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The Precast Show

CP1 – PRECAST CONCRETE REPAIR


Objective
• Repair is the process of treating an imperfection in the concrete so that
the product’s service life will not be impacted
CP1 – Precast Concrete Repair: • Repair requires 2 elements:
– Skill: The art of making the repair
Material and Procedure Selection – Knowledge: Knowing how to do it right
• Our goal is to educate those that perform or manage the repair process
of precast products
Todd Spindler, Sika Corporation – Identify repair problems
– Determine the root cause for corrective action
– Determine the repair process based on the type of repair needed
– Establish the repair procedure
– Address approval process by QC, governing agency, and/or specifying
authority
– Deliver quality product to the customer
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CP1 – PRECAST CONCRETE REPAIR


Agenda
• Determine repair strategy
– Service conditions
– Structural vs. Non Structural (cosmetic) repairs
• Repair Methods
– Material selection
– Application conditions
– Surface preparation
– Material placement
– Equipment
• Focus on precast production
– In plant, erection
– WRT causes, applications, and methods
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Root Cause Analysis Root Cause Analysis
• Take a picture to use with your repair analysis • Analyze costs
• Define what the problem is and why (if known) • Wasted profits
• Determine when the damage was caused – $18 - $45 for bag of repair material
– Production issue? – Multiplication factor to apply
– Handling? – $80 per bag at 10 bags a week = $800 wk., $40,000 yr.
• Develop a metric to measure repair costs
– What doesn’t get measured doesn’t improve
– Bag of repair material per day/week/month
– Bag of repair material per yard of concrete poured
– etc.

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NPCA 1
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Root Cause Analysis Root Cause Analysis
Corners are spalling or cracking Corners are spalling or cracking
• Is it caused by improper handling with impacts on the edges? • Do you need reinforcement?
• Does the form bind up when stripping? Is there an • Form joints tight?
indentation in the form? • Form coating – sticky leaves concrete build-up
• Is concrete bleeding in to the form joints? • Costs money to clean forms and repair products
• Is the form coating providing sufficient release? Damaged concrete around chamfer area
• Improper vibration?
• Did the forms yield while the concrete was in the plastic
state?

Handling issues – you can control


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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Root Cause Analysis Root Cause Analysis
Honey combing or voids Determine what needs to change to …
• Vibration inadequate? … Prevent this problem from occurring again
• Concrete not placed properly?
• Steel shifted or not in proper location? • Decide on corrective actions based on where the problem
• Concrete mix design too stiff? occurred.
• Concrete flash set creating placement problem? • Is it a production issue, handling, or design problem?
• Delayed placement of concrete? • Should your QC procedures be revised to address these
• Design issue with too much reinforcement congestion? problems?

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Service Requirements Service Requirements
• Service requirements to consider for determining the type of
repair and product Special Finishes:

• Exposed surfaces
– Specified coatings
that require small
bug holes to be filled

LOADS

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Service Requirements Non Structural vs. Structural Repair
Special Finishes:
• Determine requirements Surface Defects Structural Defects
based on type of • Bug holes • Deep spalling
construction • Scaling • Exposed reinforcement
– Form finish • Voids • Rock pockets
– Architectural • Honey combs • Cracking
– Surface details, colors, or • Surface spalls – Transverse
textures must be • Surface cracks – Full depth
consistent
• Architectural repairs • Under strength
• The CHALLENGE is to repair
• Capacity impaired
without making the repair
obvious

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Definition Surface Defects

• Affects the concrete’s performance


• Voids • Honey Comb ( Surface)
– Loads
– Protection and connection to reinforcement (significantly
exposed)
• Repair area engages live or dead loads
– Including lifting points
• Loss of structure cross section
• Weakening of constituent materials
• Necessary to reestablish structural capacity
– Determined by structural engineer
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CP1 – PRECAST CONCRETE REPAIR


Surface Defects

• Bug Holes • Surface Spalling

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Surface Defects Structural vs. Non Structural Repairs

• Surface Cracks • Scaling • Similar substrates and material components


– Plastic Shrinkage • Increased service requirements
– Loads
– Exposure
– Environmental conditions
– Wet / dry cycles
– Freeze thaw
– Water
– Chlorides
– Corrosion
• Require different methods and materials
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Defects Structural Defects

• Transverse Cracks • Major Spalling


• Rock Pockets (no binder)
– Exposed reinforcement

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SPALLS SPALLS
Examples, Root Cause analysis Examples, Root Cause analysis

• Detail • Detail

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NPCA 4
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CP1 – PRECAST CONCRETE REPAIR CRACKS


Structural Defects Examples, Root Cause Analysis

• Product • Detail
handling
and storage

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CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs
Identify structural spall:
• Load bearing
• Transfers load
• Exposed steel reinforcement
• Deep / full depth
• Significant stresses are likely to develop in or immediately
around the patch material due to service loads

Determine service conditions:


• Mild: Interior
• Moderate: Wet / dry cycles
• Severe: Freeze thaw, water, chlorides
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Defects Structural Spall Repairs
Causes Overview
• Poor form construction • Select orientation
• Difficult / rough removal from forms – Horizontal, vertical, overhead
• Early removal, low strengths • Select application method
• Structure design – Hand applied, form & pour, form & pump,
– Concrete mix – low pressure spray, high pressure shotcrete
– Reinforcement • Select appropriate repair mortar
• Thermal shock (forms, environment) – Cementitious, polymer modified, silica fume enhanced,
fiber reinforced, air entrained, corrosion inhibitor
• Poor handling methods enhanced, accelerated or non-accelerated
• Improper storage
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Material Properties Structural Spall Repairs – Material Properties
• Strength (compressive, flexural, tensile, bond)
• Modulus of elasticity • Select repair material to best match / meet host
• Coefficient of thermal expansion concrete properties
• Permeability • Why not use original concrete?
– Thickness (aggregates)
• Freeze/thaw resistance
– Set time
• Shrinkage – Bond
• Thickness – Orientation
• Set/cure time • What’s the big deal about M.O.E.?
• Application method
• Color
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – MOE Structural Spall Repairs – MOE
• Generally, match MOE for similar performance
Modulus of Elasticity is important: – Lower MOE attracts less of the load
• The concrete and the repair material
– Higher MOE absorbs more of the load
must react similarly to loads
– When an external load • Compared to host concrete, faster setting, higher strength
(compressive or tensile) is applied repair materials (for application convenience) are off set by a
parallel to the bond line, low lowered MOE (polymers) and greater bond strengths (load
modulus materials deform more transfer) to closely match substrate concrete performance
than the high modulus materials
• Material selection process is one of informed compromises
– Loads will be transferred from low
modulus materials to high modulus
materials
– Stress concentration may cause
failure of the high modulus
materials

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SPALLS CP1 – PRECAST CONCRETE REPAIR


Material Selection Structural Spall Repairs

• Detail Material Selection


• Cement based
• Cement based with mineral additives
• Polymer-modified
Polymer-modified cement
cement based
based
• Epoxy modified, cement-based
• Epoxy mortar

• Color is generally not a determining factor for


structural repair material selection
• Sometimes worth consideration
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NPCA 6
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Material Selection Structural Spall Repairs – Material Selection

Cement Based Cement Based with Mineral Additives


Advantages Limitations Advantages Limitations
• Compatible with concrete • Critical water:cement ratio • Improved adhesion • Workability problems
• Economical • Shrinkage, curing • High strengths • Finishing (sticky)
• Mix with water, easy • Slow reactions • Low permeability • Curing is critical
cleanup • Low tensile, flexural, bond • Abrasion, impact • Mixing is critical
• Resist high temperatures strengths resistance • Higher cost
• Surface preparation • Improved durability

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Material Selection Structural Spall Repairs – Material Selection

Epoxy Modified Cement Based Epoxy Mortar


Advantages Limitations Advantages Limitations
• Excellent adhesion • Three components • Impervious to moisture • Mixing is critical
• Adhesion on damp (typically) and de-icing salts • Vapor barrier
concrete • Ratios are critical • High abrasion, skid • Thermally incompatible
• Very low permeability • Must not freeze resistance • Creep
• Corrosion protection • Finishing difficulties • Minimal added dead • Higher cost
• Chemical resistance • Higher cost weight
• Solvents needed for
• Rapid turnaround - open to cleanup
traffic in 4 - 6 hours

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Material Selection Structural Spall Repairs – Material Selection

Polymer Modified Cement Based Polymer Modified Cement Based


Advantages Limitations
• Adhesion • Proper latex
• The use of a water-dispersed polymer as a secondary
adhesive in Portland cement concrete or mortar
• Low permeability • Application time
• Increased flexural • 45°F (vs. 40°F)and rising • 1 or 2 component
strengths • Preconditioned material – Liquid polymer added
• Increased abrasion • Finishing – Powdered polymer included
resistance • Moderate cost
• Lower modulus
Best mix of properties, speed, and
economy for STRUCTURAL REPAIRS
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Material Selection Structural Spall Repairs – Application

With or without a corrosion inhibitor? • Horizontal, Vertical, Overhead


• Owners goal • Hand Applied
• Owners budget • Form and Pour
• Physical condition of structure • Form and Pump
• Sensitivity to loss of use • Machine Applied
• Ease of installation
• Durability
• Ease of maintenance

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs Structural Spall Repairs – Surface Preparation
Application
• Remove unsound concrete Two key ingredients of
• Surface preparation for repair material a successful repair job:
• Expose and clean reinforcement
• Prime reinforcement and substrate with an anti-corrosion • 5% Material
coating or bonding agent
• 95% Surface Prep
• Place repair mortar and cure
• Mitigate active corrosion with inhibitor
• Protect from future chlorides, carbonation and freeze-thaw
cycles
• Monitor overall corrosion activity

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Surface Preparation Structural Spall Repairs – Surface Preparation

• Detailed technical guidelines • Geometry: “square”


• ICRI - International Concrete • Perimeter: saw cut edges
Repair Institute
• www.icri.org
• Depth: uniform
• Industry standards • Profile: fractured aggregate
• Useful guides include • Reinforcement: clean and accessible
– Guide # 310.2 (03732) -Surface • SSD: saturated surface dry
Prep Methods
– Guide # 310.1R (03730) -
Geometry-Rebar

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Removal Geometry Structural Spall Repairs – Removal Geometry

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Surface Profile Structural Spall Repairs – Reinforcement

• Open Pore • Remove concrete around


– Clean corroded reinforcement
– Sound • Perimeter should be cut 90
– Typical for coatings degrees to surface
• Remove concrete a minimum of
• Fractured-Aggregate ¾” underneath reinforcement
– Stone breaks before it pops out • Steel should be brushed to white
– Typical for spall repair finish to remove any corrosion
• Rebar coatings

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – SSD Structural Spall Repairs - Tools

For cementitious repairs:


• Saturated Surface Dry
• Moisture drive
• Prevents drying at glue
line
• Less than 4%
• Frost awareness

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs - Tools Structural Spall Repairs - Tools
Tools
• Proper trowels

X X X –


Mag floats for placing polymer mortars
Wood or sponge floats
May steel trowel after set

X
– Blisters!
• Mixing

X
– “WC” ratio
– Shear paddle
– Mix time
– Pot life
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CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs - Mixing
• ALWAYS consult manufacturer data sheets
• Specialty materials have specialty
requirements (for special results!)
• Mix mechanically with low speed drill
(400-600 rpm) and mixing paddle or
mortar mixer if allowed
• Start mixing by adding most of liquid (3/4
– 7/8) to a clean pail
• Add powder slowly, ensuring all powder
wets out
• Adjust liquid dosage if necessary to
achieve desired consistency
• Mix to uniform consistency, generally 3
minutes per manufacturer

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Bonding Agents Structural Spall Repairs – Bonding Agents
Are bonding agents absolutely required Recommended for:
• Not necessarily – Low slump mixes
– Vibration may be used when feasible – No slump mixes
– Pumping into forms under pressure Acceptable bonding agents
– Machine application particularly at high pressure
• Polymer liquids
• Why use a bonding agent? – Not all polymers equal, generic term
– Increases opportunity to succeed, especially for hand-applied projects – Basic performance
– Helps ensures consistent, well bonded repairs • Proper scrubcoat
– Material forced into pore structure – SSD substrate, no dilution
– Increase total bonded surface area and mechanical interlock • Epoxies
– Serves as a ‘primer’ to prepare the substrate to receive the topping – Wet on wet
– Protect reinforcement
• Epoxy cements
• Not insurance – Extended open times
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NPCA 10
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Scrub Coat Structural Spall Repairs – Vertical Overhead

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Vertical Overhead Structural Spall Repairs – Vertical Overhead

• Substrate should be SSD • Force material against edge • After filling repair, consolidate and • For multiple lifts, score top surface
before application begins of repair area working to the screed on each lift to produce a roughed
• Finish with steel, magnesium, substarte for the next lift.
• Mixed material should be center and compacting
wood, plastic floats, or damp • If previous layers are more than 6
scrubbed into substrate, around exposed sponges depending on desired hrs old, mechanically prepare
filling all pores and voids reinforcement surface texture

Learning points: overfilling, shaving, bellying, blistering


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CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Vertical Overhead

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NPCA 11
The Precast Show

CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Vertical Overhead Structural Spall Repairs – Vertical Overhead

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Vertical Overhead Structural Spall Repairs – Vertical Overhead

Learning points: proper surface preparation


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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Vertical Overhead Structural Spall Repairs – Vertical Overhead

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NPCA 12
The Precast Show

CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Form and Pour Structural Spall Repairs – Form and Pour

• For horizontal and vertical applications


• Material chosen should be low shrinkage and
provide sufficient flow
• Ensure depth appropriate for material
• Extend with SSD aggregate as allowed
• Vibrators can be used to coax material into hard to
fill areas
• Rodding material from access points aids in
consolidation

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• Concrete or repair material?


• Why?

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CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Form and Pour

• Scrub coat
• Pour in to wet
• Screed to level

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Curing Structural Spall Repairs – Summary

• Accelerated materials • Surface Preparation


mean accelerated need
for curing!
• Clean Concrete
• Cure with as much • Saturated Surface Dry Condition
diligence as you would • Scrub coat / bonding agent
your own pieces!
• Aggregate used for extension- saturated
• Wet, burlap, poly,
compounds • Temperature limitations
• Complete coverage • Curing
• Consistent curing

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Spall Repairs – Summary Structural Cracks

Things to avoid:
• Feather edges
• Abrupt changes in width or depth
• High length/width ratio
• Undercutting
• Poor surface
• Temperature extremes
• Over finishing

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The Precast Show

CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural or Non Structural Structural Cracks – Static or Dynamic

Will we: • Non-moving cracks


• Improve appearance of the concrete surface – Repair with epoxy resin adhesive
– Gravity feed or epoxy injection
• Provide watertightness
– Used for static cracks
• Restore or increase strength – Can repair horizontal, vertical and overhead cracks
• Restore or increase stiffness – If substrate is dynamic, crack will reopen or translate
• Improve functional performance elsewhere in the member
• Improve durability • Moving cracks
• Prevent development of a corrosive environment at – Repair by routing and filling with flexible sealant
reinforcement
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CRACKS CRACKS
Examples, Root Cause Analysis Examples, Root Cause Analysis

• Detail • Detail

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CRACKS CRACKS
Examples, Root Cause Analysis Examples, Root Cause Analysis

• Detail • Detail

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The Precast Show

CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Causes Structural Cracks – Causes

Concrete cracking problems Cracking due to loading


• Cracking due to loading • Early release, low strengths
• Overstressing
• Cracking in the absence of loading
• Improper design / configuration
• Construction movements
• Erection tolerance
• Subgrade movement (installation)
• Settlement (installation)
• Soft soils (installation)
• Backfilling (installation)

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Cracks – Causes Cracks – Causes

Cracking in the absence of loading Plastic Shrinkage


• Plastic shrinkage • Cracking that develops in the
• Drying shrinkage surface soon after it has been Plastic
Plastic SShrinkage
hrinkage
Cracking
Cracking
• Thermal changes placed and while still in a plastic
• Humidity state Wind

• Expansion • Plastic shrinkage cracks are


generally parallel to one
– Aggregates another and perpendicular to
– Corrosion the direction of the wind

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Cracks – Causes Cracks – Causes
Plastic Shrinkage Drying Shrinkage
Causes Prevention • Concrete is typically “restrained” so
changes in volume result in cracks
• Rapid drying • Protect concrete, moist cure
because concrete is weak in tensile
• Excessive rate of hydration • Lower concrete temperature
• Volume changes occur due to
• Dampen aggregate chemical and autogenous
• High slump, bleeding • Reduce slump shrinkage – both a result of
• Wind • Erect wind shades hydration
• Low humidity • Misting, fogging – Chemical: Absolute reduction in
volume of solids & liquids
• Dry forms • Dampen forms – Autogenous : Macroscopic volume
• Premature finishing • Proper finishing techniques reduction of cement paste
• Fibers – Concrete can shrink 1/8” in 20 ft.
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Cracks – Causes Cracks – Causes

Drying Shrinkage Thermal Cracking


• Cracking due to temperature differences within a concrete
Causes Prevention structure resulting in differential volume changes
• Inadequate curing • Protect concrete • As the interior concrete increases in temperature and
• Moist cure 5-7 days expands, the surface concrete may be cooling and
• Improper jointing • Joint spacing & depth contracting
• Form temperature • Dampen/cool forms • This causes tensile stresses that may result in thermal cracks
• Reinforcing steel • Reduce temperature at the surface if the temperature differential between the
temperature surface and center is too great.
• Fibers
– Forms
– Mass
– Environment
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Cracks – Causes Cracks – Causes
Thermal Cracking Crazing
Causes Prevention • The development of a network
• Temperature differentials • Reduce concrete temperature of fine random cracks on the
• Excessive heat of hydration • Delay cooling surface of concrete (usually no
deeper then 1/8”)
• Control cooling, heating rate
• Typically irregular hexagonal
• Utilize SCM’s
areas
• Ambient temperature • Increase tensile PSI
• Appear at a very early age
variations
• Cosmetic only

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Cracks – Causes Structural Cracks – Allowable Crack Width
Crazing ACI 224R-Table 4.1: Guide to reasonable crack widths,
Causes Prevention reinforced concrete under service loads
• Excessive finishing • Finish at the proper time
Crack width
• Finishing with bleed water
Exposure condition in. mm
• Sprinkling cement on • Cure Concrete
surface to control bleed Dry air or protective membrane 0.016 0.41
• Overly wet mixes • Use moderate w/c to reduce bleed Humidity, moist air, soil 0.012 0.30
• Weather conditions • Use wind barriers or evaporation Deicing chemicals 0.007 0.18
• Improper curing reducers
Seawater and Seawater spray, wetting and drying 0.006 0.15
Water-retaining structures 0.004 0.10

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The Precast Show

CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Allowable Crack Width Structural Cracks – Epoxy Resins

• Low viscosity – easy to pour


• Low surface tension
• Fills cracks easily
• Easy and safe to mix and apply
• High bond strength to concrete
• Bonds well to damp concrete

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Epoxy Resins Structural Cracks – Epoxy Resins
• Epoxy bond strength > Concrete tensile strength
• Allows for solid, structural repair • Use (ASTM Type)
• Viscosity (ASTM Grade)
• Temperature (ASTM Class)
• Moisture tolerance
• Set time
• Packaging

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Structural Cracks – ASTM C881 Structural Cracks – ASTM C881 Type
System for classifying 2-component, epoxy-resin • Type I
– Non-load bearing; hardened concrete to hardened concrete
bonding systems for application to Portland-cement • Type II
concrete – Non-load bearing; fresh concrete to hardened concrete

• Physical requirements • Type III


– Skid resistant material to hardened concrete; binder for mortars used in traffic
– Type I, II, III, IV, V, VI, & VII applications

• Flow characteristics • Type IV


– Load bearing; hardened concrete to hardened concrete; binder for mortars
– Grade 1, 2, & 3 • Type V
• Suitable temperatures – Load bearing; fresh concrete to hardened concrete

– Class A, B, C, D, E, & F • Type VI


– Bonding and sealing segmental precast w/ internal tendons; span-by-span erection
• Color • Type VII
– Pigmented or non – Non stress carrying sealer segmental precast; NOT span-by-span

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – ASTM C881 Grade Structural Cracks – ASTM C881 Class

• Grade 1 – Low Viscosity • A, B, & C are defined for Types I – V


– Very fluid • D, E, & F are defined for Types VI & VII
– Max 20 Poise
Temp. Range (F°)
• Grade 2 – Medium Viscosity
Class Min Max
– Oil or paint consistency
A - 40
– Min 20 Poise; Max 100 Poise
B 40 60
• Grade 3 – Non-sagging consistency C 60 -
– Peanut butter D 40 65
– Consistency at ¼” E 60 80
F 75 90
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Epoxy Resins Structural Cracks – Surface Preparation

• Remove contaminates
– Surface
– Cracks
• Do not contaminate crack
– Grinding
– Drilling
– Flushing

• Exothermic reaction!
• Mass dependent!
• Produce heat – mixing time and dispersal critical
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Surface Preparation Structural Cracks – Application Overview

• It does not have to be


• Gravity feed
complicated
– Wire brush • Hand injection
– Abrasive grinding disc • Low pressure injection
• High pressure injection
• Verification

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The Precast Show

CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Gravity Feed Structural Cracks – Gravity Feed

• Repair cracks on horizontal surface Equipment


• Use gravity to fill crack with resin • For smaller projects:
and structurally bond the concrete – Grinder and air compressor
• Pressure is not used to drive the – Mixing buckets, drills, mixing paddles
resin – Flat rubber squeegees, brooms, or
rollers
• Gravity pushes the resin in the
– Small cans or squeeze bottles
crack
• Keeps out water, salt and other • For large projects:
– Mixing tanks with spray bar
aggressive elements
• Effective method but has its
limitations
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Gravity Feed Structural Cracks – Gravity Feed
Application • Small volume
• Prep cartridges
• Apply dams
– Plumbers putty
– Basic silicone
• Mix resin
• Pour
• Distribute
• Inspect
• Remove excess
• Apply sand
• Finish smooth (if desirable)
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Gravity Feed Structural Cracks – Gravity Feed
• Small volume • Squeeze bottles
cartridges

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NPCA 20
The Precast Show

CRACKS
Gravity Fed

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CRACKS
Gravity Fed
Caution!
• Venting
• Blowholes
• Volcanos

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Caution!
CRACKS CP1 – PRECAST CONCRETE REPAIR
•Gravity
What about
Fed the bottom? Structural Cracks – Pressure Injection
• Leaks
• Benefits
– Plumbers putty
– Basic silicone
– Permanent fix
– Epoxy paste – Fills the void rather than bridging it
– High bond and tensile strengths of the epoxies prevent
yawning and elongation of the crack
– Injected resin is not vulnerable to ultra violet rays,
weathering, traffic or vandalism.
• Methods:
– Hand (easy set up, economical)
– Low Pressure (economical, duration, better penetration)
– High Pressure (best performance, travel, penetration)

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NPCA 21
The Precast Show

CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Injection Overview Structural Cracks – Surface Preparation
• It does not have to be
• Clean concrete surface complicated
• Remove foreign debris from cracks – Wire brush
• Mount injection port to cracks - either surface or – Abrasive grinding disc
socket mounted – Attention to surface
• Surface seal the cracks and injection ports
• Mix epoxy in proper ratios
• Inject resin
• Remove capseal
• Verify
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Surface Preparation Structural Cracks – Injection Ports

• Types of Ports
– Surface Mount
– Corner Ports
– Insertion Ports

• Port Spacing - How far apart ?

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Surface Mount Ports Structural Cracks – Surface Mount Ports

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NPCA 22
The Precast Show

CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Corner Ports Structural Cracks – Corner Ports

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Insertion (packer) Ports Structural Cracks – Insertion (packer) Ports

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Insertion (packer) Ports Structural Cracks – Direct Insertion ¼” Tubing

• Vacuum bit to
avoid impaction

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NPCA 23
The Precast Show

CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Port Spacing

How far apart do we space the ports?


• General guidelines
– Project dependent
– Crack width, depth, profile
• As far apart as possible
• Typically 6 – 12 inches
• 1 - 2 times concrete thickness

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CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Capseal

• Purpose
• Dimensions
• Material selection
• Application
• Common mistakes

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Capseal Structural Cracks – Capseal
• The purpose is to contain the injection • Proper capseal dimensions

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NPCA 24
The Precast Show

CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Capseal Structural Cracks – Capseal Application

Material Selection
• Strength
• Moisture tolerance
• Odor
• Dispensability
• Cure time
• Thermal compatibility
• Ease of removal
• Cost
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Capseal Application Structural Cracks – Capseal

Mistakes:
• Capseal applied too thin
• Improper mixing of epoxy paste
• Insufficient cure time
• Poor material selection

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CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Capseal Mistakes
• Capseal applied too thin

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NPCA 25
The Precast Show

And more Leaks

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Capseal Mistakes Structural Cracks – Capseal Mistakes
• Improper mixing ratio • Improper mixing equipment

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Capseal Solutions Structural Cracks – Capseal Complete
• Full unit batching (too
much volume?) Now What?
• Metered equipment • Means and Methods of injection
• Prepackaged cartridges • Where do we start to inject?
• Proper tools
• How long do we inject?

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NPCA 26
The Precast Show

CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Inject Resin Structural Cracks – Shutoff Ports
• Crimping
• Closing
• Locking
• Capping

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Injection Methods Structural Cracks – Hand Injection (Bulk)
• Hand injection
– Easy
– Inexpensive
• Low pressure equipment
– Economical
– Offers duration
• High pressure equipment
– Most reliable
– Most expensive
– Most complicated
– Pressure and duration
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Hand Injection (Bulk) Structural Cracks – Hand Injection (Cartridges)
• Individual components or kits
• Not interested in buying a kit
• Fast, easy, lowest cost
• Economical for infrequent repairs, but
still requires technical competence

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NPCA 27
The Precast Show

CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Hand Injection (Kits)

Everything needed for one repair


• Epoxy injection resin
• Epoxy cap seal
• Mixing nozzles
• Injection ports
• Gloves
• Application tool separate

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CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Hand Injection

• Caution!
• Not done yet!
• Force material
into substrate
• Leaks!

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Pressure Injection Structural Cracks – Low Pressure Injection

• Fine cracks require duration and


consistent pressure
• 4-12 minutes typical

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NPCA 28
The Precast Show

CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – High Pressure Injection Structural Cracks – Clean Up

• Remove ports
– Optional
– Grinding
– Heating and scraping
• Restore surface as necessary
• Verification
– Coring

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Clean Up Structural Cracks – Clean Up
• Heat gun
• Torch
• Scraper

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Clean Up Structural Cracks – Clean Up
• Penetration - core samples
– Fine Cracks – Epoxy glows under black light
– Structural compressive & tensile (ASTM C42)

• Non-destructive
– Impact echo
– Ultrasonic pulse velocity
– Spectral analysis of surface waves
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NPCA 29
The Precast Show

CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Structural Cracks – Injection Tips Non Structural Repairs
The purpose of the repair is to preserve the aesthetic
• Start at the widest point (versus bottom to top) look and protect the surface from further
• Use duration rather than pressure deterioration
• Don’t rely on hand pressure for very fine cracks • Similar methods and materials, different criteria
– Block outs that require some finishing to provide a smooth
• Use trained workers
finished opening
– Surface defects where steel is not exposed and color need
to be similar
– Does not affect structural integrity or intended service life
of product
– Applications under 1 ½” to 2”, cut in to sides to provide a
3/8” lip for bond
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Non Structural Repairs Non Structural Repairs

Overview Color
• Similar methodology to structural spall repairs • Color of repair needs to be similar to the host concrete
– Root cause analysis, QC procedure, approvals • Matching repair surface with a repair materials is a challenge
because the ingredients and proportions are different
– Orientation of the repair
– Concrete has aggregate & sand with around 25% cement
– Surface preparation content vs. a packaged repair material that is up to 50%
– Application conditions: wind, humidity, temperatures cement with only fine aggregate
– Bond development: SSD, scrub coat, bonding agent – Different manufacturers of cement will influence color
– Finishing and curing – Different curing conditions affect color
• Materials – Change in water cement ratio affects color
– Service and appearance driven, rather than loads

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Non Structural Repairs Non Structural Repairs – Materials

Color – Curing Conditions Repair material options


• Temperature • Job mixing
– Hot sets faster and will be lighter • Pre-bagged patching cement products
– Cold sets slower and may be darker
Critical point: How does the product accelerate set?
• Finishing of the surface affects the color
• Internal acceleration
– Rough sand finish vs. tight steel trowel
– Achieve high early set using cement chemistry
• External acceleration
• When the repair surface is wet the color will be different from – Forces cement to hydrate faster
the concrete because of a different absorption rate due to the – Non Chloride: changes PH of the mix for faster cement hardening
density of the product – Chloride: does the same with potential issues for corrosion
• You may need to coat the product for color uniformity – Gypsum: will accelerate the mix but may re-emulsify when exposed to
moisture
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NPCA 30
The Precast Show

CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Non Structural Repairs Non Structural Repairs

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Non Structural Repairs – Weather Considerations Non Structural Repairs – Bug Holes
Patching is different than placing concrete
Problems:
• The repair is very thin vs. concrete at 6-12 inches thick
• Material placement
• Does not generate heat when curing like concrete does
– Material composition is
• More vulnerable to swings in temperature
important
• Requires more protection during initial set – Too coarse will bridge small
• Precondition (warm) materials for a minimum of 24 hours cavities
• Keep the substrate temperature above minimum application – Won’t penetrate into small
temperature cavities if sticky
• Use warm water to raise the mixing temperature, cool water
to lower it

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Non Structural Repairs – Bug Holes Non Structural Repairs – Bug Holes

Surface preparation Sand and cement option


• Open bug holes by removing any • With water or bonding agent
cement laitance covering them • Sticky mix requires over working
• Wet surfaces to develop uniform to force in bug holes. Result is
suction shrinkage and unsightly
• No strength after set – no filler
• Poor consistency requires too
much dilution
• End result, the product can be
scratched out with a finger nail

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NPCA 31
The Precast Show

CP1 – PRECAST CONCRETE REPAIR


Non Structural Repairs – Bug Holes

Repair mortars are not


designed for this application
• Set time forces over working of
the product
• Sand in the mix bridges over the
bug hole instead of penetrating
• Consistency required exceeds the
no-slump consistency of the
mortar
• Product may shrink around the
perimeter of the bug hole
without the filler (sand)
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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Non Structural Repairs – Bug Holes Non Structural Repairs – Architectural

Newer Materials: Color Considerations


Pre-Engineered Cements • Dry powder is approximate color
• Designed for filling bug holes you will get when patch is cured
• Very fine aggregate filler • Amount of water can alter final
• High polymer loading for bond and color
workability • Conduct test patches to verify color
• Open set time allows for ease of
placement • Repair materials come in shades of
• Light weight product easier to work with gray, some in white, some specialty
• Expansive additive to reduce shrinkage • Repairs will rarely be exact color
• High workability with low WC ratio • Finish texture influences color Consistent mix
required each time

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CP1 – PRECAST CONCRETE REPAIR


Non Structural Repairs – Architectural

Materials:
• Site batching with your own
ingredients
• Pigment repair materials
– % of cement
– Use white based patching cement
• Pigmented prepackaged patching
cement

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NPCA 32
The Precast Show

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NPCA 33
The Precast Show

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CP1 – PRECAST CONCRETE REPAIR CP1 – PRECAST CONCRETE REPAIR


Documentation • Analysis Summary
– Pictures (before repair)
– Root cause
• Repair strategy
– Cost – Root cause & cost analysis
– Corrective action – Structural vs. Non Structural (Cosmetic)
– Objectives
– Approvals
• Structural Spall Repair
• Per Incident • Repair strategy – Materials, Methods
• Standard Repair Manual – Service / exposure
• Structural Crack Repair
– Conditions
– Decision makers – Moving vs. Non-Moving
– Materials
– Inspection process • TDS / SDS – Materials, Methods
– Engineering approval – Surface preparation
• Non Structural (Cosmetic) Repair
– Method
– Equipment – Spalls, Bug Holes, Architectural
• Report – Materials, Methods
– Verification / Testing
• Documentation
– Final Pictures

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NPCA 34

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