Motorway viaduct pier restoration
Bolzano, Italy
- Location
Colle Isarco, Bolzano, Italy
- Client
Ferrari Ferruccio
- Sector
- Year
2025
At the core of a key motorway corridor, this motorway viaduct pier restoration project represented a technically demanding intervention focused on long-term durability and structural safety.
The works combined advanced surface preparation, high-performance repair mortars, and dedicated protective coating systems to extend the service life of the infrastructure.
The structure showed signs of deterioration caused by weather exposure, reinforcement corrosion, and localised concrete detachment. Our team addressed the project using an integrated repair approach — from substrate preparation and steel treatment through to reconstruction and final protective coatings — ensuring performance in high-exposure environmental conditions.
Project phases
1. Removal of unsound concrete
All loose and non-cohesive concrete sections were mechanically removed to eliminate unstable material and prepare a sound substrate for subsequent treatments.
2. Full abrasive blasting of the piers
Complete abrasive blasting of the pier surfaces was carried out to remove rust, residues, and contaminants, ensuring optimal adhesion for repair and protection systems.
3. Reinforcement steel cleaning and passivation
Exposed reinforcement bars were treated with a passivating compound (BetonFIP), diluted with water at a ratio of 1.5 litres per 5 kg of product, to restore protection against corrosion.
4. Structural repairs
Installation of fine galvanised mesh fixed with anchors and thixotropic repair mortar to restore structurally compromised areas. Subsequent application of repair mortar to level and consolidate the substrate.
5. Cementitious mortar application
On the upper section of the piers, which is more exposed to weathering and moisture, application of a two-component elastic cementitious mortar to provide flexible, waterproof protection.
6. Protective coating cycle
Treatment of the pier shaft with a technical coating system including a primer and a grey topcoat. These layers provide anti-corrosion protection and long-term resistance to environmental agents.
Our services
Mechanical cleaning of surfaces using compressed-air abrasives to remove rust, scale, old paint, and impurities, creating a rough profile optimal for coating adhesion.
Applied treatments prevent material degradation caused by chemical and atmospheric agents. These protective coatings extend the life and functionality of steel surfaces, forming a barrier against oxidation and aggressive substances.
Results
This motorway viaduct pier restoration project delivered measurable long-term benefits:
reinforced and stabilised degraded structural areas
restored concrete continuity and surface integrity
improved resistance to moisture and corrosion
extended infrastructure service life
reduced future maintenance requirements
Through specialist materials, certified repair systems, and controlled execution, the intervention ensures the viaduct piers are protected and structurally reliable for years to come.
