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CHAPTER V: DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED

CONCRETE CONSTRUCTION COURSE : REPAIR AND REHABILITATION OF
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UNIVERSITY OF SOUTH FLORIDA

CHAPTER V: DETECTION AND REPAIR OF DEFECTS IN POST-

TENSIONED CONCRETE CONSTRUCTION

COURSE : REPAIR AND REHABILITATION OF STRUCTURES

STUDENT: JULIO JOHAN SAIRE YANEZ

USF ID : U83049840

(Reihnart R., 2018)

 DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED 2
CONCRETE CONSTRUCTION

CHAPTER V: DETECTION AND REPAIR OF DEFECTS IN

POST-TENSIONED CONCRETE CONSTRUCTION

Matthew Conley serves as a structural engineer at

Walker Consultant Company. He holds a Bachelor degree in
Civil Engineering from the University of Florida, and a Master
of Engineering from the University of South Florida. He made
a presentation about Detection and Repair of Defects in Post-
Tensioned Concrete Construction at USF.

5.1 What is Post-tensioned concrete

Post-tensioning is an up-to-date concrete design method. This method of

design has been taking relevance since the seventies. Posttensioned structures
allow reaching long and slender spans avoiding huge quantities of concrete and
steel. That considerable amount of advantages makes this kind of concrete
design more efficient and stronger. As an example, US structural engineers has
been considered posttensioned structures because its performance during
design. As a result, it decreases cost during construction. Finally, posttensioned
structures have certain inherent advantages over pre-stressed elements, which
are important during concrete design and casting in place.

Even though post-tensioned design has some similarities with pre-

stressed design, there are quite differences between each other to take into
account. Post-tensioned structures involve applying tension forces to tendons
after they have been casting into the concrete. Unlike pre-stressed structures,
post-tensioned structures need to be cast in place. According to the presenter,
post-tensioned structures are more beneficial than pre-stressed members are,
because the entire structure has a monolithic structural behavior. In contrast, pre-
cast structures need to be cast in place before and then arranged during
construction. That configuration allows more displacements it also gives an
uncomfortable physical perception to the building’s users.

Prestressed concrete (http://www.dailycivil.com) Post-tensioning (http://www.dailycivil.com)

Julio Saire
 DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED 3
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According to the presenter, posttensioned design has been taken a

considerable importance in US since the last three decades. The growth of post-
tensioned structures has been estimated about 8.6% per year. That means an
increase in revenues and profits in this civil engineering field. As an example,
during 2007 more than 225 K tons of posttensioning materials have been shipped
in US. Additionally, posttensioning concrete members allows saving around 25 %
in concrete production cost. Indeed, using posttensioning technologies, the cost
of concrete production, the elements size, and the weight of the structure
decrease.

Posttensioning is a structural method, which introduces compression

forces into the faces of concrete to compensate tensile stresses. What is more,
posttensioning members provide continuity to the concrete element. It allows a
reduction in the member size and its reinforcement. As an example, the presenter
illustrated this advantage comparing the quantity of moment, which has to be
carried by a simple supported beam in contrast to a continuous beam. The
moment in a simple supported beam is greater than the moment in a continuous
beam. That is why posttensioning method provides continuity to the members.

5.2 Types of construction defects

5.2.1 Cracking in Posttensioned beams and girders

The presenter stated that cracking in concrete beams is not necessarily a

problem. However, there some reasons why concrete cracks. To analyze cracks
in beam it is important to take into the account the size of the crack. It is possible
to determine the size of the crack by using a crack scale. If there is a narrow
crack, it is not a major issue. Nevertheless, if there is a wide crack, there is a
potential concrete issue in the beam.

Wide Crack (Conley M, 2018) Narrow Crack (Conley M, 2018)

Julio Saire
 DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED 4
CONCRETE CONSTRUCTION

5.2.2 Reverse curvature

Reverse curvature is a major structural issue in posttensioned beams. This

kind of cracking is due to misplaced tendons during concrete pour. The beam’s
cracks follow the curvature of the tendon. That is due to the tensile forces applied
to the tendon. Reverse curvature can get worse if it is not repair. As a result, the
presenter encourages the public to repair as soon as possible.

Reverse Curvature Crack Tendon and Reverse Curvature

(Conley M, 2018) Profile(Conley M, 2018)

5.2.3 Cracking Within anchorage zones

Another important reason why post-tensioned structured cracks is the

cracking within anchorages zones. This kind of cracking occurs because of some
important factors. On the one hand, the improper tendon placement is a common
reason why anchorages zones cracks. That is because, too many tendons has
been placed in a single area. This produces non-designed stresses in members.
On the other hand, another common type of anchorage failure is the insufficient
bursting reinforcement. It happens because there is not enough steel
reinforcement in the anchorage zone. Which eventually will allow concrete
cracking.

Cracking in anchorage zone –Slab Insufficient column ties in anchorage

(Conley M, 2018) zone (Conley M, 2018)

Julio Saire
 DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED 5
CONCRETE CONSTRUCTION

5.2.4 Visible and non/visible concrete consolidation issues.

A consolidation issue is a common problem in posttensioned concrete

elements. Honeycombing is the most common consolidation issue because of
poorly consolidated concrete. Indeed, it is a combination of issues: tendons are
too close together or an improperly vibration when the concrete is placed. On the
other hand, this type of concrete issue could be located in the outer part of the
element and in the interior of the element. The best way to return the durability to
the structure is remove the concrete and replace it.

Concrete Consolation Issue in above Concrete Consolation Issue visible on

tendons (Conley M, 2018) concrete (Conley M, 2018)

5.2.5 Damaged post/ tensioned tendon

A number of reasons can damage tendons. First, they are damaged

because the installation of electrical and mechanic equipment. The problem takes
place because something is being supplementary installed into the structure. As
an example, when the concrete structure has been finished, there were missing
electrical or mechanical lines. Third, another critical damage in tendons is
because core drilling. Topping installation cuts posttensioned elements in order
to accommodate new lines. During this process, it is common that some tendon’s
wires have been cut, and those tendons no longer have the integrity that they
supposed to have.

Tendon Dislodged From the anchor PT Slab Tendon Cut by a Saw

(Conley M, 2018) (Conley M, 2018)

Julio Saire
 DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED 6
CONCRETE CONSTRUCTION

5.3 Methods of detecting construction

Based on the presenter experience, there are destructive and

nondestructive approaches to identify construction defects. The most
recommendable approach is the non-destructive method because it does not
affect the element section. Indeed, the concrete has not been deteriorated to
analyze the issue. However, if there is a critical problem, a destructive method is
totally required.

5.3.1 Visual observations

Visual observation is the most simple way and cost effective way for
detecting defects in structure. Based on the presenter experience, this method
could identify effectively the structure issues if it is used properly. The presenter
recommends using some techniques to identify issues; such as crack mapping,
measuring crack width and length, taking photos.

Crack mapping
Taking Photos (http://www.concreteconstruction.net)
(https://www.videoblocks.com)

5.3.2 Hammer sounding

Hammer sounding is another cost-effective method to identify concrete

consolidation issues. Those types of concrete issues are located not just on the
surface but also they are in the interior of the member. That is why; the presenter
established that this method requires well-trained personnel because as
consequence of the assessment, the repair process will take place. Finally, It is
important to provide accommodate accessibility to the personnel during the
testing process in order to perform the test properly.

Hammer Sounding of a PT Beam Hammer Sounding of a FRP Beam

(Conley M, 2018) https://www.researchgate.net

Julio Saire
 DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED 7
CONCRETE CONSTRUCTION

5.3.3 Ground Penetrating Radar

The GRP (ground Penetrating Radar) is a device, which introduces high

frequencies into the concrete element and record the energy reflected back to the
surface. That response could be used to identify consolidation issues, tendon
position, and the reinforcement location in the member. It is important to mention
that this kind of nondestructive method has limitations for example the depth of
scan is on the range of (8” to 10”) depending on age and strength of concrete.

Ground Penetrating Radar Finding Embedded Steel in PT Beam

https://www.proceq.com (Conley M, 2018)

5.3.4 Impulse Response Testing.

The impulse response testing introduces a low –strain hammer impact in

the concrete surface. This impact sends a stress wave, which is recorded by an
accelerometer into the device. Processing this data is the properly way for
determining cracking and consolidation issues.

PT Girder with low Mobility PT Girder with High Mobility

(Conley M, 2018) (Conley M, 2018)

Julio Saire
 DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED 8
CONCRETE CONSTRUCTION

5.3.5 Localized Concrete Removal

The localized concrete removal is the last method to identify what is the
problem into the beam. This approach always requires an intrusive inspection of
the beam, which implies a concrete removal. The presenter established a
carefully attention during this repair process. The quality control and the
contractor expertise take a relevant importance during the repair process.

Local Concrete Removal on a PT Girder Concrete Removed from PT Girder

(Conley M, 2018) (https://www.structuraltechnologies.com)

5.4 Repair of construction defects

The presenter determined the most common techniques in post-tensioned

beams. Such are described below.

5.4.1 Jacketing PT beams with reverse curvatures Reverse Curvature PT

Beam (Conley M, 2018)
The reverse curvature in posttensioned beams
is a critical structural issue. This problem is the result
of a change in the tendon profile. That change
introduces non-designed forces into the concrete
element producing cracks. Even though those cracks
are not wide they should be repaired. The best approach to solve this problem is
by doing a structural analysis of the beam and establishing a repair procedure or
protocol.

5.4.2 External post tensioning Jacketing PT Beam

(https://www.structuralt.com)
The Jacketing is another approach to repair
reverse curvature problems in post-tensioned beams.
This technique adds flexural and shear reinforcement
to the element in an exterior concrete shell that is cast
around the damaged member. This method takes a lot
of time to perform that is why there is a high cost to perform it.

Julio Saire
 DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED 9
CONCRETE CONSTRUCTION

5.4.3 Forming and pumping

Forming and Pumping is a localized approach to solve some consolidation

issues in concrete. Before doing the forming and pumping approach, first all the
concrete affected area should be removed. Once the affected area has been
removed, liquid concrete should be pumped under pressure into the cavity. This
approach guarantees to fill void into the form. Indeed, this concrete repair looks
natural after casting.

PT Girder Repaired via Form and Pump Appearance of PT Repair via Form and
(Conley M, 2018) Pump (Conley M, 2018)

5.4.4 Carbon fiber wrapping

Carbon Fiber wrapping is a good approach to increase the shear and

flexural strength of members. This carbon mesh is used complementary during
forming and pumping repair process. It is recommendable to use carbon
wrapping when there are ninety-degree corners in the element. Because this can
increase the deterioration of the carbon wrapping.

Carbon Wrapping Parking PT Beam Carbon Wrapping RC Girder

(http://www.buildera.com) (http://www.buildera.com)

Julio Saire
 DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED 10
CONCRETE CONSTRUCTION

5.4.5 Splicing Existing Tendons

This method is used to repair damaged tendons. The main damage occurs
during concrete placing. Furthermore, during tendons repairing is totally required
shoring in adjacent bays in order to prevent collapse. The damaged zone should
be removed to find the broken tendon. Once the tendon has been found, it has to
be stressed and patched.

Installed PT Tendon Splice Chuck Post Tension Slab Tendon Repair.

(Conley M, 2018) (https://schnellcontractors.com)

5.5 Case Study 01: Parking structure in South Florida

To analyze this case study properly, the presenter proposed a few steps
to be followed. They will be described in this case study in South Florida, US.

5.5.1 Preliminary investigation

The presenter suggested taking notes about the whole structure. In this
punctual case study, the structure is a parking garage of five levels. It includes
slab spans of 24’ and post tensioned beam of 16” wide and 36” deep. The vertical
elements are concrete columns of 24” wide and 24” deep.

A visual inspection was enough

to determine what structural issues in
the structure were. There was a
critical cracking in Posttensioned
beams. In this particular case, It was
required shoring the beam on every
level down to the grade level.

Cracking in PT- Beam (01)

(Conley M, 2018)

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 DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED 11
CONCRETE CONSTRUCTION

Cracking in PT- Beam (02) Cracking in PT- Beam (03)

(Conley M, 2018) (Conley M, 2018)

To make sure that was a critical

concrete issue, it was necessary to
use the Ground Penetration Radar.

There was a reverse curvature

into the structure. A repair is required

Local Concrete Removal

(Conley M, 2018)

5.5.2 Repair solutions

In order to solve this problem, there were discussing some ways to repair
it. First, Epoxy Injection into cracks. This option was a temporary solution and it
does not solve the real issue. Another approach was De-stressing the
posttensioned beam and demolishing it. This approach involves a huge budget
that is why it was rejected. The last approach was the Jacketing. As it was
discussed above, this process has esthetic and monetary advantages.

Removing and replacing of Concrete

Jacket Reinforcement
(http://www.diamonddrilling.biz)
(Conley M, 2018)

Julio Saire
 DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED 12
CONCRETE CONSTRUCTION

5.5.3 Repair analysis and design

There presenter suggested an engineering approach to repair the reverse

curvature into this posttensioned beam.

Analyze the beam in a

structural software taking into account
the current stress into the tendon. That
procedure determines forces and
reinforcement required.
Modeling al Structural Analysis
Software(Conley M, 2018)

Shear Design

Design the shear reinforcement

for the jacket assuming the remain
concrete does not contribute with any
resistance.
Shear Diagrams PT Beam
(Conley M, 2018)

Flexural Design

Design the flexural reinforcement

for the jacket assuming that is a
T-beam.
Moment Diagrams PT Beam
(Conley M, 2018)

Conclusion

 Good looking
 Issue repaired
 Increase in the elements dimensions.

Repaired Beam (Conley M, 2018)

Julio Saire
 DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED 13
CONCRETE CONSTRUCTION

5.6 Case Study 02: Parking structure in Central Florida.

To analyze this case study properly, the presenter proposed a few steps
to be followed. They will be described for this case study in Central Florida, US.

5.6.1 Preliminary investigation

The presenter suggested taking notes about the whole structure. In this
punctual case study, the structure is a parking garage of five levels. It includes
slab spans of 18’ and post tensioned beam of 16” wide and 36” deep. The vertical
elements are concrete columns of 36” wide and 24” deep.

Critical cracking was found in

the posttensioned beam. Before
continuing with the analysis, the
presenter determined to put shoring
close to the beam to avoid more
cracking.
Cracking in PT Beam
(Conley M, 2018)

The ground penetrating radar

was used to analyze the reason why
the concrete element was cracking.

Even though this method is

accurate, It did not give a conclusive
result.

Ground Penetrating Radar test

(https://www.gp-radar.com)

Destructive method of analysis

were required to determine the reason
why the concrete element was
craking. Removing a layer of concrete,
the whole bottom of the beam began
crumbling. A concrete consolidation
issue caused beam craking.
Removing Concrete from PT Beam
(Conley M, 2018)

Julio Saire
 DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED 14
CONCRETE CONSTRUCTION

5.6.2 Repair solutions

Once the concrete issue were detected was fundamental to determine the
repair option. The presenter had a variety of good approaches to solve this
problem. First, forming and pumping. This approach was not selected because it
does not correct the real concrete issue. Second, demolishing the existing beam,
and reconstructing a new beam. This solution was so expensive and it took long
time. Finally, by carefully removing poorly consolidated concrete around
Posttensioned tendons and patching the member with a fine aggregate repair
material. That was the approach selected because it requires a short time and it
looks good on the structure.

Demolishing Existing structures Carbon Wrapping Proposal in PT Beam

(http://www.grantmackaydemolition.com) (Conley M, 2018)

5.6.3 Repair analysis and design

The presenter determined a detailed

set of performance requirement to do
the restoration:

 Concrete removal limits

 Repair material requirements
Repair Proposal - Jacketing
 PT sheathing repair requirements (Conley M, 2018)

A restoration contractor developed the

repair details.

Further, the restoration contractor

completed the work via from and
pump. Final surface was painted to
hide the repair. Final Product (PT BEAM)
(Conley M, 2018)

Julio Saire
 DETECTION AND REPAIR OF DEFECTS IN POST-TENSIONED 15
CONCRETE CONSTRUCTION

5.7 REFERENCE

Online Resources

[1] Carbon Wrapping Parking PT Beam (2008). Buildera Inc.,

http://www.buildera.com. Accessed February 2018.
[2] Crack mapping (2009). Cracking Scale,
http://www.concreteconstruction.net. Accessed February 2018.
[3] Concrete Removed from PT Girder (2010). Structural Technologies,
https://www.structuralt.com. Accessed February 2018.
[4] Demolishing Existing structures (2001). Grant Mackay Demolition,
http://www.grantmackaydemolition.com. Accessed February 2018.
[5] Ground Penetrating Radar (2013). Proceq Instrument,
https://www.proceq.com. Accessed February 2018.
[6] Ground Penetrating Radar test (2017). GP radar,
https://www.gp-radar.com. Accessed February 2018.
[7] Hammer Sounding FRP Beam (2015). Research Gate,
https://www.researchgate.net. Accessed February 2018.
[8] Matthew Conley, (2018). Detection And Repair of Defects in Post-Tensioned
Concrete Construction [PowerPoint presentation]. Retrieved from CANVAS.
[9] Post Tension Slab Tendon Repair (2006). Schnell Contractors,
https://schnellcontractors.com. Accessed February 2018.
[10] Prestressed concrete (2003). Daily Civil, http://www.dailycivil.com.
Accessed February 2018.
[11] Removing and replacing of Concrete (2012). Diamond Drilling Inc.,
http://www.diamonddrilling.biz. Accessed February 2018.
[12] Repair Project Documentation (2013). Project Documentation,
https://www.videoblocks.com. Accessed February 2018.

Text Books

[1] ACI 318-14 Building Code Requirements for Structural Concrete (2014).
American Concrete Institute https://www.concrete.org. Accessed
February 2018.
[2] ACI 440.2R Guide for the Design and Construction of Externally Bonded
FRP Systems for Strengthening Concrete Structures (2017). American
Concrete Institute, https://www.concrete.org. Accessed February 2018.

Julio Saire

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