Concrete Pavement Repairs on the A40/A449 near Abergavenny

Product: Heidelberg Materials Ready-Mixed Concrete
Volume: 20m³
Main contractor: Heidelberg Materials Contracting

Overview: 
Heidelberg Materials successfully completed major concrete pavement repairs on the A40/A449 near Abergavenny in early 2025. The project involved replacing 20m³ of defective concrete patches to restore structural integrity and extend pavement life. A rigorous process ensured safety and quality, including controlled work zones, precision cutting, reinforced substrate preparation, and stringent concrete testing. The works were delivered to high standards, demonstrating our expertise in durable road surfacing solutions under challenging conditions.

Project description:
In early 2025, Heidelberg Materials was appointed to undertake a programme of major concrete pavement repairs on the A40/A449 near Abergavenny. The works involved the replacement of 20m³ concrete patches across the dual carriageway to restore structural performance and extend the service life of the pavement.

To ensure both safety and quality, a systematic approach was adopted.

1. Worksite Preparation - A controlled safety zone was established around the works area, complete with temporary lighting to maintain visibility.
2. Cutting & Removal - Each defective patch was marked and cut out using precision saws. At the match cast joint, a double cut, approximately 300mm apart, was made to prevent spalling during removal. Spoil was excavated with mechanical plant and transported to a pre-approved waste facility.
3. Substrate Preparation - The cut section was drilled and reinforced with rebar dowels to integrate with the existing pavement.
4. Concrete Placement - Fresh concrete was delivered to site, tested for slump and temperature, and then poured into the prepared cavity. A 50 mm high-frequency poker was used to consolidate the material before a vibro-screed was drawn through to achieve road levels. Final finishing was completed with an easy float to seal the surface and ensure level accuracy.
5. Curing - A spray-applied concrete sealant was applied immediately after finishing to prevent hydration loss and surface dusting.

A strong emphasis on workforce and public safety. Dust suppression was used during drilling operations to minimise exposure to respirable silica and a robust traffic management system and exclusion zone prevented plant–people interface risks.  Temporary site lighting ensured safe visibility during extended working hours.  

To guarantee compliance and long-term performance, all concrete was subject to stringent testing:

• On-site testing: Prior to discharge, slump and temperature tests were carried out by an independent third party.  Only once results confirmed compliance, was pouring authorised.     
• Cube sampling: In accordance with BS EN 12390, four test cubes were taken and compressive strength tested at 7, 14, and 28 days, with a spare retained for contingency.  

The successful completion of the patching programme restored pavement integrity on this strategic route, with strict adherence to safety, environmental, and quality standards throughout. The works demonstrate Heidelberg Materials’ capability in delivering durable, high-quality road surfacing solutions under challenging site conditions.