
Prior to applying spray concrete or mortar, all deteriorated or defective concrete shall be removed and
substrate prepared as follows:
 Carbonated concrete shall be removed to a depth of at least 20mm behind rebar and 50mm into
non-carbonated concrete.
 Where concrete deteriorated due to chloride attack, concrete shall be removed to a depth of at least
30mm behind rebar and 100mm into sound concrete.
 Area to be repaired shall be marked clearly.
 Sprayed concrete shall not be used in temperatures below 2C or on substrates exposed to windy
conditions or rainfall.
 Substrate must be damp but without free water prior to application of sprayed concrete.

4.4.2 Re-casting concrete elements

Where concrete deteriorations extends to more than 100mm deep use replacement concrete to repair
the affected area. For horizontal surfaces prepare the area as stated ii section 4.1.1 and cast new
concrete onto sound substrate. A hand float shall be use to achieve the desired surface finish. For
vertical surfaces formwork shall be installed in accordance with the formwork requirement of this
document.
The new concrete shall meet at least the minimum material specification for the parent concrete used in
the structural element unless an updated design base supersedes the parent concrete specification.
Where entire concrete elements have deteriorated, these elements should be recast. Deteriorated
concrete elements shall be demolished and rubble cleaned. Formwork shall be erected in accordance
with the Formwork requirements of this the document. Elements shall be cast with concrete
specifications in accordance with the current design.

4.4.3 Spray concrete or mortar

Spray concrete or mortar shall be used where large repairs to Shotcrete is required. For smaller areas
refer to section 4.4.2 of this document.

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Prior to applying spray concrete or mortar, all deteriorated or defective concrete shall be removed and
substrate prepared as follows:
 Carbonated concrete shall be removed to a depth of at least 20mm behind rebar and 50mm into
non-carbonated concrete.
 Where concrete deteriorated due to chloride attack, concrete shall be removed to a depth of at least
30mm behind rebar and 100mm into sound concrete.
 Area to be repaired shall be marked clearly.
 Sprayed concrete shall not be used in temperatures below 2C or on substrates exposed to windy
conditions or rainfall.
 Substrate must be damp but without free water prior to application of sprayed concrete.

4.4.4 Increase cover by adding additional concrete or mortar

In areas with inadequate cover to reinforcement was provided during either the design phase or
construction, the cover shall be increased in accordance with the following requirements:
 If reinforcement is visible remove concrete to at least 25mm behind the reinforcement.
 In cases where the reinforcement has corroded with insignificant effect to structural integrity, the
reinforcement shall be cleaned using a steel brush and protected from further corrosion in
accordance with section 4.4.6 of this document;
 In cases where the corrosion affected the structural integrity of the reinforcement, the reinforcement
shall be removed and replaced. Lap lengths of newly installed reinforcement shall be in accordance
with the applicable SANS standard.
 Formwork shall be installed in accordance with the formwork requirements of this document, and
concrete or mortar cast to increase the concert cover to at least 40mm, or as otherwise specified..

4.4.5 Protective coatings

In areas where concrete defects have an identified root cause of reinforcement corrosion, the existing
and/or new and additional reinforcement shall be painted with a protective coating.
Coatings can either be cement; epoxy or epoxy modified cement based and should be selected based
on the following requirements:
 Cement based products shall be used where good resistance to water and chloride penetration is
required.
 Epoxy modified cement based products shall be used in demanding environments where more
resistance to water ingress and chloride penetration is required, but not complete isolation of the
reinforcement.
 Epoxy based products shall be used where high resistance to moisture and no chloride penetration
is required. This is applicable to barrier coatings where the reinforcement needs to be completely
isolated.
All protective coatings to be applied as stated in the selected product TDS.

4.4.6 Corrosion inhibitors

Corrosion inhibitors can be added as admixtures to the repair mortar or concrete to extend the surface
life of repaired concrete. Corrosion inhibitors shall be applied in accordance with the product TDS and
where necessary. Corrosion inhibitors should be applied in areas where the environment is favourable
for corrosion deterioration to the concrete.

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4.4.7 Repair method where certain there is no more movement in the structure
The following repair methodology should be followed for cracks in both vertical and horizontal structure
where there is no movement in the structure.
Repair methodology:
 Prepare substrate in accordance with section 4.1.1of this document.
 Ensure the area is free from free water.
 Cut a slot with a width of min 20 to 30mm to a depth of 50mm unless otherwise specified by the
product TDS.
 Apply repair mortar using a trowel and finish with a render model to desired surface finish.
 Cure repair work for minimum 7 days or as specified in the manufacturers material Technical Data
Sheet.

4.4.8 Repair method Cracks on horizontal surfaces where there is movement in the structure
Repair methodology:
 Prepare substrate in accordance with section 4.1.1of this document.
 Widen the crack with a diamond blade about 10mm deep with a V-shape to contain crack injection
resin, else build a retaining wall around the crack using neutral builders’ silicone.
 Clean the surface and remove any loose material.
 Fill the crack by capillary action (place resin in reservoir created) using a low viscosity crack injection
resin.
 Grind the excess product of and smooth the surface after resin has set.
 Allow to cure as indicated on the product TDS.

4.4.9 Repair method Cracks on vertical surfaces when there is movement in the structure
Repair methodology:
 Wire brush the length of the crack to remove any lose material.
 In a staggered arrangement on either side of the crack, drill 10mm diameter holes, ranging from
70mm to 150m deep into the crack at an angle between 30 and 45 degrees to the horizontal. Drill the
holes at a distance centre to centre 300mm along the crack.
 Clean the drilled holes and crack with compressed air.
 Secure packers in the drilled holes by use of a hammer.
 Inject the resin using a manual or mechanical injection pump. Start injecting at the lowest point.
Pump the resin into the packer until it exudes from the next. Then start at the next packer and repeat
until it is completely filled.
 Allow to cure for 24 hours or as indicated in the product user manual. Grind down the packers and
excess material and restore surface to the desired finish.

4.4.10 Converting cracks to joints

Cracks to be treated to accommodate movement shall be repaired by forming a joint. The joint shall
extend through the full depth of the repair. The position of the joint shall be confirmed by a Structural
Engineer. The cracks must be filled and sealed with a suitable elastic or flexible material. The decision to
convert a crack into a movable joint shall be made by a Structural Engineer.

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4.4.11 Cracks on horizontal surfaces where there is no movement

Repair methodology:
 Prepare substrate in accordance with section 4.1.1of this document
 Cut a void along the area to be converted in to a crack. Min 40mm wide or as specified by the
product TDS
 Clean void with pressurized water or air.
 Pre-saturate the exposed void for at least 2 hours or as per manufactures TDS.
 Remove excess water prior to applying repair material.
 Mix the repair material into a pourable consistency to allow the material to be poured into the
prepared section commencing from the bottom.
 Fill to less than 50 mm from the level of the concrete surface.
 Allow 30 minutes, or as per manufactures TDS for the product to initially set before commencing with
the final filling of the void (final filling viscosity should be thicker than the first application).
 Smooth the finished surface with a trowel ensuring that the material is flush and level with the
surrounding concrete.
 Apply curing agent if/when necessary as per the manufactures TDS.

4.4.12 Cracks on vertical surfaces where there is no movement

Repair methodology:
 Prepare substrate in accordance with section 4.1.1of this document
 Install suitable formwork to contain repair material until set;
 Follow the same repair method as per section 4.4.11.

5. SELECTION OF REMEDIAL ACTION METHODS FOR DIFFERENT DETERIORATION

MECHANISMS
Once the defect and level of damage is identified the remedial actions can be determined. The table
below serves as a guideline for selecting remedial actions for deterioration due to defects in concrete
and deterioration due to reinforcement corrosion.
Table 3: Selection guideline for concrete repair for deterioration due to defects in concrete

Visible defect Minor Damage Medium Damage Severe damage

Cracks  Crack Filling  Crack filling  Crack injection
 Create joints  Crack filling
Spalling  Hand applied  Hand applied mortar  Recasting with
mortar  Recasting with concrete or mortar
concrete or mortar  Spraying concrete or
 Spraying concrete or mortar
mortar

Damage from  Hand applied  Hand applied mortar  Spraying concrete

overload or mortar and or mortar and
earthquake  Adding mortar or  Adding or replacing Bonding plate
concrete embedded or external reinforcement

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Visible defect Minor Damage Medium Damage Severe damage

reinforcing bars  Recasting with
 Hand applied mortar concrete or mortar
and adding  Replacing elements
reinforcement
 Reinforcement
anchored in pre-
formed or drilled
holes

Scaling  Hand applied  Cement based coating  Adding mortar or

mortar  Adding mortar or concrete
 Cement based concrete
coating

Chemical Attack  Cement based  Cement based coating  Adding mortar or

coating  Adding mortar or concrete
concrete  Recasting with
concrete or mortar

Table 4: Selection guideline for concrete repair for deterioration due to reinforcement corrosion

Visible defect Minor Damage Medium Damage Severe damage

Concrete spalling due  Hand applied  Hand applied mortar  Recasting with
to carbonation mortar  Recasting with concrete or mortar
reinforcement concrete or mortar and adding or
corrosion replacing embedded
 Spraying concrete or
mortar or external
reinforcement bars
 Spraying concrete or
mortar and adding
reinforcement
anchored in drilled
holes
 Replacing
contaminated
carbonated concrete
Reinforcement  Hand applied  Hand applied mortar  Replacing elements
corrosion due mortar  Recasting with  Replacing
to chlorides concrete or mortar contaminated
 Spraying concrete or concrete and adding
mortar or replacing
embedded or external
reinforcement bars
 Replacing
contaminated
concrete and adding
reinforcement

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 Standard for Eskom Power Stations Concrete Remedial Work Unique Identifier: 240-144332407
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Page: 15 of 18

Visible defect Minor Damage Medium Damage Severe damage

anchored in drilled
holes
 Bonding plate
reinforcement

6. REMEDIAL ACTION FOR CONCRETE EXPANSION JOINTS

Where concrete expansion joint are deteriorated, the following methodology should be used:
 Remove all dust, liquids and debris from area surrounding joint to be repaired.
 Remove all old material in the joint. Use pressurized water.
 Apply a bonding adhesive into the joints with a brush. Allow the adhesive to dry for a min of 10min or
as specified in the product TDS. The adhesive should be sticky to touch not completely dry.
 Insert a shock absorbing material.
 Apply a layer of self-levelling sealant to seal the joint.
 Barricade the area until sealant has cured as per the requirements of the product TDS.

7. REPAIR MATERIALS REQUIREMENTS

All repair material shall meet the following requirements unless otherwise stated:

 Repair material shall be stored, prepared (mixed) and used in strict accordance with the
manufactures instruction provided under the material safety and technical data sheets.
 Repair mortars should match or exceed the grade of the structural concrete they have to replace.
 Repair materials should be used as soon as possible after the preparation (mixing) and should never
be used after the expiry of their pot life.
 It is not allowed to add water to lengthen the pot life of a mixed repair material.
 Only water which meets the requirements of the repair material manufacturers TDS and acceptance
testing applicable in the normative criteria shall be used for construction and repairs.
 Different products used in conjunction (e.g. bonding agent & repair mortar) shall be from the same
manufacturer to ensure full chemical compatibility.

8. FORMWORK REQUIREMENTS
All formwork shall be according to the following requirements unless stated otherwise:

 Formwork shall be selected based on the required surface finish;

 If timber formwork is used, de-molding oil shall be applied to avoid water absorption;
 Foam strips be used where necessary/practicable to prevent grout loss;
 Suitable openings to facilitate release of trapped air shall be provided where necessary;
 Adequate support shall be provided to prevent formwork from moving during casting.

9. EQUIPMENT REQUIREMENTS
All equipment shall be in accordance with the following requirements unless stated otherwise:
 Pneumatic chipping hammers should be hand-held unless noted otherwise, and capable of removing
concrete beneath reinforcing bars;

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 Standard for Eskom Power Stations Concrete Remedial Work Unique Identifier: 240-144332407
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 Sandblasting equipment should be capable of removing corrosion from the reinforcement and
contaminants and laitance from newly exposed concrete surface;
 Compressed air equipment should be capable of removing dust and loose material from concrete
and steel surfaces;
 Water blasting equipment should be capable of cleaning the reinforcement and roughened concrete;
 All equipment and cleaning material used shall not damage reinforcing steel nor the concrete
substrate in any way.

10. CURING REQUIREMENTS

All repair works shall be cured for 7 days or as per the manufacture’s repair material recommendations
and TDS.

11. PERSONNEL REQUIREMENTS

Skilled, competent and trained personnel shall be allowed to perform repair works of concrete structures.

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 Standard for Eskom Power Stations Concrete Remedial Work Unique Identifier: 240-144332407
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Page: 17 of 18

12. AUTHORISATION
This document has been seen and accepted by:
Name & Surname Designation
Galia Dudenska Senior Manager Civil & Structural)
Terrance Mavunda Manager (Acting): Geotechnical Engineering
Funeka Grootboom Manager (Acting): Dams, Waterways & Hydro
Maanea Mabannda Manager (Acting) Roads & Rail
Riaan Venter Chief Engineer: Roads & Rail
Gareth MacIntosh Manager (Acting): Structural Design
Dan Dukhan Chief Engineer: Lines
Andre Kreuiter Chief Engineer: Geotechnical Engineering
Qingbo Cai Chief Engineer: Structural Design
Alicia Simbudayal Senior Geologist: Geotechnical Engineering
Tau Chokoe Civil Engineer: Geotechnical Engineering
Saihendra Govindasami Civil Engineer: Geotechnical Engineering
Lusani Ramathavha Geologist: Geotechnical Engineering
Keshia Jungbahadur Geologist: Geotechnical Engineering
Nielen Toerien Engineering Manager: Duvha Power Station
Ntombenhle Mkhize Engineering Manager: Majuba Power Station
Gert Brink Engineering Manager: Arnot Power Station
Morongwe Raphasha Engineering Manager: Hendrina Power Station
Lele Masote Engineering Manager: Matla Power Station
Malibongwe Mabizela Engineering Manager: Kendal Power Station:
Wikus Janse Van Rensburg Engineering Manager: Matimba Power Station
Mokgoba Mathabatha Engineering Manager: Camden Power Station
Bongani Mashimbye Engineering Manager: Komati Power Station
Harry Sewsunker Engineering Manager: Lethabo Power Station
Karlheinz Von Bentheim Engineering Manager: Tutuka Power Station
Thabo Montja Engineering Manager: Grootvlei Power Station
Zakhele Nkosi Engineering Manager: Kriel Power Station
Ntebogeng Mhlungu Engineering Manager: Kusile Power Station
Stephen Likhethe Engineering Manager: Medupi Power Station

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 Standard for Eskom Power Stations Concrete Remedial Work Unique Identifier: 240-144332407
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Page: 18 of 18

13. REVISIONS
Date Rev. Compiler Remarks
February 2019 0.1 C Radford Compile document, based on the gap identified, to
standardize concrete remedial work within Eskom Power
Stations, final draft after Review Process
February 2019 1 C Radford Final Document for Authorisation and Publication

14. DEVELOPMENT TEAM

The following people were involved in the development of this document:
 Charmaine Radford

15. ACKNOWLEDGEMENTS
 Not Applicable

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