04b Concrete Repair Methods
04b Concrete Repair Methods
04b Concrete Repair Methods
Concrete Repair
Repair Strategy
Material selection Method selection Support Design Safety Precaution Costs Logistics
Emmons, 1993, p.98
4
Process
Re-bars
Undercutting Cleaning Repair Protect
Concrete
Patch Repair
Cementitious mortars Resin-based mortars
10
Preparation
Marking out, Hack back to 10-20mm behind re-bars, ensure concrete cover Saw cut the edge, Brush/grind the re-bar Prime coat for re-bar, bond coat for substrate Batching of repair mortar and apply. Dowel bars: Holes drilled with rotary-percussive drills to provide keys Air blown by pneumatic device Required length of insertion Give it a 1/2 turn and then turn back to original position Give 2 hrs initial set off time
11
Cleaning of reinforcement
For cleaning of reinforcement rust, high pressure water-abrasive blasting should be the best ways of ensuring a chloride-free surface for the reinforcement. Probably, it is the only way of removing chlorides from the pits in rusting reinforcement. If the damage is caused by carbonation, it is less critical to remove rust from the reinforcement. Coating with a layer of firmly adhering cement paste will be sufficient to prevent further deterioration. Other material for coating can be used if the repair is not in a cementitious one.
http://www.sadgrovesquay.com.au /abrasive/sandblast1.jpg
12
1. Patch Repair
It is most suitable for small-volume repairs as to restore concretes durability. The damaged concrete should be removed and patched up with appropriate repair mortars. In general, there are two common repair mortars used for repairing works:
Cementitious mortars Resin-based mortars
i. Cementitious mortars: Cementitious mortars is one type of repair mortars for patch repair on small-volume repairs. It is used to restore durability of the structure. The damaged concrete is removed and these areas will be patched up with appropriate repair mortars.
13
1. Patch Repair
Emmons, 1993
14
15
16
Types of Mortar
Suitability For area where superior resistance is required to chlorides and carbon dioxide. For general purpose concrete reinstatement. For repair of spalling, honeycombing, stair nosing, ramp etc. For repair load-bearing concrete
Reference Renderoc GP; Renderoc HB40 (with higher performance) Lanko 731
Barra Mortar HL; Nitomortar HB; Renderoc HB; HB25 Unicell 25; Unicell 40, and unicell ultra rapid.
18
19
Nitomortar S
20
10
21
11
Core
A 75mm dia. Core containing the full thickness of the repair was produced
23
Cored hole
Substrate
24
12
Dummy
A suitable metal plate was glued to the cored hole and let it dry for one hour; this attachment was pulled with increasing tensile force using a calibrated device until failure occurs.
25
Result 1
Criteria:
fracture shall be at least half in the substrate concrete, unless the pull-off stress is not less than 1/4 (i.e. 0.5 MPa) of the minimum 7 days bond strength of the repair mortar (2.0 MPa).
Result 1
Fracture at bond surface, bond strength = 27psi (0.9 MPa) - PASS
26
13
Result 2
Half of the fracture at substrate, bond strength = 18psi (0.6 MPa) - PASS
27
Results 3 & 4
Result 3: less than half of the fracture at substrate, bond strength = 12psi (0.4MPa) - FAIL Result 4: fracture at surface material, bond strength = 9psi (0.3 MPa) - FAIL
28
14
2. Recasting
In this method, the damaged part of the structural element will be demolished, replace corroded reinforcement and recast it with same or even better grade concrete in order to restore its structural strength. Considerations for practical uses Pay attention to the discontinuity which causes any instability to the linked structural elements due to demolition. Dowel bars and/or replacement steel bars should be placed on the cleaned reinforcement bars. For recasting of slabs, evacuation may be required for flats above or below the element. The joint between old and new concrete should be paid with special attention. Poor joints will result easy seepage of water and causes of corrosion. Shear key is required for large areas of recasting. Pre-soaking of substrate is necessary Avoid air trapping by thorough compaction of repair mortar.
29
15
31
3. Sprayed Concrete
Sprayed concrete is a technique which is widely used in high-volume concrete repair work. The concrete mix will be sprayed with or without admixture or polymers to the defected areas under high air pressure. This process can be done by means of nozzle gun.
32
16
Dry process spraying is the process which the mixture of damp sand and cement is passed through the delivery hose to the nozzle and the water is mixed at that time. This process is often used for repair work. It is because of its fast application process and restoration of structural strength at an early stage. The performance characteristics of dry sprayed concrete are they have good density and high strength. It has very good bond to a suitable substrate. These advantages make it more variable than conventional concrete and wet process sprayed concrete. (SCA, 1999)
(SCA, 1999)
33
(SCA, 1999)
34
17
Cracks prevention
Concrete surface must be reinforced with small-mesh small diameter reinforcement before carrying out sprayed concrete. This can prevent developments of cracks when the concrete shrinks.
35
Spray Concrete
Considerations for practical uses The process should be in a continuous process. Concrete mixed should be complied with acceptable standard and quality. The operation should be carried by experienced nozzleman. Acceptance test should be carried out to test the skill of the nozzleman. The process should be held at right angle to and at one meter from the surface of the repair areas. Min. spray concrete thickness should be considered before spraying process. Reference should be made to Code of Practice for Structural Use of Concrete. Good surface preparation should be done. Sufficient safety precautions must be taken. Application ranges Large areas of repairs with thickness > 50mm In vacant flats and/or public areas, this can minimize the nuisance to peoples. Partial strength is to be restored.
36
18
Types of sprayed concrete Dry Spray Polymer modified cementitious repair mortar
Suitability
Reference
For large area repairs (rather low compressive strength developed) Should not be used when the temperature is <5C and falling. Should not be exposed to moving water. Specially prepared for use in dry shotcrete applications. (compressive strength: 30-40 N/mm2)
Renderoc DS (aggregates used are classified as non-reactive.); Renderoc SC; Optimix RM770 Sika Rock 30
Gunite mortar (cementitious based) Wet Spary General concrete repair work
38
19
1. Micro-concrete
By applying this method, the contaminated or damaged concrete are removed and replaced by fluid micro-concrete. It is used to re-form desired concrete profiles. Usually, prescribed mixes are available in the market with shrinkage compensators to control shrinkage in plastic and hardened states. Considerations for practical uses It needs special design by the supplier and specialist advice is required. Formwork with leakproof is required. Pre-soaking of the formwork and substrate is required. Aggregates used should not be greater than 10mm. In order to improve workability, aggregates should be rounded in size. Good curing of the repair is essential. Application ranges For use in area with limited working space or congested reinforcement For use in thin sections where the use of normal concrete is impractical
39
Suitability For area where access to the repair zone is restricted or where reinforcement is congested which unable to carry out compaction and vibration. Difficult access which make hand/trowel-applied mortars impractical.
Reference Renderoc LA
40
20
2. Pre-packed Concrete
Graded aggregates similar to the substrate concrete will be placed firstly in the formwork. After the placement of graded aggregates, cement grout will be injected into the formwork from THE BOTTOM. The resulting concrete will be in excellent quality in proper implication.
41
Considerations for practical use All loose and spalled concrete should be repaired prior to the application. Target compressive strength of the pre-packed concrete should be compatible with that of the substrate. Trials on compressive strength before operation are recommended. Careful design on aggregate size and grading is recommended. Aggregate size shouldnt be too fine in order to avoid blockage of grout patch. Similar to micro-concrete, formwork with leakproof is required. Pre-soaking of the substrate with water is necessary. Aggregate should be clean and free from silt before application. Application ranges For use at areas where concrete placing is difficult, e.g. at beam soffits. For areas with congested reinforcement or depth of repair is greater than 75mm where patch repair is not suitable. For where the structural strength have to be restored. Advantages Compare to sprayed concrete, it has greater density, greater uniformity, lesser permeability, lower shrinkage, less dependence on personal skills of equipment operators, less dust, less clean-up work, and more economical. Limitations All works in vertical surfaces require formwork. At least 3 to 4 inches of space is required for replacement.
42
21
3. Non-shrink grout
cementitious, epoxy resin or polyester resin based In repair works, non-shrink grout is used in crack injection repair. Also, it is used to repair porous concrete and in those areas with very congested reinforcement. Usually, it has a very high workability, it can be applied either flowable or in fluid. If mixtures are according to specified instruction, the compressive strength of non-shrink grout can be higher than 50 N/mm2 although it has high workability.
43
Non-shrink grout
Considerations for practical use Please refer to micro-concrete Application ranges used in crack injection repair, To repair porous concrete, Very congested reinforcement or in limited working spaces, Thickness of repair is thin.
44
22
Types of non-shrink grout Epoxy resin based Low viscosity epoxy resin injection grout Ultra low viscosity expoxy resin injection Thixotropic epoxy resin injection grout Epoxy resin suitable for structural element Epoxy resin suitable for structural element (suitable for use underwater) Cementitious based Non-shrink cementitious grout
Suitability For injection of cracks of about 0.259mm wide. Permits maximum resin penetration As resin binder in flooring screeds or for repair of cracks subject to movement. For injection of cracks of about 0.59mm wide. Permits injection of open-ended cracks High strength resin and capable of restoring structural integrity Capable of restoring structural integrity and can be used under water
Reference Nitofil LV; Sikadur 752; HICrete 85; Conbextra EP; Expocrete S Ronabond EP 21SLV; Ronabond EP 21 FLV (more flexible) Nitofil TH
For general purpose of crack injection. Different kinds of cementitious grout are available such as, rapid set, high strength, high performance or specifically for underwater application
Conbextra GP; Conbextra Conbextra HES; Conbextra HF; Conbextra UW; Calgrout No 1
45
46
23
Joint sealing Permanent elastic one-compound joint Sikaflex PRO 2HP compound sealing compound (Polyurethane base) One component polyurethane sealant/adhesive Instant-setting hydraulic mortar/grout As an elastic adhesive and elastic joint Sikaflex-11FC sealant. Sealing of waterways Fast setting, Used underwater High resistance to pressure. Some of the products are with different properties, such as, high strength, flexible and elastic for use in different situation. ERTOBLOC 224; Ronabond PU 10; Ronabond PU 20 (High strength); Ronabond PU
47
Protection Methods
Protective Coating Apply Cathodic Protection Provide Additional Concrete Cover Realkalization or Desalination Overcladding and Insulation Protection with Corrosion Inhibitors
48
24
5. Protective Coating
The protective coating is a thin outer layer which used to protect the substrate concrete by acting as an impermeable barrier or slowing the rate of penetration of active components from the surrounding environment. Three main functions of protective coating are:
Change appearance; Improve surface properties; Barrier against the penetration of aggressive gases, liquids and vapours.
Good protective coating should allow water vapour to pass out through it in order to stop the building up of vapour pressure in the substrate concrete which causes blistering. (BSIS)
49
Considerations for practical use Good surface preparation before application of the coating, such as completed repairing of concrete and removal of surface contaminations and voids. Remove all loose part of existing painting and check the compatibility of the existing paints before application. If a solvent based protective coating is selected, it should be in an open space with good ventilation for coating to evaporate. Application ranges It should be applied on repaired concrete substrate to prevent further deterioration. In those areas where frequent wetting of concrete surface is unavoidable. On surfaces where exposed to aggressive surroundings.
50
25
Suitability
Reference
Single component epoxy As an anti-corrosion primer for Nitoprime Zincrich; zinc primer exposed steel reinforcement for Frianzinc EPE (corrosion protection) use with concrete repair mortars Acrylic resin protective coating for concrete Protection and enhancement of concrete and asbestos cement building elements, especially facades. As a barrier to resist chemical resistance, such as carbon ion. Sikagard 680 S-Concrete Cosmetic
Provides an effective barrier against SikaTop Seal 107; the transmission of liquid water. Ronabond Joltec It should be applied on concrete, Finish; Ronabond brickwork and blockwork. Jotec Transparent; Ronabond Nigatex
51
6. Cathodic Protection
The purpose of applying cathodic protection is to stop the setting up of anodes on the reinforcement by applying a low voltage electric current or by a sacrificial anode.
52
26
In sacrificial anode system, the steel is connected to a metal which is less stable in electro-chemical series, e.g. zinc. Since zinc is more anodic than steel, the current will flow from zinc to steel and zinc will be corroded instead of steel.
Sacrificial anodes fixed to the rebar with tie wires. (Fosroc: Galvashield XP) 53
54
27
Disadvantages:
Ongoing cost to maintain Many structures not suitable (access, noncontinuous reinforcement, pre-stressing steel, etc.)
55
Cathodic Protection
Considerations for practical use Installation and maintenance costs for the systems are much higher than other repair methods. It needs special design by the supplier and specialist advice is required. Defects must be repaired before implication of cathodic protection. Electrical continuity has to be assessed before implication. Application ranges In area where corrosion is active or chloride content is high. Recasting or large scale patch repair is not feasible. Corrosion of steel reinforcement is not that serious while application.
56
28
Suitability
Reference
Drilled in sacrificial anode for For pre-stressed/post tensioned reinforced concrete structures (Not for use with structures epoxy and polyester repair mortars or primers. Embedded zinc anode which acts to prevent corrosion of reinforcing steel in concrete: Impressed Current System Discrete cathodic protection anodes For protection of steel corrosion in reinforced concrete structures and steel framed buildings
To be embedded within repairs Galvashield XP performed in chloride contaminated concrete to protect adjacent steel from the onset of corrosion.
Ebonex
57
Realkalization
Advantages:
Based on reversing the principles of cathodic protection Limited concrete removal No ongoing maintenance
Disadvantages:
Very high installation cost Not all structures are suitable Environmentally unsound
58
29
Overcladding
Advantages:
Greatly improves appearance Provides the additional benefit of insulation Provides a long-term solution
Disadvantages:
Very expensive Can hide latent defects Extended contract period
Corrosion Inhibitors
See Sika FerroGard-903 Corrosion Inhibitor or Tyfo CIS Inhibitor
Tyfo CIS Inhibitor Layer 2
DESCRIPTION Tyfo CIS Layer 2 is a single-component, clear, waterbased liquid with a mild odor. It may be applied by roller or spray following the application of Tyfo CIS Layer 1. Layer 2 controls the pH, purges and encapsulates water-soluble chlorides, fills voids in the concrete, and inhibits further penetration of moisture. Layer 2 also acts as a contact corrosion inhibitor on the reinforcing steel. After receiving both Layers 1 & 2, the exposed surfaces are cleaned by washing with fresh water or by abrasive blasting. All exposed steel is then treated with the Tyfo CB material and the concrete section is restored using Tyfo P or Tyfo PF as required. USE Tyfo CIS Layer 2 is used with the Tyfo Concrete Repair System on new or old concrete surfaces to seal porosity, increase compression strength, maintain pH, protect from acid and alkali attack, pacify and extract chlorides, and inhibit embedded steel corrosion. MATERIAL PROPERTIES ADVANTAGES Ease of application Can be applied to horizontal, vertical or overhead surfaces Restores properties of deteriorating Portland concrete cement Can penetrate concrete 2 to 3 inches, depending upon existing porosity Dramatically improves condition of substrate prior to repairs Protects new concrete For new and old structures Non-toxic Property Corrosion Inhibition Compression Strength Hardness Increase New concrete C-418 14% ASTM Method C-876 Typical Test Value* 50% reduced voltage in 14 days (400 to 200mV) Increases 2,000 psi (13.8 MPa)
C-42
60
30
61
Re-bar
31
2) Concrete strengthening
An advanced technology of concrete strengthening techniques which do not need to recast the concrete structure for strengthening. This technique apply the use of placing an bonding CIFIRP (Fibre Reinforced Polymer) plates or sheets to surfaces of structural concrete members.
64
32
Composite fabrics for structural and seismic strengthening Fibre reinforced polymer (FRP) system
SikaWrap
For structural strengthening for post-reinforcement of structural members, such as beams, columns, slabs)
65
3) Chloride Extraction
If there is a presence of chloride ion, the concrete will deteriorate at a faster rate. It is mainly due to the depassivating effect of chloride ions. Usually, a value of 0.8% (a critical acceptance value) is adopted for practical use. In this method, chloride ions are removed from concrete by dissolving in electrolyte and drawing it to an external electrode by an electrical potential. The external electrode being used in this method is a titanium wire mesh which is embedded in electrolytic paste of cellulose fibre. The paste is adhered onto the surface of concrete.
66
33
4) Concrete Re-alkalization
Alkaline is a substance which can protect reinforcement from corrosion. When concrete is carbonated, its alkalinity decreases and hence the protection of reinforcement is decreased. This method is used by diffusing alkaline chemicals like metallic hydroxides into concrete for increasing pH value and cause repassivation. Recently, this technique is still under testing and not yet been developed for field test. Therefore, it is difficult to find this service in the market.
67
34
prevents ingress and migration of moisture and damaging corrosive Deplete soluble chlorides in concrete and inhibit corrosion of imbedded reinforcing steel
69
6) Corrosion Inhibitor
With the addition of calcium nitrite, the standard threshold of corrosion is elevated i.e. the protective passivity layer can tolerate a higher level of chloride ions. http://www.na.graceconstruction.com/conc rete/
70
35
Reading
Rostam, Steen. (1996) High performance concrete cover why it is needed, and how to achieve it in practice, Construction and Building Materials, 10(5), 407-421.
71
References
Buildings Department, (1998), Interim Technical Guidelines on The Inspection, Assessment and Repair of Buildings for The Building Safety Inspection Scheme, The Government of the Hong Kong SAR. Mays, G. and Wilkinson, W., Polymer Repairs to Concrete: Their Influence on Structural Performance, ACI-SP 100-22 Katherine and Bryant Mather International Conference 1987, pp.351-338. Mailvaganam, N.P. and Taylor, D.A., Compatibility of Repair Systems for Concrete Structures, CANMET/IRC Symposium on Advanced Materials, Ottawa, 1994, 11 p. Pullar-Strecker, P., (1988). Corrosion Damaged Concrete: Assessment and Repair. London: Butterworths, 1988. Buildings Department, (1998), Interim Technical Guidelines on The Inspection, Assessment and Repair of Buildings for The Building Safety Inspection Scheme, Highway Department, HKSAR Govt (2002) Guidance Note on the Repair of Spalled Concrete Road Joints, GN028. The Government of the Hong Kong SAR. Currie, R. J. (1994). Repair and Maintenance of Reinforced Concrete. Building Research Establishment Report. Watford: BRE publication. Schmick, Bonnie L. Pollington, Annette. (2002) Concrete repair manual American Concrete Institute. Imprint Farmington Hills, Mich. : ACI International, [2002?] 2nd ed.[HKU 624.18340288 C7 S] The Australian Corrosion Association and The Asian Pacific Materials and Corrosion Association, (2001). Fosroc galvashield: New ways to repair and protect reinforced concrete, Corrosion & Materials, vol 26 (4), 6-7. The Sprayed Concrete Association, (1999), Introduction to Sprayed Concrete, The Sprayed Concrete Association. 72
36
The End
For enquiries, please send email to Edward CY YIU
Department of Real Estate and Construction The University of Hong Kong
ecyyiu@hkucc.hku.hk
73
37