Repair of Reinforced Concrete Structures

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Commonly Encountered Problems

1. Spalling, cracking, water leakage, surface erosion, staining. 2. Water and corrosion related deterioration a improper design and detailing b. cracks c. carbonation d. poor original quality concrete, porous concrete e. lack of maintenance or improper maintenance f. presence of chlorides
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Commonly Encountered Problems

3. Volume changes - creep and shrinkage 4. Structural failure 5. Fire

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Condition Assessment
1. Information Gathering 2. Field Survey 3. Field Tests 4. Laboratory Tests

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Repair Methods & Materia

1. Repair Materials a. portland cement b.polymer modified concrete c. resin mixtures d.substitute materials

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Nomenclature
polymer concrete (PC): formed by polymerizing a mixture of a monomer and aggregate (no other bonding material) latex-modified concrete (LMC): also known as polymer portland cement concrete. Conventional concrete made by replacing part of mixing water with a latex. polymer-impregnated concrete (PIC): produced by impregnating or infiltrating a hardened concrete with a monomer and subsequently polymerizing the monomer in situ.

Significance
Both PC and LMC have been in commercial use since the 1950s; PIC was developed and has been in use since the 1970s. Depending on the materials employed, PC can develop compressive strengths of the order of 140 MPa (20,000 psi) within hours or even minutes and is therefore suitable for emergency concreting jobs in mines, tunnels, and highways.
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Significance -- LMC
LMC possess excellent bonding ability to old concrete, and high durability to aggressive solutions; it has therefore been used mainly for overlays in industrial floors, and for rehabilitation of deteriorated bridge decks.

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Significance -- PIC
In the case of PIC, by effectively sealing the microcracks and capillary pores, it is possible to produce a virtually impermeable product which gives an ultimate strength of the same order as that of PC. PIC has been used for the production of highstrength precast products and for improving the durability of bridge deck surfaces.

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Polymer Concrete
Polymer concrete (PC) is a mixture of aggregates with a polymer as the sole binder. To minimize the amount of the expensive binder, it is very important to achieve the maximum possible dry-packed density of the aggregate.

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Polymer
Commercial products are available with a variety of formulations, some capable of hardening to 105 MPa (15,000 psi) within a few minutes without thermal treatment. Epoxy resins are higher in cost but offer advantages such as adhesion to wet surfaces. Styrene monomer, and methyl methacrylate (MMA) with benzoyl peroxide catalyst and an amine promoter are often used. Products with increased strength have been obtained by adding to the PC monomer system a silane coupling agent, which increases the interfacial bond between the polymer and aggregate.

Properties
The properties of PC are largely dependent on the amount and properties of polymer in the concrete. PC made with MMA is a brittle material that shows a nearly linear stress-strain relationship with high ultimate strength, but the addition of butyl acrylate produces a more ductile material

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Stress-Strain Diagram

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Properties
Due to good chemical resistance and high initial strength and modulus of elasticity, industrial use of PC has been mainly in overlays and repair jobs. Thermal and creep characteristics of the material are usually not favorable for structural applications of PC. Polyester concretes are viscoelastic and will fail under a sustained compressive loading at stress levels greater than 50 percent of the ultimate strength. Sustained loadings at a stress level of 25 percent did not reduce ultimate strength capacity for a loading period of 1000 hr.
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Latex-Modified Concrete
The materials and the production technology for concrete in LMC are the same as those used in normal portland cement concrete except that latex, which is a colloidal suspension of polymer in water, is used as an admixture.

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Latex-Modified Concrete
Earlier latexes were based on polyvinyl acetate or polyvinylidene chloride, but these are seldom used now because of the risk of corrosion of steel in concrete in the latter case, and low wet strengths in the former. Elastomeric or rubberlike polymers based on styrenebutadiene and polyacrylate copolymers are more commonly used now.

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Latex
A latex generally contains about 50 % by weight of spherical and very small (0.01 to 1 m in diameter) polymer particles held in suspension in water by surface-active agents. The presence of surface-active agents in the latex tends to incorporate large amounts of entrained air in concrete; therefore, air detraining agents are usually added to commercial latexes.
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Latex
10 to 25 percent polymer (solid basis) by weight of cement is used in typical LMC formulations, the addition of latex provides a large quantity of the needed mixing water in concrete. The application of LMC is limited to overlays where durability to severe environmental conditions is of primary concern. LMC is made with as low an addition of extra mixing water as possible; the spherical polymer molecules and the entrained air associated with the latex usually provide excellent workability.
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Concrete Mix
Typically, water-cement ratios are in the range 0.40 to 0.45, and cement contents are on the order of 650 to 700 lb/yd3 (390 to 420 kg/m3).

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Curing
The hardening of a latex takes place by drying or loss of water. Dry curing is mandatory for LMC; the material cured in air is believed to form a continuous and coherent polymer film which coats the cement hydration products, aggregate particles, and even the capillary pores.

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Properties
The most impressive characteristics of LMC are its ability to bond strongly with old concrete, and to resist the entry of water and aggressive solutions. It is believed that the polymer film lining the capillary pores and microcracks does an excellent job in impeding the fluid flow in LMC. These characteristics have made the LMC a popular material for rehabilitation of deteriorated floors, pavements, and bridge decks.

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Polymer-Impregnated Concrete
The concept underlying PIC is that if voids are responsible for low strength as well as poor durability of concrete in severe environments, then eliminating them by filling with a polymer should improve the characteristics of the material.

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Polymer-Impregnated Concrete
It is difficult for a liquid to penetrate it if the viscosity of the liquid is high and the voids in concrete are not empty (they contain water and air). Therefore, for producing PIC, it is essential not only to select a low-viscosity liquid for penetration but also to dry and evacuate the concrete before subjecting it to the penetration process.

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Polymer-Impregnated Concrete
Monomers such as methyl methacrylate (MMA) and styrene are commonly used for penetration because of relatively low viscosity, high boiling point (less loss due to volatilization), and low cost.

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Polymer-Impregnated Concrete
After penetration, the monomer has to be polymerized in situ. This can be accomplished in one of three ways. A combination of promoter chemical and catalysts can be used for room-temperature polymerization; but it is not favored because the process is slow and less controllable. Gamma radiation can also induce polymerization at room temperature, but the health hazard associated with it discourages the wide acceptance of this process in filed practice. The third method, which is generally employed, consists of using a monomer-catalyst mixture for penetration, and subsequently polymerizing the monomer by heating the concrete to 70 C with steam, hot water, or infrared heaters.
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Sequence of operation
Casting conventional concrete elements: Since the quality of concrete before penetration is not important from the standpoint of properties of the end product, no special care is needed in the selection of materials and proportioning of concrete mixtures. Section thickness is generally limited to a maximum of about 150 mm, since it is difficult to fully penetrate thick sections.
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Sequence of operation
Curing the elements Following the removal of elements from forms, at ambient temperatures conventional moist curing for 28 days or even 7 days is adequate because the ultimate properties of PIC do not depend on the penetration concrete quality. For fast production schedules, thermal curing techniques may be adopted.
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Sequence of operation
Drying and evacuation: The time and temperature needed for removal of free water from the capillary pores of moist-cured products depend on the thickness of the elements. At the drying temperatures ordinarily used (i.e., 105 C), it may require 3 to 7 days before free water has been completely removed from a 150- by 300-mm concrete cylinder. Temperatures on the order of 150 C can accelerate the drying process so that it is complete in 1 to 2 days.
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Sequence of operation
Soaking the dried concrete in a monomer The in situ penetration of concrete in the field may be achieved by surface ponding, but precast elements are directly immersed in the monomer-catalyst mixture. Commercial monomers contain inhibitors that prevent premature polymerization during storage; the catalyst serves to overcome the effect of the inhibitor.
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Sequence of operation
Sealing the monomer To prevent loss of monomer by evaporation during handling and polymerization, the impregnated elements must be effectively sealed in steel containers or several layers of aluminum foil; in the rehabilitation of bridge decks this has been achieved by covering the surface with sand.
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Sequence of operation
Polymerizing the monomer Thermal-catalytical polymerization is the preferred technique. The time for complete polymerization of the monomer in the sealed elements exposed to steam, hot water or air, or infrared heat at 70 to C may vary from a few to several hours. In the case of a MMA-benzoyl peroxide mixture, no differences in strength were found between specimens polymerized at C with hot air for 16 hr or with hot water for 4 hr.
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Recommendations for Improved Durability

1. Increase concrete cover 2. Better quality assurance during construction (including curing) 3. Better concrete quality (low w/c ratio) 4. Epoxy coated bar (controversial) 5. Sealing and painting 6. Maintenance

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Repair Materials and Methods

Goals: Strength of repair work should be, at least, as much as the old concrete. Bond between old and new concrete should be very good.

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Parameters Affecting the Repair

1) Permeability The subbase can be wet leading to a significant amount of moisture below the repair. The moisture will evaporate and it will develop vapor pressure; therefore overlays should be able to breath. If the permeability is too low the repair will delaminate. Portland cement concrete is able to breath. Epoxies and polyesters are not able to breadth causing delamination.
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Parameters Affecting the Repair

2) Drying Shrinkage If the same mix is used the concrete will shrink and crack, losing the bond. This causes the development of microcracks at the interfacial bond producing delamination.

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Parameters Affecting the Repair

3) Coefficient of Thermal Expansion () quartz sand has a high a value. differences in a between old and new concrete will cause differential strains. use a as close as possible to the old concrete. 4) Elastic Modulus
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

General Considerations fo Repair

1) How thick is the repair section? Thin layer --> may not need form --> shotcrete Extensive deterioration --> have to remove old concrete, e.g., corroded bars. 2) Substrate moist/dry? 3) Temperature very low --> cement will hydrate slowly very high --> cement will hydrate fast
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

General Considerations fo Repair

4) Ventilation In closed rooms do not use urethane and MMA (toxic) 5) Vertical x Horizontal Surface 6) Traffic Conditions Critical traffic conditions epoxies set in 5 min.; in 1/2 h it develops fc = 10,000 psi
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

General Considerations fo Repair

7) Appearance

8) Durability of the repair

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Construction Techniques
a) Cast in place formwork section thickness: 6-8 in remove old concrete --> clean --> use water jets (sand blast is not as used because of pollution)

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Construction Techniques
b) Shotcrete for thin repair c) Tremie underwater repair --> large operations d) Pumping slurry cement paste e) dry packing mix sand and cement --> compact --> wet --> hydration little drying shrinkage ( due to particle contact) f) crack injection MMA --> good sealer --> thin fluids

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Shotcrete Rehabilitation

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

DRY-MIX SHOTCRETE PROCESS

Cementitious binder and aggregates thoroughly mixed (central mixing, transit mixer, volumetric proportioning mixer or dry bagged premix) Water Added if necessary to bring shotcrete to Earth Dry consistency 3 to 6% moisture content. Mix added to shotcrete delivery equipment or gun.
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

DRY-MIX SHOTCRETE PROCESS

Compressed air conveys the shotcrete from the gun down the hose. Water introduced under pressure through a water ring at the nozzle. Shotcrete jetted from a nozzle at high speed onto a surface with the force of the impacting jet compacting the material.

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Wet-Mix Shotcrete Proces

All ingredients including mixing water thoroughly mixed. The mortar or concrete is added to the chamber of the delivery equipment. The mix is either pumped or pneumatically conveyed down the hose by compressed air. High-pressure air is added at the nozzle to jet the shotcrete at high velocity onto the impacting surface.
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Comparison of Wet and Dry Mix Shotcretes

Wet Mix Shotcrete Advantages Less Rebound Less Dust Less Nozzleman Skill Required Air Entrainment Possible Large Volume Rates of Placement Possible Lower Cost Ready Mix Supply Often Possible
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Wet Mix Shotcrete

Disadvantages Generally Lower Compressive Strengths (unless silica fume and superplasticizers used) Cannot Adjust Moisture Content at Nozzle when Shooting Wet Areas Restricted to Layers 2 to 3 inches thick in a single pass Not suitable for small volume, intermittent work
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Dry Mix Shotcrete

Advantages Generally Higher Compressive Strengths Nozzleman Can Adjust Water For Better Adherence in Wet Substrate Conditions Available in Premixed Dry Bags Form for StopStart Type Work Air Entrainment Possible Greater Thickness of Application Possible on Vertical and Overhead Surfaces
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

Dry Mix Shotcrete

Disadvantages Higher Rebound More Dust Larger Air Compressor Required High Level of Nozzleman Skill Required Potential for Laminations, sand lenses, dry pockets, etc. Difficult to entrain air Lower volume rates of placement
CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction

CE CE 165: 165: Concrete Concrete Materials Materials and and Concrete Concrete Construction Construction