INSPECTION,

PREVENTIVE

MAINTENANCE

AND

REPAIRS

OF

EXISTING

STRUCTURAL CONCRETE STRUCTURES THE serial life and safety of reinforced concrete structures has been guaranteed through timely maintenance measures since preventing concrete structures deterioration is much easier and more economical than repairing. Generally the maintenance system expected to start from the initial prevention steps which entails; Selection of proper materials. Mixture proportions. Placement. Curing. Sound construction procedures.

If additional protection against deterioration is required, the need should be recognized and be provided for during design of the structure. However, all potential hazards to the structure cannot always be predicted, and some well engineered techniques and procedures may prove unsuccessful. Thus, there is generally a need for follow up maintenance action. These actions follow certain criteria; Preventive and maintenance procedure i. ii. Condition survey and evaluation. Choice of maintenance and preventive and or repair implementation required.

Condition survey and evaluation Involves: Checking the condition of the structure both visually and mechanically. History of the structure is first evaluated from the design data and construction time and method.

Onsite condition survey will usually include a mapping of the various types of concrete deficiencies that maybe found. Cracks are usually mapped on fold-out sketches of the monolith surfaces. The mapping must include inspection and delineating of pipe and elastic galleries e.t.c additionally the condition survey will frequently include core drilling to obtain specimens for laboratory testing and analysis. Onsite mechanical testing of some properties of the concrete structure is also carried out using non-destructive methods. Generally, during evaluation the following details are taken into account;

Strength of the concrete (for non-destructive methods) Surface disorders on the concrete structures (e.g. spalling, flacking, staining) Reinforcement disorders (e.g. rusting, exposure) Structural distortions (e.g. excessive deflection and cracking ) Current circumstances (external environmental exposure conditions and usage of the structure)

Photography of the affected areas of the concrete structure Analysis chosen for residual capacity of the structure.

Based on the condition of the structure from the onsite evaluation, its category can then be decided upon. The evaluation categories are based on the degree deterioration of the evaluated structure, load carrying capacity and level of maintenance required. The categories are; 1. Good 2. Fair 3. Poor EVALUATION OF THE STRENGTH OF THE CONCRETE STRUCTURES i. Measurements

Insitu concrete strength on site is carries out using rebound hammer method. The Schmidt hammer provides an inexpensive, simple and quick method of obtaining an indication of concrete strength. This is usually followed by mechanical characterization of the concrete on the extracted samples from the structures.

Other methods

Dynamic tests (ultra-sonic pulse velocity) methods are used but not commonly now used in Kenya. In detailed survey core samples taken from the designated parts of the concrete structures are evaluated to further establish their quality and deterioration extent. Under detailed survey; Material deterioration properties such as carbonated thickness, chloride content as well as core compression strength are measured from the core test specimen (cylinder with a diameter of 100mm and a height of 200mm). In addition, the particle size distribution is measured from broken core specimens to determine the materials ingredients. This assists in strengthening the identity of the causes of the deterioration as well as in making repair materials. In structures such as reinforced concrete bridges, an initial assessment of the carrying capacity of the bridge is done in order to determine the vehicle load, the carrying capacity as corporeal to the original design capacity. This allows the bridge designer to produce a more realistic evaluation since in the detailed stage (evaluation of actual failures, strengths, e.t.c), the causes of failure in the structure would be clearly defined either as due to overloading beyond the design capacity or as a result of log-term effects such as fatigue, environmental influence, design shortcomings or age. ii. Analysis checks.

In some cases, the structural integrity of the concrete structure is establishes through detailed structural analysis to evaluate its load carrying capacity and the current behavior of its structural

members in the current condition. The latter allows for the determination of the effect which is critical e.g. shear, flexure, excess deflection and cracking. From detailed site inspection, actual structural dimensions, dead loads, live loads and material properties can be obtained correctly as it is and used in the structural analysis. Mostly the analysis is carried out based on simplified methods commonly applied.

Evaluation of concrete surface and reinforcement disorders Survey of cracking patterns (extension, length and depth); conditions of the concrete (deterioration, rebar covers); conditions of the steel bars (corrosion) are surveyed and documented. Commonly visible features include cracks, carbonations/effects, rebar cover loss, spalling. This stage allows for identification of critically affected points in the structural concrete elements as well as allow for identification of areas in which sampling for a detailed mechanical and chemical tests can be carried out in the laboratory. Choice for the maintenance type The choice of the maintenance type depends on the category and type of the deterioration. Category one implies that the structure requires minor or no maintenance at all. Most of the structures that do require maintenance interactive measures normally fall within category two. Those with serious structural shortcomings will fair in category one whereas more than often complete demolition maybe recommended. category Bad/poor condition action Major structural cracks (more than 3mm Demolition of the structure and in thickness) cutting through the primary or structural strengthening e.g. system. Severe distortion or movement (deflections, buckling, faulting, settling, tilting) of the concrete structure. Breakage or major loss of cross-sectional area or more than 50% of the rebars due to retrofitting.

corrosion or otherwise. Overall integrity of the concrete structure being very poor (load carrying capacity Fair compromised). Normal cracking (crazing, random, Crack sealing, replacement of where necessary streng thening to improve service life. Check on reinforcement status and replacement if necessary

traverse, e.t.c) disintegration (spalling, corroded rebars, overlaying and weathering, dusting, e.t.c) Spalling/poports Minimal corrosion and exposure of rebars. Erosion (cavitations, abrasion). honeycombing). Good Seepage through concrete structure. Water services leakage into concrete. e.t.c.) Repair of pipes and other water Application of water proof

Construction faults (bug holes, cold joints, crack sealing and overlaying.

Staining (by carbonation, efflorescent, conduits . materials, painting, cleaning.

MAINTENANCE IMPLEMENTATION The assessment process ultimately leads to conclusion of the adequacy of a certain structure in fulfilling its required trend of performance. If the structure has adequate capacity and its condition does not indicate any need for remedial work, then the structure can be put back into service. If on the other hand it is concluded that the structure is substandard, then remedial maintenance measures are taken. The remedial measures to curb the deteriorating effect on the reinforced concrete structure are carried out based on the evaluation report recommendations. The basis of maintenance implementation would be within the following criterion; Repair and strengthening (major maintenance). Cleaning and protection (minor maintenance). Apply restrictions (applicable to bridges)

Repairs and strengthening There are many repair materials and techniques that are applied in reinforced concrete maintenance/repairs to provide strong and durable rehabilitation. These include;
1. Replacement of deteriorated portion of the concrete structure by overlaying, replacement of

rebars or use cathodic protection and corrosion inhibitive and surface protection. The primary type of maintenance for reinforced concrete structures is the repair of cracks and spalls, replacement of corroded rebars, cleaning of concrete to remove unsightly material, surface protection, and joint restoration. Concrete structures such as floors, beams, columns that have deteriorated are repaired by using cement based materials such as concrete which are less expensive and those readily available in Kenya. Prior to applications of these cementitious materials overlays, the surfaces are prepared by mechanical means. In some instances where the reinforcements have been exposed and severely corroded, the affected part is removed and new reinforcements applied before covering. Crack sealants such as epoxy are used to bond cracked concrete where the severity is not much and when movement is determined to not be taking place. Nonstructural sealants such as urethane is sometimes utilized in waterproofing cracks, filling voids, stabilization in concrete water structures such as dams and water tanks. 2. Specific concrete repair materials. The concrete surface is first prepared by limited grinding (in case of

unevenness/mechanical cleaning), removal of severe block cracks, cleaning and cements mortar. Depending on the severity of the deterioration, Portland cement mortar, dry pack mortar (combination of Portland cement and sand and using number 16 sieves mixed with just enough water to hydrate the cement) or concrete filling are used.

3. Concrete filling. This is the most commonly applied method given that most repairs involve major reinforced concrete deteriorations. Concrete filling is carried mostly in areas in which the repair holes cut through or extend beyond the reinforcement bars. Replacement concrete repairs are made by bonding raw concrete to the repair areas without the use of a bonding agent or Portland cement grout. The combination of a deep repair and good curing practices ensure adequate hydration water will remain at the bonding surface zones for at least 28 days, allowing the cement hydration process to develop to good bond. Because the defective concrete is being replaced with high quality concrete very similar to the surrounding concrete (mix proportions having being determined during the evaluation stage), the repair is compatible in thermal expansion and other physical and chemical properties with the old concrete. For this reason, in many cases, the best repair material is the use of replacement concrete only when an unusual increase in durability is needed or when placing conditions and dimensions dictate otherwise, should other materials be considered. 4. Portland cement and dry place mortar. Portland cement mortar is used for repairing defects on surfaces not prominently exposed where the defects are too wide for dry-pack filling or where the defects are too shallow for concrete filling and no deeper than the far side of the reinforcement which is nearest the surface. Dry pack is used for filling holes having a depth equal to, or greater than, the least surface dimension of the repair area generally small dimension holes such as those left by bolt anchorages. Application of the repair material is made either by use of short crate or by hand application methods, although hand application methods are generally recommended for areas subject to public view in historic preservation applications. Replacement mortar is at times used to make shallow, small size repairs to new or green

concrete, provided that the repairs are performed within 24 hours of removing the concrete forms. In certain structures, accomplishing successful mortar repairs to old concrete without the use of a bonding resin is unlikely or extremely difficult. Evaporation loss of water from the surface of the repair mortar, combined with capillary water loss to the old concrete, results in unhydrated or poorly hydrated cement in the mortar. Additionally, repair mortar bond strength development proceeds at a slower rate than compressive strength development. For these reasons mortar is used jointly with a resin bond coat (such as epoxy) to repair old concrete structures. Cleaning and protection
a) Cleaning.

Stains seldom affect the service life of a structure, although they are often unsightly, especially on architectural concrete finishes. Some of the most common stains are iron rust, oil, grease, dirt, efflorescence, rot and graffiti. Stains often penetrate the exposed surface because concrete is porous and absorbent. Therefore, stains are normally removed as soon as possible to prevent deeper migration into the concrete. Also, stains tend to bind more tightly to the concrete with time, and some undergo chemical changes that makes removal more difficult, hence certain measures are applied in order to remove them;

Identification and removal; the first step in the removal process is the identification of the stain and the selection of a cleaning agent and method accordingly.

Stains removal; stains are removed with several methods including brushing and washing, steam cleaning, water blasting, abrasion, flame cleaning, mechanical cleaning and chemical cleaning. However, costs and after effects on the concrete are considered in order to make a choice of an optimum removal method. Therefore advantages and limitations of each potential method are considered in making a final selection.

Water washing; a fine mist spray is normally applied on the stained surface since excessive water pressure can drive the stain further into the concrete. The can also be used in conjunction with the following in the order listed; i. A soft brush.

ii. iii.
iv. v.

A mild soap. A stronger soap. Ammonia. Vinegar.

Flame cleaning; is used to remove organic materials that do not respond to solvent. However, this method usually causes scaling of the concrete surface and at times produces objectionable fumes.

Mechanical cleaning; power tools (grinders, buffers, chisels, brushes) are at times used in improving damaged thin sections or remove more concrete than is desirable. Chiseling or grinding can give an effective cleaning provided a rough and or uneven surface is acceptable.

Chemical cleaning; organic solvents are also used with little dilution. Inorganic solvents such as ammonium hydroxide, sodium hypochlorite, and hydrogen peroxide are available in ready-mixed solutions. Other organic solvents are available in solid form and are mixed with water according to manufacturers directions.

b) Protection.

Surface coating and sealing compounds are applied on concrete structures for protection against chemical attack of surfaces by acids, alkalis, salt solutions or a wide variety of organic chemicals. Coatings and sealants may also be used to reduce the amount of water penetration into concrete as well as a decorative system for concrete. Before a protective coating or sealant is used on concrete it is first established if the concrete actually needs protection. The cause and extent of the deterioration, the rate of attack, the condition of the concrete and environmental factors having being established normally during the condition survey stage, the selection of a coating or sealant is nade deoending on these circumstances. For example, application of an impermeable coating or overlay may, under certain conditions, trap moisture within the concrete, thereby doing more harm than good. Before application of these protections, proper concrete surface preparation is made for successful application of a coating.

The concrete surface is made sound, clean and dry before the coating is applied. Surface contaminants such as oils, dirt, curing compounds, and efflorescence must be removed. It is required that the materials use to repair substrata surface defects before application of coats should be compatible with the coating to be used. To avoid poor performance of the protection material, latex modified mortar cannot be used in cases where the coating to be used is solvent based. While highly filled epoxy resins are used with the surface having been slightly abraded before it is applied.
c) Apply restrictions (apply to bridge restrictions).

In situations where the structure, such as a bridge, is to be kept in service while rehabilitation is undertaken albeit in stages, the traffic capacity restrictions is implemented. This may occur in cases where the cost implication of traffic detours and complete overhaul of the structure may lead higher costs. Limitation of the traffic by use of barriers to reduce the lanes reduces the load on the bridge and hence minimizes further deteriorations.