Concrete Repair and Patch Work

Concrete repair involves removing defective concrete and reinstating it with repair mortars or grouts.
Breakout of existing concrete using breakers and scabblers generates high levels of silica dust and noise.
Repair mortars may contain Portland cement, polymer modifiers, or epoxy resins requiring COSHH controls.
Working at height on bridges, buildings, and structures is common during concrete repair operations.
Hand-arm vibration from pneumatic breakers and needle guns must be managed under vibration regulations.
Exposed reinforcement may be corroded — handling it can cause cuts, and it may contain reduced steel area.
Concrete repair on highways and bridges requires traffic management and often involves working over live traffic.
Primer coats and bonding agents used before repair mortar application contain solvents and irritants.
Patch repairs must cure properly before being loaded or exposed to environmental conditions.
Quality of the repair depends on thorough preparation — cutting back to sound concrete is essential.

Silica dust	Breaking out concrete generates high concentrations of respirable crystalline silica that causes silicosis and lung cancer.
Vibration exposure	Prolonged use of pneumatic breakers and scabblers causes HAVS, leading to permanent hand and arm damage.
Chemical hazards	Repair mortars, primers, and bonding agents contain irritants and sensitisers requiring skin and respiratory protection.

Do

Don't

Use dust extraction and water suppression during all concrete breakout operations
Wear RPE rated for silica dust and hearing protection during breaking work
Manage vibration exposure by rotating operators and limiting breaker use times
Complete a COSHH assessment for all repair mortars, primers, and bonding agents
Wear chemical-resistant gloves and eye protection when mixing and applying repairs
Provide safe working platforms for repair work at height on structures
Cut back defective concrete to sound material as specified by the engineer
Protect fresh repair patches from rain, frost, and premature loading during curing
Deploy traffic management when repairing concrete on highways or over live routes
Record all repair locations, materials used, and curing conditions for quality records

DON'T break out concrete without silica dust controls and RPE in place
DON'T exceed daily vibration exposure limits when using pneumatic breakers
DON'T mix repair mortars without gloves and eye protection — they are caustic
DON'T apply repair material over unsound or contaminated concrete substrates
DON'T allow repair patches to dry out prematurely — protect and cure them properly
DON'T work at height on structures without fall protection and safe platforms
DON'T use incorrect repair materials — follow the engineer's specification exactly
DON'T carry out repairs over live traffic without approved traffic management
DON'T ignore skin irritation from cement-based products — wash and apply barrier cream
DON'T load repaired areas until the specified curing period has been completed

See also: Concrete Burns Prevention | Respirable Crystalline Silica (RCS)

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