BRD/Inspection Repair/TBT-BRD-006

Concrete Repair on Bridges

Bridges & Structures › Inspection Repair › Concrete Repair on Bridges

All Categories/Bridges & Structures/Inspection Repair/Concrete Repair on Bridges

Concrete Repair on Bridges

Toolbox Talk Record

Ref: TBT-BRD-006  |  Issue: 1  |  Date: March 2026
PresenterProject
LocationDate

What?

  • Bridge concrete repairs restore structural integrity to spalled, cracked, or corroded elements.
  • Work involves removing defective concrete using breakers, exposing and treating reinforcement, and patching.
  • Repairs take place at height, over traffic, over water, or in confined spaces under bridge decks.
  • Silica dust from concrete breaking is a carcinogen requiring water suppression and RPE.
  • Access is often from under-bridge units, suspended scaffolds, or rope access techniques.
  • Exposed reinforcement may be live with stray electrical currents from cathodic protection systems.
  • The Work at Height Regulations 2005 and COSHH 2002 apply to all bridge concrete repair activities.
  • Repair materials including epoxy mortars, bonding agents, and coatings contain hazardous chemicals.
  • Traffic management or railway possessions may be required for work on or under highway or rail bridges.
  • Falling debris from repairs onto traffic, waterways, or people below must be controlled with netting.

Why?

Fall riskBridge repair at height using specialist access creates serious fall hazards.
Silica exposureConcrete breaking generates respirable silica dust causing lung cancer and silicosis.
Public safetyDebris falling from bridge repairs onto traffic or waterways endangers the public.
Chemical hazardsEpoxy repair materials cause skin sensitisation and respiratory irritation.
Do Don't
  • Use water suppression when breaking out concrete to control silica dust.
  • Wear RPE with minimum APF of 20 during all concrete removal operations.
  • Install debris netting below the work area to catch falling material.
  • Ensure traffic management or possessions are in place before starting.
  • Use approved access equipment — under-bridge units, scaffolds, or rope access.
  • Read safety data sheets for all repair materials before use.
  • Wear chemical-resistant gloves when handling epoxy and bonding agents.
  • Check for cathodic protection systems before touching exposed reinforcement.
  • Carry out a risk assessment specific to each bridge repair location.
  • Monitor noise and vibration exposure for operatives using breakers overhead.
  • DON'T break out concrete without water suppression and RPE in place.
  • DON'T allow debris to fall onto traffic, waterways, or people below.
  • DON'T apply repair materials without reading the safety data sheet first.
  • DON'T touch exposed reinforcement without checking for stray currents.
  • DON'T work on or under bridges without appropriate traffic management.
  • DON'T use improvised access — only approved platforms and techniques.
  • DON'T handle epoxy materials with bare hands — skin sensitisation is permanent.
  • DON'T exceed vibration exposure limits when using overhead breakers.
  • DON'T store repair chemicals near heat sources or in direct sunlight.
  • DON'T continue repairs if the structural condition appears worse than assessed.

See also: Bridge Construction Safety Awareness | Cutting Concrete and Block
ebrora.com

RAMS Builder

Generate professional Risk Assessment and Method Statements in minutes. 10 document formats, site-specific content, instant Word download.

Learn More