Strengthening and

Repair of Reinforced
Concrete
Structures
Ian Wienholt
Business Development Manager

34 years of Concrete
Repair and Strengthening
Experience
Over 12,000 Repair Project

Over 25,000 PT Projects

1,500 Employees

22 Offices- International

UAE and UK

Structural Group delivers services, systems and technologies

that build, repair, protect, strengthen and reinforce
concrete, steel, masonry, wood, timber and soils.

Concrete Repair & Waterproofing

Masonry Restoration

Building Envelope Group:

Historic Division

Building Envelope Group:

Multi-Family Division

Concrete Repair Services

Construction
Defects

Missing Reinforcement

Honeycombs

General Repair Group:

Strengthening Division

Agenda

Strengthening Case Studies

CFRP & NSM Rod

External / Internal PT
Section Enlargement /
Supplemental Beams

CFRP & NSM

Externally Bonded FRP Sheet

550,000 psi Tensile

10x that of steel
Lightweight
Does NOT corrode

FRP Design Guidelines

440.2R-08

Em
er
g

in
g

Te
ch
no
lo
g

440.2R-02

To Date:
Nationwide 15-18M sqft installed
SPS 7M sqft installed on over 700 + projects

ACI 440.2R-08

FRP Materials

SEM Image of FRP

Resin

Fiber

What Is FRP Flexural Strengthened R/C?

Yield
Tension

Steel
FRP carries

TENSION
Positive Moment

What Is FRP Flexural Strengthened R/C?

Negative Moment
FRP carries

TENSION
TOP
Steel

Tension

Yield
Concrete carries

COMPRESSION

BOTTOM
Column

Compression

What Is FRP Shear Strengthened R/C?

SHEAR

CFRP Installation Step 1

Surface Grinding / Shot Blasting to open pores

CFRP Installation Step 2

VE primer

CFRP Installation Step 3

VE putty

CFRP Installation Step 4

VE tack coat

Carter Ave Bridge Upgrade

Tack coat QC

CFRP Installation Step 5

CFRP saturator

CFRP Installation Step 6

CFRP sheet lay up

CFRP Installation Step 7

Embedding of CFRP in tack coat

CFRP Installation Step 8

Rib rolling

CFRP Installation Completed

Finished CFRP- Top, Sides, Bottom

Carter Ave Bridge Upgrade

Carter Ave Bridge Upgrade

Acrylic / Intumescent Topcoat installation

CFRP Finished Product

Supplemental Strengthening ONLY w/FRP!

FRP?

Supplemental Strengthening ONLY w/FRP!

CFRP Interfacial Shear Failure

FRP Plates

FRP Rods

Flexural Strengthening Case Study

FRP Rod Installation

Parking Garage Ramp

Parking Garage Ramp FRP Sheet

NSM Rods

Parking Garage Ramp

Damaged Double T

Dropped 2T in Parking Garage

Shear upgrade of 2T stem with FRP

Flexural Detailing Guidelines

Step plies

U Wrap

Quality Control
Field Application

Quality ControlCure Test Cups Daily

BA
1Gal.

Pour off sample

To verify cure

Sounding and Bond Tests

Puck

Ping

`
Tap test or other

Pull test

Sounding

Witness Panels for Testing

Pull off Bond Test

Min. 200psi

Locate Bond Test Dollies outside

work area or on an additional piece of FRP

Locate Bond Test Dollies outside

work area or on an additional piece of FRP

Ear plug to protect threads

Frequency for Pull Testing

1 PULL PER INSTALLATION DAY MINIMUM

OR
PER ENGINEERS SPEC (per sqft installed)

Repair Procedure
1 - Identify Repair Area
Less than 2 Sq. In. / 5% Total Area Max. OK
If 2 to 4 sq. in. inject with low pressure

Repair Procedure

Repair Procedure
Step 2 - Remove Composite Material
If greater than 4sq. In. grind or sawcut area

Repair Procedure
Step 3 - Prepare Lap Area
Minimum repair lap = 6 inches
6

New Loads or low strength concrete

CFRP Column Confinement

Increased:
Axial
Capacity
Buckling
Resistance
Bomb
Blast
Resistance

General Concept

Structural Upgrade
Resorts Casino- Atlantic City

Structural Upgrade
Resorts Casino- Atlantic City

Structural Upgrade-Buckling Resistance

Resorts Casino- Atlantic City

Structural Upgrade
Resorts Casino- Atlantic City

Blast Mitigation for Columns

Truck bomb at
curbside

Blast Mitigation for Columns Truck bomb at curbside

No FRP

Blast Mitigation for Columns Truck bomb at curbside

No FRP

Blast Mitigation for Columns Truck bomb at curbside

Guggenheim Museum NYC

1959

Guggenheim Museum NYC

Guggenheim Museum NYC

Guggenheim Museum NYC

Goal: Extend the life of the structure by
100 years
Exhaustive investigative survey
completed and found 11 coats of paint
on the exterior
All exterior surfaces would be restored
so that the original form lines would
once again be visible

Original Construction Photo Circa 1957

Destructive
testing to
open
crack

Steel
T-Section
Rebar
Discontinuous

Original
Construction
Photos

Guggenheim Museum

Guggenheim MuseumAnalysis & Monitoring

Circumferential Forces

Vertical Forces

Initial repair concept

FRP

Steel brackets b/n web walls

Bond

Grout

Double
Barrier
Walls

Museum remained
open!

Surface Preparation
8,000 psi

1,674,345,869 Diamond Cup Wheels Used!

Extensive Crack Repair Required

Rout & Seal

vs.
Epoxy Injection

CFRP
Installation

Web Wall
Brackets

Gunite wall to apron slab bracket

FRP

Bracket

Apron bracket

s
s
e
l
n
Stai el
Ste
t
u
Gro

Shear transfer plate across cracks

Completed repair prior to insulation and drywall

South
South Locust
Locust Point
Point Marine
Marine Terminal
Terminal
Roll-On
Roll-On // Roll-Off
Roll-Off Platform
Platform

Pier expansion design

included new pre-cast
deck panels as well as a
new 92 ramp for RO/RO
cargo
Change in use and
heavier loads required
strengthening upgrade to
pier caps
CFRP system designed
for increased strength and
long-term durability in
marine environment

South
South Locust
Locust Point
Point Marine
Marine Terminal
Terminal
Roll-On
Roll-On // Roll-Off
Roll-Off Platform
Platform

Challenge #1:
Time Critical Schedule

South
South Locust
Locust Point
Point Marine
Marine Terminal
Terminal
Roll-On
Roll-On // Roll-Off
Roll-Off Platform
Platform

Challenge #2:
Weather conditions

South
South Locust
Locust Point
Point Marine
Marine Terminal
Terminal
Roll-On
Roll-On // Roll-Off
Roll-Off Platform
Platform

Challenge #3:
Access via work
floats

South
South Locust
Locust Point
Point Marine
Marine Terminal
Terminal
Roll-On
Roll-On // Roll-Off
Roll-Off Platform
Platform

Challenge #4:
Coordination with
other trades

Crane

South
South Locust
Locust Point
Point Marine
Marine Terminal
Terminal
Roll-On
Roll-On // Roll-Off
Roll-Off Platform
Platform

Challenge #5:
Employee safety
Water danger
Wind / Waves
Boat wakes
Rising tides
Enclosed space

South
South Locust
Locust Point
Point Marine
Marine Terminal
Terminal
Roll-On
Roll-On // Roll-Off
Roll-Off Platform
Platform

Change of Scope:
Concrete repair performed per ICRI guidelines

South
South Locust
Locust Point
Point Marine
Marine Terminal
Terminal
Roll-On
Roll-On // Roll-Off
Roll-Off Platform
Platform

CFRP Termination Detail

NSM CFRP
Rods

2
Concrete
Pile Cap

CFRP
Fabric U
Wrap

South
South Locust
Locust Point
Point Marine
Marine Terminal
Terminal
Roll-On
Roll-On // Roll-Off
Roll-Off Platform
Platform

Completed CFRP Strengthening

South
South Locust
Locust Point
Point Marine
Marine Terminal
Terminal
Roll-On
Roll-On // Roll-Off
Roll-Off Platform
Platform

Completed Platform Ready for Cargo

Why do we
love core
drills?

- They keep us in business

- They challenge us.

- They make us laugh..

Penetrations and the Core Drill

Shortest distance between 2 points is a straight line

Process for New Slab Penetrations

Variables-

Quantity of bars cut and size of Hole

New Penetrations
p
i
r
t
s
n
m
u
l
Co

New Penetrations

Internal & External

Post Tensioning

External Post Tensioning

NEW LOAD

ION
S
TEN F

Live end

Dead end

F
Uplift
at Deviator

Flexural Strengthening Case Study

Environmental Overload

US Census Bureau HQ Suitland, MD.

Flexural Strengthening Case Study

Environmental Overload

4-6
30

Flexural Strengthening Case Study

Environmental Overload

Tension

Tension

YIELD

Flexural Strengthening Case Study

Environmental Overload

Flexural Strengthening Case Study

Environmental Overload

Amplitude

Form & Pump

Flexural Strengthening Case Study

Environmental Overload
High Pressure Water Blasting
Dowel Hole Drilling

Dowel Insertion

Flexural Strengthening Case Study

Environmental Overload

Flexural Strengthening Case Study

Environmental Overload

Flexural Strengthening Case Study

Environmental Overload

Flexural Strengthening Case Study

Environmental Overload

Flexural Strengthening Case Study

Environmental Overload

Flexural Strengthening Case Study

Environmental Overload

43

Internal PT

Drill
PT

Higher Loads on 2T- Load Path

Heat Resistant Tendon

Polyethylene
Sheathing

Polyethylene
Sheathing
Intumescent Fire
Retardant Coating

270k P.T.Strand

Grease

Higher Truck Loads-

Ext. PT & Overlay

Anchorage
pin
External PT

Deviator

Higher Truck Loads-

Ext. PT & Overlay

Higher Truck Loads-

Ext. PT & Overlay

Higher Truck Loads-

Ext. PT & Overlay

Higher Truck Loads-

Ext. PT & Overlay

Deviator

Higher Truck Loads-

Center Z Anchor

Ext. PT & Overlay

Higher Truck Loads-

Ext. PT & Overlay

Anchorage
pin
External PT

Deviator

Section
Enlargement &
Supplemental
Beams

East Coast Ski Resort

Transfer Slab Upgrade

Transfer Slab Cracking

Foundation & Column

Enlargements

Foundation & Column

Enlargements

18 Column Enlargements

Demo and Prep

PAM Machine in Action

Supplemental Beam-Column
Connection

Mechanical Anchoring and

Reinforcement Cage

3000 Hilti
Studs

2000
Undercut
Anchors

Through-Bars at Column Head

SCC Pumping Anyone???

40 Tons of
Steel

1100
LF

Enlargement

Prep & Placement

New
Existing

Finished Product

185 CU YDS /
375 Tons of
Concrete

Finished Product

Finished Product

Repair, Upgrade and Strengthening Process

Existing Capacity

g
n
i
r
e
e
n
i
g
e
c
En
n
e
i
c
S
l
a
i
r
e
t
n
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o
i
t
M
a
c
i
f
i
r
e
Test/V

New Demand

y
t
i
l
i
b
a
ct
u
r
t
s
Con
s
c
i
t
e
h
s
Aest
c
i
m
Econo

Repair and Strengthening Process

Existing Capacity
Engin
e
ering
Mate
rial S
cienc
Test/
e
Verifi
catio
n

Reverse
Engineer

New Demand

Cons
t r uc t
Aesth ability
etics
Econ
omic
s

Concluding Remarks
THANK YOU!

Contracting Services

Preliminary Design and

Estimate Support

D/B Capabilities

Optimizing Repairs

Load Testing

Comprehensus