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Concrete Repairs Limited

We will be showcasing on our stand the range of services which we provide to inspect, repair and strengthen concrete highway structures in Scotland based on over 60 years’ experience in the industry. This includes UKAS Accredited inspection services, concrete repair, corrosion control systems and structural strengthening using FRP composites.

We have been providing specialist concrete inspection and repair services to maintain highway structures in Scotland for over 60 years working closely with Transport Scotland, Local Authorities, and Consultants. Our surveys division, CRL Surveys Ltd, provides a comprehensive service for the inspection of highway structures using the latest techniques and NDT equipment to identify the nature and extent of any deterioration. The company is UKAS Accredited for on-site investigations, which provides clients with the assurance that the work is undertaken to the required standard. Our survey reports can also include recommendations on suitable repair options and budget costings for the repairs. Our contracting division is able to undertake the full repair of highway structures. This includes concrete repair, brickwork repair, guniting, resin injection, grouting, corrosion control systems, protective coatings and structural strengthening. Our corrosion control services includes impressed, hybrid and galvanic cathodic protection systems to enhance durability and minimise future maintenance costs. Structural strengthening is undertaken using FRP composite materials bonded to the surface of the structure or buried in cut chases in the concrete. Due to an increased demand for our services we have recently moved to new premises in Falkirk to accommodate additional staff and enhance our capabilities. We undertake small survey projects from £1000 up to full structure refurbishment with contract values up to £5M. For further information or to arrange a CPD presentation at your offices please visit our website www.crl.eu.com .

Contact Details

John Drewett +44 01324 821400 Visit Website

Categories

Products at the Show

FRP Composite Footbridges

This lighweight footbridges manufactured off-site are an alternative to steel, timber and concrete structures. They are cost competitive, low maintenance, reduced carbon and energy embodiment and quick to install.

Videos

M5 Oldbury Viaduct - TM Switch (Time Lapse Video)

This video shows the Southbound surfacing, the TM switch and northbound surfacing removal on the M5 Oldbury Viaduct project that CRL are currently involved on. CRL's repair teams have completed all areas of repair on the southbound deck. The whole of Zone 5 and part of Zone 4 (approx 1km) have been completed and handed over to the deck waterproofing teams. Surface preparation, verge waterproofing and kerb laying is underway.

CRL still has two hydro-demolition crews, three welding crews and four trim and repair teams working double shifts, to complete recently released repairs. These are progressing well. Joinery teams are working under the deck preparing areas beneath the northbound carriageway, A CRL team is also underneath doing soffit and edge beam repairs.

The BMV Oldbury team are pushing forward with waterproofing, kerb laying and lighting duct laying and re-surfacing should commence later in May.

At more than £100 million, M5 Oldbury is the largest concrete repair project, by value, ever carried out in Britain. The works, taking place along a two mile section on the viaduct’s southbound carriageway, between junctions 1 and 2, involves almost 500 people on the project.

New lightweight footbridge is one of a kind

A UNIQUE solution has been found to bridging the gap over an East Sussex river by installing an innovative lightweight footbridge. The new footbridge, which crosses the River Brede in Sedlescombe, is the first of its kind to be designed and manufactured in the UK. The 8m long fibre reinforced polymer (FRP) crossing, designed and supplied by Surrey based CRL Composites, has a 60year life expectancy and requires minimal maintenance. It is also a fraction of the weight of the 50-year-old timber footbridge it replaced, which had reached the end of its lifespan. The new structure, which runs alongside the B2244 south of the village, has an expected minimum 60-year lifespan and will require minimal maintenance. The bridge was manufactured at a specialist factory in Poole, Dorset, and transported 130 miles on the back of a lorry, before being hoisted and secured in place in less than an hour. The old bridge had been in place since 1965, with the last major overhaul coming in 1979, when most of its timbers were replaced. The new bridge, which came ready fitted with powder-coated steel railings, weighs in at just one ton. Its installation over the River Brede in Sedlescombe was carried out by Uckfieldbased civil engineers Thornes and overseen by contractor Kier. East Sussex County Council lead member for transport and environment Carl Maynard said: “The old wooden footbridge had deteriorated over the years and was requiring regular work to replace rotting timbers. “The materials used in the new structure mean it will need far less maintenance work, saving time and money in the long run. The new composite bridge had the added benefit of being built offsite, allowing us to minimise the disruption to pedestrians which would have been caused by lengthy construction work.”

Remote Breakout

CRL are leading industry standards in the management of health and safety and are actively fulfilling their moral obligation to protect employees from long term ill health. With this in mind CRL are always investigating innovative methods to eliminate or greatly reduce exposure to vibration. With this in mind, CRL recently invited P.A.M. to our offices to demonstrate their latest piece of equipment which could assist us in reducing hand arm vibration whilst breaking out concrete on our numerous repair and rehabilitation projects. Anyone who has experienced holding a chipping hammer all day knows how painful this job can be. Finding good guys to do the job and keeping them is even harder. There is now an alternative to this problem; an ergonomic tool support. Simply put your tool on the carrier connect your pneumatic line to the unit and you're all set to work. In just a few hours anyone can be efficient in chipping/breaking out concrete. It's like an electronic game controller; aim the tool where needed and let the tool do the job. It does all the supporting and positioning for overhead work, beams, walls and inclined surfaces. By providing effortless handling for the worker the benefits are immediate:- 1. Protects employees from the long term ill health effects of hand arm vibration syndrome by greatly reducing daily exposure to vibration. 2. Increased production by extending the amount of work an individual can do in the working day. 3. Assists the employer in controlling HAVs. This unique method illustrates that the employer has taken positive action to reduce exposure to vibration. 4. Enables the use of heavier breakers that can carry out the work in a fraction of the time that standard hand held breakers would take. 5. Ergonomically designed, eliminates the manual handling of heavy breakers 6. Increases production by allowing the use of heavier breakers that can be used for longer periods than traditional hand held breakers

CRL Composite Bridge Installation

CRL specialises in the use of FRP composites both for structural strengthening and for the construction of new or replacement bridges and decks. Fiber Reinforced Polymer (FRP) composites are a combination of fibres such as carbon, glass and aramid with resins which are generally epoxy or polyester. These are used to form structural profiles which are high strength, low maintenance and lightweight. FRP composites have been successfully used since the 1940s in the marine, aeronautical and automotive industries exposed to a range of aggressive environments. The transfer of this knowledge and technology over the next ten years will transform some areas of the construction industry where traditionally steel and concrete has been used. CRL is at the forefront of this technology leading an industry steering group preparing design guidance for FRP composite materials and linking with European partners to develop the use of composite profiles in bridge construction and maintenance. These materials are being used to construct fully composite vehicle and foot bridges or a combination of steel spanning beams and composite deck. They are also being used to replace existing steel, timber and concrete decks. With the speed of installation, reduced dead load and minimal future maintenance these materials can provide some significant advantages over traditional steel and concrete. CRL has been in business since 1954 providing asset maintenance services across the UK through a network of 5 regional offices. The Company is a member of CECA and can provide presentations on bridge maintenance and FRP bridges if requested.

CRL Strengthening of Cast Iron Beams at Embankment

As part of the London Underground station upgrade and refurbishment works, during routine investigations, it was found that the cast iron beams that support the tunnel roof of Covered Ways CW17 & CW20 gave cause for concern in that they could fail without warning. Covered Ways CW17 & CW20 are situated in one of the capital's earliest Tube tunnels which is a cut and cover railway tunnel located between Embankment and Temple Station below Victoria Embankment Gardens in the London Borough of Westminster. It comprises of a series of cast iron roof beams, precast concrete box beams and steel beams supported on buttressed brickwork abutment walls. The cast iron beams have a clear span of about 7.6 metres and are spaced at 2.44 m centres. There are a total of 91 cast iron beams with brick jack arches spanning between the pairs of adjacent beams. The cast iron beams carry the weight of Victoria Embankment Gardens over the District and Circle Line tracks. They also support an area of footway on either side of Temple Place. A section of covered way roof was replaced in the late 1960s by precast concrete beams, but this did not appear to increase the load bearing capacity of the beams.. In order to to provide an additional reserve of strength that will remove this concern, it was decieded to strengthen them using ultra high modulus carbon fibre composite (CFC) plates with an outer fire protection layer of glass fibre in phenolic resin, bonded to the soffit of the beams. Approximately 7,5 metres long and 7 mm thick, the Sika DML ultra-high modulus plates are resin bonded to the exposed underside of the cast iron flange, offering very strong resistance to bending forces, and effectively increasing the section strength of the beams at the point where tension loads are greatest. In order to minimize disruption to the travelling public, all the works are required to be carried out at night in Engineering Time, between the hours of 1.00 am and 4.30 am, or, if by some stroke of luck, during extended occupation of the line, if this occurred for some unknown reason. Part of the conditions of the strengthening was that the park and pavement area directly above the tunnel roof were to be kept clear of heavy loadings until a minimum of 2(two) weeks had elapsed after the application of the last CFC plate. Working as a specialist sub-contractor, to LUL term contractor, Clancy Docwra, the soffits of the beams where the plates are to be bonded are grit blasted to remove any existing surface coatings, or other deleterious material, to ensure adequate adhesion of the bespoke carbon fibre plates. The cleaned areas are then primed and leveled, prior to the application by trowel of a thin layer of epoxy adhesive. At the same time, a thicker layer of epoxy adhesive is also applied to the prepared plate, which is then offered up to the beam soffit. Working from the centre of the plate, all surplus epoxy is 'rolled' out, the temporary straps/supports are clamped in position and the edges sealed with an approved fire protection. Once the epoxy has cured, straps/supports are removed and the plates are tested over their entire area for voids. While London's Tube network is subject to constant maintenance, this half kilometre section of line was originally singled out because, at just six metres depth, it is one of the shallower tunnels in the network; and because of cast iron's brittle nature.
This contract, the latest in a long series of projects carried out by CRL for London Underground reinforces CRL's standing as the leader in the field of rail structure repair and refurbishment.
A spokesperson for the project team commented: "Strengthening the old cast iron beams required a bespoke solution with each of the carbon fibre plates being made to measure. CRL has a lot of experience in using the system and the work has been progressing well." CRL , with 5(five) regional offices and a £30 million turnover. is a nationwide structural repair and refurbishment contractor which has been providing professional contracting services throughout the UK for more than 50 years. It is able to undertake projects on a variety of structures across all market sectors, offering expertise in concrete repair, cathodic protection, composite strengthening, structural waterproofing and bridge-jacking with bearing replacement.