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Following site visits by Frescrete with NPS’s Structural Engineer, it was found that the front elevation of Rutland Court was constructed from load bearing masonry over 3 storeys in height. The independent reinforced concrete balconies cantilevered out from the buildings structure and a steel safety handrail cast into the slab which are all suffering from severe reinforcing bar corrosion exacerbating the deterioration of the concrete slabs
In total there were 4 single balconies each 2.4m wide with 2 double balconies servicing 4 properties each at 5.2m wide. Apart from one balcony, which was repaired by ourselves (No.14) in 2016 all the balconies were suffering from substantial cracking due to re-bar corrosion causing stress delamination of the concrete cover
The existing protective paint to all balconies, with the exception of No.14, is badly flaking and would require complete removal and refurbishment.
Access to all balconies was to be provided by Mears, consisting of a fully boarded traditional scaffold with Mears also providing safety protection signage and advices to tenants regarding the works that was going to take place.
Following a cover meter/hammer test survey all loose defective concrete had to be mechanically broken back to a sound dense solid base by Frescrete operatives and all exposed corroded reinforcing steel exposed and mechanically cleaned back to bright steel and treated with an anti-corrosion primer i.e. Sika Monotop 610
Using temporary form work we had to build out the repair areas to the existing concrete profile using pre-bagged polymer modified repair mortar in compliance with BS EN 1504 R3 and using abrasive discs on Hilti angle grinders (fitted with dust extractors) fully remove all existing coatings to all areas of exposed concrete. To all areas of exposed concrete we then skim applied a minimum 1-2mm thick polymer modified fairing coat left with a fine sponge finish to match existing concrete. Finally, a minimum of 2 coats of a crack bridging decorative protective anti-carbonation paint in a desired standard colour shade to match existing was applied.
In addition to eliminate further water penetration through the existing mastic asphalt surface the surface was thoroughly cleaned with high pressure water jetting followed by installation of Deckmaster polyurethane anti-slip finish.