The Lubetkin Designed Station Cafe at Dudley Zoo is currently being stripped out and restored. The previous blog describing the project can be found here.
Below are some images showing the concrete repair process;
Areas of spalling concrete or exposed reinforcement were identified and the affected area cut out.
Carbonation tests were then performed to ensure enough concrete had been removed.
Exposed reinforcement was treated with zinc rich paint to stop corrosion and offer future protection.
Repairs were then shuttered and filled. A Cement / sand / aggregate mix was preferred to a proprietary repair mortar. The ratio of these and different aggregates were trialled to achieve the best match to the original concrete.
The new repairs will be protected with a translucent mineral paint that will show the original texture and pigment of the concrete.