Definition
Recasting is a structural repair process where severely damaged or deteriorated concrete is removed and replaced by rebuilding part or all of the original concrete section to restore strength, durability, and design performance.
Explanation
This method is used where local patch repairs are insufficient due to extensive reinforcement corrosion, deep spalling, major cracking, section loss, or structural weakness. The defective concrete is broken out to sound substrate, reinforcement is cleaned or replaced, and the section is rebuilt using form-and-pour concrete, repair mortar, or spray-applied systems.
Recasting may apply to beams, columns, slabs, balconies, retaining walls, and bridge elements where load-bearing performance must be fully reinstated. Temporary propping is often required during the works to maintain safety and structural stability.
The repair design must consider bond, reinforcement continuity, concrete compatibility, and long-term durability under service conditions.
Why It Matters
Recasting restores structural capacity where deterioration is too advanced for localised repair. It is a critical intervention for extending asset life and preventing more extensive structural failure.