By Ben du Preez
Good preventative maintenance undertaken by a concrete repair specialist delays large concrete repairs and replacement. This saves industrial clients significantly.
There are three maintenance phases in the lifecycle of a typical concrete structure, namely:
- Preventative maintenance
- Repairs
- Large-scale repairs or replacement
Costs are usually fixed in the preventative maintenance cycle. This phase can last 20 years or even longer. However, this depends on the quality of the concrete and the sum of money invested into maintaining the concrete structure. Hindle Mason Projects, a concrete repair specialist, has a more than 30-year track record prolonging this phase for our clients. This is by deploying state-of-the-art methods that retard the effects of chlorides, carbonation and other deleterious effects. We have shown time and again that Rands spent here yield a good return-on-investment. Our solutions are also both practical and cost-effective.
Appoint a concrete repair specialist
It is especially important to appoint a concrete repair specialist to assist you with the subsequent phase.
This phase occurs once a structure has been sufficiently exposed to deterioration elements. The costs of repairing the damage varies and increases over time. However, the rate at which they increase depends on how soon repairs are undertaken. A concrete repair specialist will be able to correctly advise you on the interventions you need to take. However, it also needs be given the opportunity to detect problems early. Hindle Mason Projects also always ensures top-notch workmanship. This is another factor that influences the rate at which costs increase during this cycle. It is well known that many concrete repairs are failing prematurely due to poor workmanship. This is due mainly to poor quality workmanship by contractors appointed to execute the repair design. Refer to https://www.sciencedirect.com/science/article/pii/S187770581300876X for more reading on the topic. In such incidences, clients incur unnecessary costs by having to redo repairs.
Certainly, these factors also influence the duration of the repair phase. We often succeed in extending this phase to 20 years or more through strategic evaluation. This undertaken while working closely with our clients’ engineers who are tasked with the repair design. In many instances, these professionals also harness our knowledge to inform the repair method. Based on this, we can implement effective concrete repair programmes. These usually consist of multiple proactive or preventative maintenance repair stages. Therefore, the cost and timeframe of this phase varies. Obviously, extending this phase also yields favourable returns for our clients. This is considering the cost of undertaking major repairs or demolishing and rebuilding structures. It many instances, it is impossible for clients to pursue either option without significantly impeding production.
Engaging a concrete repair specialist
Unfortunately, many companies make the mistake of engaging a concrete repair specialist when concrete structures have already significantly deteriorated. At this stage, maintenance and minor repairs will not work.
Large-scale repair costs can be just as much as those involved in replacing the structure in its entirety. This is over-and-above the costs associated with interruptions to production. Then there are the other intangible costs associated with this. They include the inability to service customers and, consequent, loss of market share. Oftentimes, in these instances, temporary solutions also have to be implemented at a high cost just to keep operations running. This is until such time that a practical solution can be executed. Obviously, companies will choose one that can be implemented the fastest. This is to get production up-and-running to full capacity as soon as possible. Considering the sheer complexity and extent of the work involved, it is advisable to only deal with concrete repair specialist. Hindle Mason Projects is an expert in both large-scale repairs and rebuilds.
Industrial concrete repair specialist
It is important to always deal with an industrial concrete repair specialist. This is considering the typical specifics and complexities of maintaining and repairing industrial infrastructure. For example, within an industrial plant, there are usually many different types of structures. Each of these are normally exposed to various environmental conditions. They also experience distress due to different mechanisms.
These structural assets are also exposed to heavier loads; dynamic loading, including vibration and impact; extreme temperatures; and corrosive elements. Thus, each may require different repair procedures to suit specific conditions, service environments and functions.
Industrial facilities also feature concrete water-retaining structures or those that hold hazardous materials or other deleterious liquids. Inadequate joints and cracks are often the lead causes of problems and concerns in terms of these concrete structures.
Then there is the intense process heat to which many industrial structures are exposed regularly that need to be considered. Deterioration mechanisms, including corrosion, alkali-silica reactivity and sulphate attack, are more aggressive in hot and moist environments.
Even structures or concrete elements that are not exposed to exterior environments are at risk. This is because they maintain high moisture contents and relevant humidities for years – sometimes even decades. High internal humidities on their own can sustain deterioration mechanisms.
Consult a concrete repair specialist
When you consult a concrete repair specialist, you obtain the best advice right from the outset. This is without the risk of incurring unnecessary costs due to poor decision-making.
It is important to remember that severe deterioration of reinforced concrete elements can have disastrous outcomes. The biggest risk, of course, is the safety of your plant personnel. They may be injured by falling materials; exposure to hazardous materials leakages; or tripping over degraded materials. The acceptability limit for potential injury to your teams is a decision that cannot be taken lightly! Also remember the consequences of non-compliance. Certainly, responsible companies will always prioritise the health and safety of their employees. However, they are also legally bound to do so. There are consequences for non-compliance. These include fines, shut-downs and even imprisonment – depending on the severity of the transgression. Refer to https://www.gov.za/documents/mine-health-and-safety-act and https://www.gov.za/sites/default/files/gcis_document/201409/act85of1993.pdf.
A concrete repair specialist will be able to best advise you on the steps that need to be taken urgently. This helps you to better plan and budget for repairs. For example, it is of utmost importance to ensure that damaging supporting elements are strengthened at all times. Meanwhile, the repair of non-load bearing concrete elements can be set aside for a later stage. Another important consideration is the risk of potential process interruptions due to distressed concrete. These areas have to be prioritised.
Engaging a concrete repair specialist
Engaging a concrete repair specialist early will save you in the long run. The cost of early repair and maintenance can be 100 times less than that associated with waiting.
When awarding condition evaluation and restoration/repair projects, our clients are always best served by involving all key stakeholders. They include the consulting engineer and concrete repair specialist. This is in addition to key client personnel. In this way, we can implement a reliable solution, which brings “value for money”!
Hindle Mason Projects is industry’s preferred concrete repair and corrosion/erosion protection specialist.
As such, we are approved applicators of:
- SprayLock Concrete Protection [https://www.concreteprotection.com/]
- StonCor Africa [https://www.stoncor.co.za/]
- ABE Saint Gobain [https://www.abe.co.za/waterproofing-product-selector/]
- Sika [https://zaf.sika.com/?gad_source=1&gclid=EAIaIQobChMI0fr46-a3hgMV1ZlQBh3AcQOREAAYASAAEgJBK_D_BwE]
- Mapei [https://www.mapei.com/za/en/home-page]
- Bostik [https://www.bostik.com/global/en/]
- Penetron Africa [https://penetron.africa/]
Du Preez is Contracts Director of Hindle Mason Projects