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Eifers Concrete Solutions
4/141 Sherbourne Road
Montmorency, VIC, 3094
Phone: 0416 259 415
Fax
: 03 9432 5214
E-mail:daniel@ecsolutions.net.au
www.ecsolutions.net.au
CASE STUDY
DEMOLITION, REMOVAL AND REPLACEMENT OF DEFECTIVE CONCRETE
PANELS USING CTS RAPID SET CONCRETE ON THE METROPOLITAN
RING ROAD, GREENSBOROUGH
The Metropolitan Ring Road, Melbourne has been in service since approximately
1994. Over this time, deterioration to sections of the concrete pavement has
occurred requiring immediate rectification works.
Vic Roads invited Eifer Concrete Services to investigate using CTS Rapid Set
Concrete produced via Volumetric Mobile Mixers as a solution to repairing these
sections with minimal delay and road closures required due to the volume of
traffic the Metropolitan Ring Road receives.
Scope: Remove and replace five defective concrete slabs, base and sub-base
concrete layers with CTS Rapid Set Concrete (base) and CTS Rapid Set Lean
Mix Concrete (sub-base), Greensborough bound on the Metropolitan Ring Road
near the Macorna Street Overbridge. Approximate panel sizes were, 3.97m x 5m
(19.85m²). Works were conducted over two nights (2nd and 3rd May, 2012 in 11
hour shifts each night) with the road being handed back for traffic by 6.00am the
next morning after each nights work.
EIFER’S CONCRETE SOLUTIONS – PROVIDING INNOVATIVE SOLUTIONS TO THE NEEDS
OF AUSTRALIA’S CIVIL INDUSTRIES
2nd May

8.00pm-9.00pm Traffic management setup
Slab 1
 9.00pm-10.00pm Saw cutting
Saw Cutting slab 1

10.30pm-11.30pm - Lifting of slabs carried out by 20t excavator and
removed by tipper truck to a holding compound.

11.15pm-11.45pm Once slabs had been lifted, the sub-base was
inspected and determined to be faulty, sub-base lifted up and removed
EIFER’S CONCRETE SOLUTIONS – PROVIDING INNOVATIVE SOLUTIONS TO THE NEEDS
OF AUSTRALIA’S CIVIL INDUSTRIES
Removing slab panels

11.45pm-12.15am The drilling of 20mm starter bars into existing slabs

1.15am-1-35am
Placement of dowel bars
CTS Lean Mix Sub-base placement / Dowel bar placement
EIFER’S CONCRETE SOLUTIONS – PROVIDING INNOVATIVE SOLUTIONS TO THE NEEDS
OF AUSTRALIA’S CIVIL INDUSTRIES



12.15am-12.35am Pouring of Lean Mix for sub-grade out of volumetric
mixers-4m3
2.40am-3.15am
Pouring of CTS Rapid Set Concrete out of volumetric
mixers-4m3
4.00am-onwards Water Curing of slabs
Finishing and Water Curing Panel
The CTS Rapid Set Concrete Mix design used is designed to achieve
compressive strength of 20Mpa after 1 hours, 30Mpa after 4 hours
and 60Mpa after 28 days.
A total of 20m3 of CTS Rapid Set Concrete and 19m3 of CTS Rapid
Set Lean Mix were placed over the 5 damaged slabs of the two nights
produced from Volumetric Mobile Mixers. The project was completed
on time each night and handed back to Vic Roads each morning to
receive the busy peak traffic loading.
EIFER’S CONCRETE SOLUTIONS – PROVIDING INNOVATIVE SOLUTIONS TO THE NEEDS
OF AUSTRALIA’S CIVIL INDUSTRIES
Completed Panel replacement open to traffic
Summary of further slab details
Slab 2
10.30pm-11.30pm -Saw Cutting
1.00 am -1.30am -Lifting of slabs
1.30 am -2.00am -Sub-grade removal
1.25 am -2.35am -Drilling Starter Bars
2.15am -2.35am -Pour (sub-grade)
4.00am -4.30am -Pour (top slab)
5.00am –onwards -Water Curing and cleanup
Commenced saw cutting slabs 3,4,5
Thursday night
7.00pmTraffic Management Setup
7.45pm-9.30pm completed saw cutting
Slab 3
7.45pm -9.30pm
9.30pm -10.00pm
10.00pm-10.30pm
10.30 pm-11.05pm
11.30pm -11.50pm
1.30am -1.50am
2.00am –onwards
-Saw Cutting
-Lifting of slabs
-Sub-grade removal
-Drilling Starter Bars
-Pour (sub-grade)
-Pour (top slab)
-Water Curing and cleanup
EIFER’S CONCRETE SOLUTIONS – PROVIDING INNOVATIVE SOLUTIONS TO THE NEEDS
OF AUSTRALIA’S CIVIL INDUSTRIES
Slab 4
7.45pm -9.30pm
10.30pm -11.00pm
11.00pm-11.30pm
11.30 pm-12.05pm
12.45pm -1.05pm
2.51am -3.04am
4.00am –onwards
-Saw Cutting
-Lifting of slabs
-Sub-grade removal
-Drilling Starter Bars
-Pour (sub-grade)
-Pour (top slab)
-Water Curing and cleanup
Slab 5
7.45pm -9.30pm
11.30pm -12.00pm
12.00am-12.30am
12.30 am-1.05am
1.38pm -1.58pm
4.30am -4.50am
5.30am –onwards
-Saw Cutting
-Lifting of slabs
-Sub-grade removal
-Drilling Starter Bars
-Pour (sub-grade)
-Pour (top slab)
-Water Curing and cleanup
Summary: Eifer Concrete Solutions successfully completed the slab replacements
each night/shift on time with the replaced sections of road placed back in
service on time to receive the morning traffic flows.
Minimal disruptions to normal use was achieved.
EIFER’S CONCRETE SOLUTIONS – PROVIDING INNOVATIVE SOLUTIONS TO THE NEEDS
OF AUSTRALIA’S CIVIL INDUSTRIES
EIFER’S CONCRETE SOLUTIONS – PROVIDING INNOVATIVE SOLUTIONS TO THE NEEDS
OF AUSTRALIA’S CIVIL INDUSTRIES