CRL was engaged by the Northern Grampians Shire Council to deliver carbon fibre reinforced polymer (CFRP) strengthening to the Concongella Bridge, a regional road bridge located near Stawell, Victoria. The works were required to increase the shear capacity of the bridge’s two headstocks to accommodate a new deck overlay, ensuring the structure met current loading requirements. In partnership with Mapei, the project combined technical innovation and cost efficiency, with CRL providing a value-engineered redesign that achieved the required structural enhancement while reducing material and construction costs.

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Stage 1: Surface Preparation

• ‍Concrete Surface Preparation:
  • Wet abrasive sandblasting was used to prepare the headstock surfaces.
  • Environmental containment (tarps and garnet collection) was implemented to prevent contamination of surrounding land and waterways.

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Stage 2: CFRP Strengthening & Testing

• ‍CFRP Application:
  • 220 linear metres of 10 mm-wide carbon fibre fabric applied in a fan pattern to optimise shear reinforcement.
  • Carbon fibre anchors were installed at termination zones to provide load transfer where development length was limited.
  • Mapei CFRP system supplied and installed to meet project specifications.
• Quality Assurance Testing:
  • Confirmed suitability for the adhesion of CFRP materials.

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Stage 3: Protective Coating & Finalisation

• Following CFRP installation, headstocks and columns were coated with an anti-carbonation protective system to provide long-term durability.
• Site was demobilised following a successful final inspection, with all works delivered on time and to specification.

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Project Outcomes & Key Achievements

• Increased shear capacity of the bridge headstocks, enabling safe operation under new deck loads.
• Value-engineered redesign delivered measurable cost and program savings.
• Compliant and environmentally responsible surface preparation and waste containment.
• Successful QA testing to verify bond strength and CFRP performance.
• Enhanced long-term durability of bridge elements through protective coating application.