Concrete Repair to EN 1504; Diagnosis, Design, Principles

and Practice
Univ.-Prof. Dr.-Ing. Michael Raupach,
RWTH Aachen University, Institute for Building Materials Research, ibac

INTRODUCTION

Protection and repair of concrete structures has become an important market. As an example
the costs for the maintenance of bridges are higher than 1 billion $ per year. The total costs
for maintenance of all types of buildings can be assumed to be higher than about 20 billion $
per year. A significant part of this costs are spent on repair and protection of concrete
structures. On the contrary to the amount of work spent on building new structures, the
market of repair and protection has grown considerably as the age of the existing
infrastructure is increasing. The extensive development of new methods and materials for the
repair and protection of concrete structures has led to the need of standards for such works
and products.
Table 1 shows the structure of the new EN 1504, consisting of 10 main standards and 61 standards for test methods. As shown in table 1 the series of standards is focused on parts 2 to 7,
which are the basis for CE marking of the different products and systems to be used for
protection and repair of concrete structures. However, part 9 of EN 1504 is not less important,
describing the principles for the use of the products, which are explained in the following
sections. Part 1 gives definitions, part 8 regulates the quality control of the products and part
10 gives a general guideline for site application and quality control of the works. To allow CE
marking of the products 61 standards describing test methods for the different properties of
the products have been published. These standards ensure that testing of the products are
according to the same standards for all products for protection and repair of concrete
structures used in Europe.
Table 1:

Structure of EN 1504
Futher test
methods

EN 1504-1 Definitions

EN 1504-9
Principles for the
use of the products

EN 1504-2 to 7:
Products
surface protection
repair mortars
bonding materials

EN 1504-10
Site application
and quality control
of the works

injection materials
anchoring products
coatings for steel

Test methods
(61 standards)
EN 13 396
(chloride ingress)
.
.
.
.
EN 14 497
(filtration stability)

EN 1504-8 Quality control of the products

PHASES OF REPAIR PROJECTS

The phases of repair projects follow a logical sequence, which is dominated by engineering
aspects (Table 2). However, the systematics of general planning is quite new related to the
actually existing recommendations and standards. It consists of a hierarchy of levels, namely
options, principles and methods, which are described in more detail in section 4.
Table 2: Systematics of planning according to EN 1504-9
Assessment of the status of the structure (defects ...)

Elaboration of the repair strategy (do nothing, repair, ..., demolition)

Definition of the repair principles (e.g. protection against ingress ...)

Selection of the repair method (e. g. impregnation ...)

Definition of the repair materials (strength, modulus, adhesion, etc.)

Definition of inspection and maintance requirements

PROCESS OF ASSESSMENT

Table 3 shows common causes of defects according to figure 1 of EN 1504-9. With respect to
later planning of repair, generally it should be distinguished between defects in concrete and
defects caused by reinforcement corrosion. The purpose of the main assessment is
to identify the cause or causes of defects
to establish the extent of defects
to establish where the defects can be expected to spread to parts of the structure, that are
at present unaffected
to assess the effect of defects on structural safety and
to identify all locations, where protection or repair may be needed.
More details on requirements for assessment are given in EN 1504-9.

Table 3: Common causes of defects

Common causes of deterioration
Concrete

Reinforcement corrosion

Abrasion
Fatigue
Impact
Overload
Movement (e.g. settlement)
Explosion
Vibration

Carbonation

Cement content & type

w/c ratio
Curing
Rainfall
Temperature/humidity

Chemical

Alkali-aggregate reaction
Aggressive agents
(e.g. sulfates, salts, soft water)
Biological action

Corrosive
contaminants

Physical

Freeze/thaw
Thermal effects
Salt crystalization
Shrinkage
Erosion
Wear

At mixing:
Chloride salts
From external environment:
Sea water
Road salt
Other contaminants

Mechanical

Stray
currents

Fire

OPTIONS, PRINCIPLES AND METHODS FOR PROTECTION AND REPAIR

As already mentioned, the rules for the use of products and systems for protection and repair
of concrete structures is based on a hierarchy of different levels, namely options, principles
and methods. According to EN 1504-9 the following options shall be taken into account in
deciding the appropriate action to meet the future requirements for the life of the structures:
(a) Do nothing for a certain time
(b) Re-analysis of structural capacity, possibly leading to downgrading of the function of the
concrete structure.
(c) Prevention or reduction of further deterioration, without improvement of the concrete
structure.
(d) Improvement, strengthening or refurbishment of all or parts of the concrete structure.
(e) Reconstruction of part or all of the concrete structure and
(f) Demolition of all or part of the concrete structure.
For protection and repair, different principles have been defined, separately for repair and
protection of damages to the concrete and damages induced by reinforcement corrosion.
Tables 4 and 5 show the 6 principles for protection and repair of concrete and the 5 principles
to prevent damages due to reinforcement corrosion respectively. Theses principles are based
on the RILEM Technical Recommendation 124-SRC Strategies for repair of concrete
structures damaged by steel corrosion. To protect or repair a concrete structure according to
the principles different methods are available. Tables 6-13 of this paper show the methods and
short descriptions for the 11 principles. Altogether 43 methods are described within EN 15049. Not all of them are covered by the EN 1504 series, but by other standards, and some of
them are actually not standardised, but expected to be regulated in future.
The system of options, principles and methods is the basis for the selection of products by the
designer. The process of planning and selection of products is described within the next
section.

Table 4: Principles for repair and protection for damages of the concrete

Principle No.

Principle and its definition

Principle 1 [PI]

Protection against ingress

Principle 2 [MC]

Moisture Control

Principle 3 [CR]

Concrete Restoration

Principle 4 [SS]

Structural Strengthening

Principle 5 [PR]

Physical resistance

Principle 6 [RC]

Resistance to chemicals

Table 5: Principles for protection against reinforcement corrosion

Principle No.

Principle and its definition

Principle 7 [RP]

Preserving or Restoring Passivity

Principle 8 [IR]

Increasing Resistivity

Principle 9 [CC]

Cathodic Control

Principle 10 [CP]

Cathodic Protection

Principle 11 [CA]

Control of Anodic areas

Table 6: Protection against ingress

Principle
No.

Principle and
its definition

Principle
1 [PI]

Protection against ingress

Reducing or preventing the
ingress of adverse agents,
e.g. water, other liquids,
vapour, gas, chemicals and
biological agents

Methods based on the principle

1.1

Hydrophobic impregnation
Applying liquid products which
penetrate the concrete and block
the pore system

1.2

Impregnation

1.3

Coating

1.4

Surface bandaging of cracks

1.5

Filling of cracks

1.6

Transferring cracks into joints

1.7

Erecting external panels a

1.8

Applying membranes a

These methods may also be applicable to other principles.

Table 7: Moisture control

Principle
No.
Principle
2 [MC]

Principle and
its definition

Methods based on the principle

Moisture control

2.1

Hydrophobic impregnation

Adjusting and maintaining

the moisture content in the
concrete within a specified
range of values

2.2

Impregnation

2.3

Coating

2.4

Erecting external panels

2.5

Electrochemical treatment
Applying a potential difference across
parts of the concrete to assist or resist
the passage of water through the
concrete
(not for reinforced concrete without
assessment of the risk of inducing
corrosion)

Table 8: Concrete restoration

Principle
No.
Principle
3 [CR]

Principle and
its definition

Methods based on the principle

Concrete restoration

3.1

Hand-applied mortar

Restoring the original

concrete of an element of
the structure to the
originally specified shape
and function

3.2

Recasting with concrete or mortar

Restoring the concrete

structure by replacing part
of it

3.3

Spraying concrete or mortar

3.4

Replacing elements

Table 9: Structural strengthening

Principle
No.

Principle and
its definition

Principle
4 [SS]

Structural strengthening

4.1

Increasing or restoring the

structural load bearing
capacity of an element of
the concrete structure

Adding or replacing embedded or

external reinforcing bars

4.2

Adding reinforcement anchored in

pre-formed or drilled holes

Methods based on the principle

4.3

Bonding plate reinforcement

4.4

Adding mortar or concrete

4.5

Injecting cracks, voids or interstices

4.6

Filling cracks, voids or interstices

4.7

Prestressing (post tensioning)

Table 10: Increasing physical resistance/Resistance to chemicals

Principle
No.

Principle and
its definition

Principle
5 [PR]

Increasing physical
resistance

5.1

Coating

5.2

Impregnation

5.3

Adding mortar or concrete

Resistance to chemicals

6.1

Coating

Increasing resistance of
the concrete surface to
deteriorations by chemical
attack

6.2

Impregnation

6.3

Adding mortar or concrete

Increasing resistance to
physical or mechanical
attack
Principle
6 [RC]

Methods based on the principle

Table 11: Preserving or restoring passivity

Principle
No.
Principle
7 [RP]

Principle and
its definition

Methods based on the principle

Preserving or restoring
passivity

7.1

Increasing cover with additional

mortar or concrete

Creating chemical
conditions in which the
surface of the reinforcement
is maintained in or is
returned to a passive
condition

7.2

Replacing contaminated or
carbonated concrete

7.3

Electrochemical realkalisation of
carbonated concrete

7.4

Realkalisation of carbonated concrete

by diffusion

7.5

Electrochemical chloride extraction

Table 12: Increasing resistivity/Cathodic control

Principle
No.
Principle
8 [IR]

Principle
9 [CC]

Principle and
its definition

Methods based on the principle

Increasing resistivity

8.1

Hydrophobic impregnation

Increasing the electrical

resistivity of the concrete

8.2

Impregnation

8.3

Coating

Cathodic control

9.1

Limiting oxygen content

(at the cathode) by saturation or
suface coating

Creating conditions in which

potentially cathodic areas of
reinforcement are unable to
drive an anodic reaction

Table 13: Cathodic protection/control of anodic areas

Principle
No.

Principle and
its definition

Principle
10 [CP]

Cathodic protection

10.1 Applying an electrical potential

Principle
11 [CA]

Control of anodic areas

11.1 Active coating of the reinforcement

Creating conditions in which

potentially anodic areas of
reinforcement are unable to
take part in the corrosion
reaction

11.2 Barrier coating of the reinforcement

Methods based on the principle

11.3 Applying corrosion inhibitors in or

to the concrete

PLANNING AND SELECTION OF PRODUCTS

Table 2 shows the systematics of planning according to EN 1504-9. Planning starts with the
assessment of the status of the structure. The following points are selection of options (repair
strategy), repair principles and repair method, as defined in the previous section. Based on
this selection scheme the repair materials can be chosen. EN 1504-9 defines performance
characteristics for every repair method, separately for all intended uses and for certain
intended uses. The designer selects the performance characteristics based on the requirements
of the special repair project and the selected repair methods. Table 14 gives 3 examples of
certain cases, with the performance characteristics relevant for the selected repair methods.
EN 1504-2 to 7 contain the performance characteristics of the products together with the
corresponding test methods. In this way the products are selected individually for the
demands of the special case of repair or protection of a concrete structure. As a result, the
products are described by a list of required performance characteristics instead of simple
classes, resulting in a high level of flexibility, but also responsibility of the designer.
Finally inspection and maintenance requirements shall be defined by the designer.

Table 14: Examples of the application of the classification system in 3 individual cases according to EN 1504-2

CONCLUSIONS AND OUTLOOK

An European standard on protection and repair of concrete structures is available, based on

the actual state of knowledge regarding the properties of the products, the principles for the
use of the products, application and quality control. Parts 2 to 7 regulate the performance of
the products and systems for protection and repair of concrete structures with respect to CE
marking. The use of the products is based on a logical sequence consisting of options (repair
strategies), repair principles and repair methods, which are listed in tables in part 9 of EN
1504. This scheme ensures that suitable products are selected based on the requirements of
the practical case. It is expected that this new series of standards will have significant impact
for European and other countries.