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Durban South, KwaZulu-Natal
EB Cloete Interchange - Deck Strengthening
- Client: Base Major and China State JV
- Subcontractor: Smart Civils
- Duration: 3 years
- Contract Value: R38 million
Project Overview
The EB Cloete Interchange, also called spaghetti junction, is made up of six concrete bridges and hasn’t been renovated in decades. Certain bridge decks and piers require carbon Fiber wrapping, structural protective treatments, and other important and unique work, all of which Smart Civils has been contracted to complete.Â
Scope of Work
Smart Civils’ scope included the following:
- Surface Preparations -which includes but not limited to
- Grinding of Concrete Shutter Joints.
- Patch Concrete Defects.
- Protective Treatments
- Migratory inhibitor Application.
- Cementitious Coatings.
- Carbon Fiber – which includes but not limited to:
- Carbon Fiber Wrap.
- Fiocco Anchors.
- Carbon Fiber Plate.
Project Challenges
The project required careful planning and technical expertise due to:
- Dealing with live traffic while working at height.
- Bars that are crowded when drilling through deck.
- Slow production progress as a result of restricted work access.
- Extreme heat can result in resin waste because it reacts quickly to heat conditions, and weather conditions were viewed as a distraction because our product or activity doesn't require rain, which would cause wet surfaces.
Execution Highlights
Smart Civils implemented specialised corrosion protection systems tailored to the site conditions:
Carbon Fiber Wrap
- Surface preparation, where patchwork and shutter joint grinding are necessary to create a smooth surface for carbon Fiber wrap installation.
- After high pressure washing, allow the surface to dry so that dollies can be used to test the concrete's strength within a specific range.
- Test pull: Verify the tensile strength, which is commonly stated in megapascals (MPa).
- Application of protective treatments: Migratory Inhibitor.
- Installation of carbon Fiber wrap according to the drawing's specifications, with each layer having its own grams and sizes.
Fiocco Anchors (Fiber) – Drilling Through DeckÂ
- Drilling at an angles of approximately 75-80 Degrees
- Bevelling holes on top to make nice curve for Fiocco when installing.
Top Deck Surfaces:
- Mark out where we will lay them and grind surface, 800mm long fanned out by 200mm.
- High Pressure Washing the surface at certain pressure of 350 bars.
- Apply Adesilex PG2 on surface for smoothy surface to lay Fiocco.
Deck Sides: (Existing Carbon Fiber Wrap)
- Wipe the existing Carbon fibre wrap using acetone, this causes the existing resin to react well with new resin of Fiocco.
- Acetone also creates a smooth surface on which to lay the 400 mm long by 200 mm wide Fiocco.
- In order to fill the hole with resin, we uses epoxy HM30 Horse / Adesilex PG2 to seal the bottom hole after installation.
- To make it rough for coatings, we broadcast Final Wrapping with sand while the resin is still wet.
Carbon Fibre Plates:
- Surface preparation where grinding concrete, patchworks where its required for smooth surface when installing Carbon Fiber Plate.
- High Pressure washing the surface.
- Pull of test to check tensile strength which is typical expressed in megapascals(MPa)
- We then start to Install Carbon Fiber Plate as specifications from the drawing.
Protective Treatment:
Cementitious CoatingsÂ
- Surface Preparation:
- Grinding concrete and Patch concrete defects
- Surface High Pressure Washing at 350 bars where there is no Caborn Fiber wrap.
- Application of Migratory Inhibitor on concrete.
- Measure working area in square metres to maintain good work as well wastage, also 2mm thickness was considered as a better treatment/coating.
Daily toolbox talks and risk assessments ensured continuous compliance with safety and environmental standards.
Outcome
The rehabilitation of the Nagle Aqueducts has extended the lifespan of this critical water supply infrastructure. Smart Civils’ precision execution and technical expertise ensured that the pipelines are now fully protected against corrosion and environmental damage — securing continued, reliable water delivery for years to come.
