Balby Flyover is restored with Sika repair system

A Sika concrete repair system has been specified for the restoration of the steel reinforcement of the Balby Flyover.

The steel reinforcement began to suffer from corrosion due to carbonation and chloride attack, and Doncaster Council required a reliable renovation method that would provide long term protection.

The chosen solution also had to enable the bridge to remain open during repair works.

Preventing the corrosion of steel reinforcement in concrete is essential.

Consisting of high performance mortars, anti-corrosion agents and sealants, Sika's proven concrete repair system ensures that any structure will be able to stand the rigours of usage for years into the future.

Sika was involved with the project from the start, having been approached directly by the Bridges Division of Doncaster Council.

After meeting with the council's engineers, Sika's technicians analysed the problems facing the bridge and specified a suitable system.

Sika recommend possible contractors for the scheme.

Repairs were undertaken by ROK Concrete Repairs, and were required across the structure of the bridge, including the soffit, columns, deck and abutment walls.

The bridge is a key part of Doncaster's road infrastructure and remained open for the duration of works.

Sika's concrete repair system can be quickly applied and has a life expectancy upwards of fifteen years, meaning that the disturbance of renovation is brief and need not be repeated regularly.

The smaller concrete repairs were conducted using cementitious polymer modified Sika Monotop 610/615.

Monotop 610 is first applied and inhibits corrosion, improving the lifespan of steel reinforcements.

It also acts as a bonding bridge for Sika Monotop 615 high build repair and re-profiling mortar.

Sikacem 133 Gunite was used where more extensive concrete repairs were required.

The cement based, polymer modified one component repair mortar contains silica fume and a high range of water reducing agents.

It can be spray applied for quick application, making it suitable for large scale projects such as the Balby Flyover.

The entire reinforced concrete sections of the bridge were then covered by a spray applied coat of Sika Ferrogard 903, a liquid that inhibits corrosion, delaying its start and slowing its rate.This extends the maintenance and service life cycles of reinforced concrete for fifteen years.

For a final level of concrete protection, a coat of Sikagard 680S Clearglaze was applied, the one part solvent coating is resistant to weathering, alkalis and ageing.

Suitable for a variety of mineral surfaces, it has a self cleaning effect and does not adversely affect the characteristic texture of concrete.

Following extensive testing, Sika's entire range of concrete repair products is certified to BS EN 1504, the European standard for concrete repair.

This accreditation applies not only to the production quality of the products themselves but also to the guidance issued with them.

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