Diagnostics approach

towards
Structural repairs
Typical issues in RCC structures

- Corrosion
- Cracking
- Spalling of concrete
- Leakage / seepage
- Bulging of concrete
- Deflection of structural members, etc.,
CRACKS indicate the beginning of
deterioration in most cases
 LEAKAGE

Can be very ugly and dangerous

 S
SPALLING
G

Result of neglected leakage & cracks for long time

 Factors that lead to Problems
Built in problems (Internal)
External Causes
Man made causes
Natural calamities
Internal Cause

Design issues
Improper selection of materials
Wrong waterproofing specifications

Faulty construction methods

E t
External
lCCause
Environmental attack
Chlorides
Carbon dioxide
S l h t
Sulphates
Humidity
Man made causes
Change in use of structures
Over loading
Unplanned modifications /alterations
Poor maintenance
N t
Natural
l calamities
l iti
Earthquake
q
Flood
Fire
Cyclones
C l
Typical Causes:
Corrosion of rebar
- Chemically active soil
- Pollution
- Industrial abuse
(chemicals)
- High relative humidity
- Environmental attack

Chloride & Co2

induced
Cracks due to
corrosion
A major
j problem
p

Protection reduced

Concrete becomes porous

Entry
E off CO2 &
Chlorides & moisture
Co2 induced corrosion
Chloride induced corrosion
Approach to systematic repairs
Inspection most important activity
must be done by a professional
- Every structure requires different approach.
E.g. building structure, industrial str, jetty,
cooling
li ttowers, iintake
t k pump hhouses, dams,
d
bridges, etc.,
- All locations of distress should be noted
- Original drawings, if available, should be
referred
Approach to systematic repairs

Cause and need identification:

-What is main cause?
-Why repairs?
-What is the life expectancy?
-What is the importance of structure?
-Isthe need only to patch repairs? Or any
other
Unless the cause is identified and
removed, repairs can not be
effective & complete.
Approach to repairs must be
different for different structures

River Pump House

Jetty

Industrial Building
NEED??
- Life extension
- Strengthening
g g
- Increase in loads
- Seismic
- Restoration
i to
original design
values
- Protection
Diagnosis:
(Visual inspection + Diagnosis)

Comparison
Structural engineer = Doctor
Pathological tests = NDT
 Diagnosis:
NDTs are effective tools to
determine the health of concrete

TO ASSESS PERFORMANCE
LEVEL DURING SERVICE
LIFE
PARAMETERS TO BE EVALUATED
a) STRENGTH (IN-SITU)
b) DURABILITY PERFORMANCE

presence of internal voids/ cracks,

materials likely to cause disruption
of
concrete (sulphate or alkali reactive
aggregates), extent or risk of reinf.
corrosion, chloride content, cover
thickness, permeability etc.
NDT:
Common NDTs are

1. Rebound hammer test

2. USPV
3. Half cell potential meter
4. Rebar locator
5. Core test
6. Thickness test
7. Carbonation test
8. Chemical analysis
NDT:
Rebound hammer
test
- To know strength of
concrete / surface Aah.
hardness
- Range: 10 to 70 N /
sqmm
Guidelines: IS : 13311
(Part 2) : 1992 &
Bs 1881 : Part 202 :
1986.
1986
NDT:
Ultrasonic Pulse Velocity
Test
- To know strength of concrete
- Penetration
P t ti Range:
R 10mm
10 to
t 5
m
Guidelines: IS : 13311 (Part 1)
: 1992 &
BS 1881 : Part
P t 203 : 1986.
1986

Ultrasonic Pulse Velocity by Cross

probing (Km/Sec) Concrete
quality grading

1. Above 4.5 Excellent

2. 3.5 to 4.5 Good
3 3
3. 3.0
0 to 3.5
3 5 Medium
4. Below 3.0 Doubtful
NDT: Core Test
- To know strength
of concrete
- Core dia Range:
25 mm to 125 mm
-

Guidelines: Clause
4.8 of BS 1881;
Part 120: 1983 for
flatness &
parallelism
NDT: Core Test
AFTER DRESSING,
CAPING & CURING :
THE CORE IS TESTED
IN COMPRESSION
TESTING MACHINE
NDT:
Strength analysis
- Based on the results of Rebound hammer,
USPV and
d Core
C tests,
t t theth average compressive
i
strength for concrete shall be considered.
NDT:
Chemical analysis
Chloride Content:
Whenever there is chloride in concrete there is increased
risk of corrosion of embedded metal. The higher the
chloride content, or if subsequently exposed to warm moist
conditions, the greater the risk of corrosion.
As per IS : 456:2000, the maximum total acid soluble
chloride
hl id content
t t expressedd as Kg/m3
K / 3 off concrete
t should
h ld be
b
0.6 for reinforced concrete

Sulphate Content:
The excessive amount of water soluble sulphates can
cause expansion or disruption of concrete. The total water
p
soluble sulphate content of the concrete mix,, expressed
p as
SO3, should not exceed 4 per cent by mass of cement in
the mix.
NDT:
Chemical analysis contd..

pH of concrete sample:
The Ph of freshly prepared concrete is around
12 and hence it is highly alkaline in nature.
Carbonation of concrete by attack from
atmospheric carbon dioxide will result in
reduction in alkalinity of the concrete, and
increase the risk of reinforcement corrosion.
NDT:
Half cell Potential Meter: for corrosion

Reference Code : ASTM C 876

Objective :To find out the probability of corrosion

of steel inside concrete.
NDT:
Half cell Potential Meter: Guidelines

HALF-CELL POTENTIAL(mV) PERCENTAGE CHANCE

RELATIVE TO OF ACTIVE CORROSION
COPPER/COPPER SULPHATE
REFERENCE ELECTRODE
< -350 90%

-200 TO 350 50%

> -200 10%

NDT:
Carbonation
b i Test:

To find out the alkalinity of

concrete

If p
pH is more than 10,, concrete
turns pink when sprayed with
phenolphthalein solution.
Part 2

Repair materials & techniques

Case studies.
studies
Repairs specifications

- Based on visual inspection

- NDT result
- Need
- Life of repair expected
- Selection & evaluation of repair
materials
- Budget
- Limitations
Repair materials must offer ..

Compatibility With Old Concrete

Excellent Bonding Properties
Low Shrinkage
Good Strength
Dimension Stability
Crack Resistance
I
Impermeability
bilit
Ease of Application
Durability
All repair scheme must include

Holistic job specifications

Compatible materials
Cause identification & elimination
Protective coatings
Corrosion control mechanism,,
wherever possible
Post NDT
Common repair materials available

Rust removers
Bonding agents
Latex, SBR and Acrylic
Epoxy
Epo resin
esin based
Injection grouts
Cement
Low viscous epoxy
PU
Zinc rich epoxy primers for re bar
Common repair materials available
Hand applied polymer mortars
Site modified
Ready to use 2 component
Ready to use single component
component, high build

Hand applied
pp epoxy
p y&ppolyester
y resin
mortars

Flowable
Fl bl self
lf compacting
ti micro
i concrete
t
Low strength to high strength
Common repair materials available
High
g strength
g p polyester
y resin anchor grouts
g
Under water range (cement & epoxy based)
Glass and Carbon fibre wrapping systems
Protective coatings
Silane Siloxane based
Solvented acrylic based
Water based acrylics
Aliphatic
p PU based
Aliphatic epoxy based
Repair techniques

Repairs using injections and Polymer

mortars
Normal concrete jacketing
Micro concrete jacketing
Fibre wrapping glass, carbon & Aramid
Carbon strips normal, pre
pre-stressed
stressed
Steel plate bonding
Anchor stitching
E- chem repairs (sacrificial anodes)
Repair Techniques Polymer Mortar Application

Polymer Modified Mortar is available in two types

Site Mixed
Pre-mixed (Single Part)

PMM is
i very d
dense and
d is
i hand
h d applied
li d

Proper bond coat shall be used for the application

of PMM
Repair Techniques Polymer Mortar Application
Repair Techniques Micro Concrete

Micro concrete is free flow, self compacting,

high strength

Available as pre mixed, ready to use

Can be used with addition of aggregates

also

Microconcrete is used for the jacketing of

Columns & Beams
Repair Techniques Micro Concrete
Repair Techniques Micro Concrete
Repair techniques Injection Grouting

Different types of Injections are available

Cement with non shrink additive
Epoxy
PU

Type of material to be injected depends on the

porosity and the strength required
Repair techniques Injection Grouting
Repair techniques Fibre Wrapping

Different
Diff t types
t off Fibre
Fib Wrappings
W i are available
il bl
E- Glass Fibres
Carbon Fibres
Aramid Fibres
These fibres are available in diff. unit weights
Glass Fibres in 600 & 900 GSM
Carbon Fibres in 230 to 430 GSM
Fibres are used for the strengthening of structural
members like Columns & beams
Selection of material depends on the strength required
Application of fibres is wet-on-wet lay up or dry-on-dry
lay
y up.
p
Fibres are used along with primer & saturant.
Repair techniques Fibre Wrapping
Repair techniques Carbon Laminates with PT

Carbon Laminates are available in 1.5 mm thk & 50 mm

width.

Laminates are used for the strengthening of beams in

Flexure

Laminates are used with or without post tensioning

Repair techniques Carbon Laminates with PT
Repair techniques Steel Plate Bonding

Steel Plate Bonding is used for the strengthening

of Columns

Repair techniques Steel Plate Bonding

Repair techniques Cathodic Protection

Cathodic Protection is used for the protection of

structure from residual corrosion
Repair techniques Cathodic Protection
Case Study
Scope Of Work:

Repairs and Strengthening of

Marine Structure.
Areas of Concern:

Loss of reinforcement by corrosion due to constant

contact with saline water.
Spalling of concrete
Delamination of main cover of all main beams
Corrosion of steel
Cracks in many members.
Carbonation
Methodology adopted:
Removal of loose materials and cleaning;
Removal of rust
P idi additional
Providing ddi i l reinforcement
i f steell
Application of epoxy based bond coat between old and
new concrete;
Protection of reinforcement by providing sacrificial
anode system
Repair of soffit beams and slabs using micro-concrete;
Application of Aliphatic acrylic based anti-carbonation
coating.
coating
Critical aspects for repairing marine
structures:
Creation of proper access
Ethylene & LPG gas lines on the jetty
No hot work allowed during ship unloading
Special arrangements for people & material
movement
Hi h safety
High f t norms
Man power & material planning
D bilit parameters
Durability t
Critical aspects for repairing marine structures:
Material
M t i l specifications
ifi ti
Anti carbonation coatings are the key to long lasting repairs
Micro concrete preferred over ordinary jacketing
Polyester resin for fast repairs to broken edges of fender
blocks
Prevention of further corrosion is the keyy to such repairs.
p
Trained man power required
Higher cost of mobilization.
One time planning for all manpower & materials
Aggressive climatic conditions.
Fatigue during work.
Pre Heater Building
Main Issues ( As per NDT report)
- Honey combs
- Major cavities in concrete
- Uneven
U concrete pattern
- Leachingg
- Spalling of concrete
Pre Heater Building

What report says summary

Corrosion
C i level
l l isi alarming
l i att few
f locations.
l ti
- 75 % places corrosion is less than 10% probability
- Concrete strength is average to good
- Less cover to the main steel at several locations.
- Protection level to the main bar is reducing
- Carbonation is progressing
FIRE AFFECTED BUILDING
History:

The third floor in the Port Users building caught fire in

May 2006 . Most off the
h furniture
f i b
burnedd down.
d But the
h
concrete members of the building remained intact
without visible distortion. Due to fire exposure p
serviceability of the members was adversely affected.
And it became necessary to restore strength to these
members.
b
Diagnosis:
Plaster was removed, inspection of RCC structures
was carried out.
Extensive NDT was carried out to see the extend of
damage.
-Rebound hammer test
-USPV

-Half cell potential meter and

-Core test
Findings:
g
zall beams required strengthening in flexure
& shear zones
z slab strengthening in flexure
z columns were ok,
ok required only grouting
z expansion joint was damaged
z overall steel bars were in good condition,
condition
corrosion was within permissible limits.
Remedial measures adopted:
zCementitious Grouting to the beams & slabs, location
decided based on USPV readings

zAdditional grouting in all visible cracks

zFlexural & shear strengthening of beams by both

directional glass fiber (2 layers)

zAdditional 75 mm jacket to beams with Micro concrete

Remedial measures adopted:

zSlab strengthening in flexure

zGrouting of all columns and floor slab

zExpansion joint treatment

zPlastering & terrace waterproofing.

zPost NDT
Cementitious grouting:

- A hole of required size is drilled and

cleaned with electric blower

- A nipple is fixed into the hole by using

cementitious putty.

- Grout is prepared using cement and

Expansive additive. This mixture is then
grouted in to the holes using low
pressure until refusal.
-
GFRP Wrapping & weld mesh fixing:

- Beam surface is cleaned of any

irregularities
irregularities. Cavities are filled
with Polymer modified mortar.
Corners are chamfered.

- Epoxy adhesive is applied over the

beam surface. The GFRP fabric is
then stuck to this surface using
rollers to avoid air from entering.

- After sticking the fiber saturant is

applied on GFRP.
-
Micro-concrete Jacketing:

- Holes of required diameter are drilled into

the beams and shear keys of 10mm
diameter are anchored into the same.

- Weld mesh is then tied to the shear keys to

cover the whole area of beam to be
jacketed. And shuttering is fixed.

- Holes of about 50mm are drilled in the slab

just over the shuttering to facilitate
pouring.
pouring

- Micro-concrete is then prepared and

poured in to the shuttering.
Fresh Plastering:

- Damaged plaster is
removed completely to be
replaced by good quality
fresh plaster.
Project Highlights:
z More than 5500 nos grouting points
z More than 2500 nos of shear connectors
z More than 800 sqm of fiber wrapping
z Almost 110 MT of Micro concrete was used
z All the beams & slabs were jacketed through holes
made in slab.
z The entire jjob was finished in 3 months
Scope Of Work:
Repairs and Strengthening of ESRs
History:

-The two ESRs at Ramchandra talkies and one at Ayre

road with a total capacity of 5.15 million litres provide
water to almost 50% area of the Dombivli (East).

-Structural evaluation of these reservoirs by IIT Powai

in 2002-03 revealed that structural rehabilitation was
necessary.
Findings during evaluation

Loss of reinforcement due to corrosion;

Excessive spalling of concrete leading to accelerated

corrosion;

Crack in many members, mostly at beam column junctions;

Probably weak joints which may be hazardous in case of an
earthquake;

Through cracks in container walls leading to leakages;

Carbonation on all the surfaces of structures

Methodology
gy adopted:
p
Removal of loose materials and cleaning;
Grouting of honeycombs and cracks;
Removal of rust
Pl
Placement t off additional
dditi l steel
t l where
h required;
i d
Application of bond coat between old and
new concrete;
Building the surface of concrete with polymer
modified mortar;
Methodology
gy adopted:
Application of GFRP wrap to improve the joint
ductility
Application of UV resistant protective coatings over
exposed surfaces;
W
Wrappingi columns
l from
f Ground
G d level
l l to
t first
fi t level
l l
of tank for peripheral columns;
Additional re-building of concrete sections using
Polymer Modified Mortar;
Increasingg the cross sections of affected beams;;
Condition of structures at the start of the
project
Top slab was broken and re-cast
Shear zone damage
Wrapping of columns and Joint strengthening
using GFRP wrapping
Wrapping of columns and Joint strengthening
using GFRP wrapping
Application of protective Coatings.
Scope Of Work:
Seismic Retrofitting of Industrial Structures.
Structures
Seismic Retrofitting of Industrial Building at
Mahad
Diagnosis
g
Preliminary analysis of buildings revealed that they
have not been designed for earthquake loads as per
the Indian standard available at the time. Hence
seismic retrofitting measures were taken.

Scope of work:
Structural strengthening of various members to
enable total structure to withstand possible seismic
loads in the region.
region
Methodology adopted:
Footing Expansion
C l
Column Jacketing
J k i
Addition of shear walls
Wrapping of beams/ columns with high
strength composites
Structural bracing
Footing Expansion:
Weak footingsg were
exposed and
strengthened by
increasing their
dimensions. Bonding
between old and new
concrete was ensured
using
i shear
h anchors.
h
 Footing Expansion & Column Jacketing

Original
Columns

Jacketing
 Fiber Wrapping

Beam Wrapping for

h
shear
Column Wrapping
 Addition of shear walls

shear walls
 Non-metallic pre-cured fiber plate

Non-metallic pre-cured fiber plate fixed to beam for flexure

Structural Bracing