Causes for Distress and

Simple Remedies for

achieving Quality Concrete

P.Rathish Kumar
Department of Civil Engineering
NIT Warangal
 INTRINSIC AND EXTRINSIC CAUSES
AND STAGES OF DISTRESS(Physical)

• Construction Deficiency (Intrinsic)- High

w/c ratio- High Capillary porosity
Manifestation- Carbonation-depasivation-
increased volume of corrosion-
increased cracking-Accelerated
corrosion-Spalling-Reduction is bar
diameter- Pushing and buckling of the
bar-failure of reinforcement
 INTRINSIC AND EXTRINSIC CAUSES
AND STAGES OF DISTRESS
• Inadequate Curing (Intrinsic)- High
Capillary porosity
• Poorly graded aggregates-Poor concrete
due to air voids-Allowing harmful
chemicals-initiate corrosion
Manifestation- Carbonation-depasivation-
increased volume of corrosion-increased
cracking-Accelerated corrosion-Spalling-
Reduction is bar diameter- Pushing and
buckling of the bar-failure of
reinforcement
 INTRINSIC AND EXTRINSIC CAUSES
AND STAGES OF DISTRESS
• Inadequate Compaction(Intrinsic)-
Porous concrete due to air voids-
Allowing harmful chemicals-initiate
corrosion
Manifestation- Carbonation-
depasivation- increased volume of
corrosion-increased cracking-
Accelerated corrosion-Spalling-
Reduction is bar diameter- Pushing and
buckling of the bar-failure of
reinforcement
 INTRINSIC AND EXTRINSIC CAUSES
AND STAGES OF DISTRESS
• Shuttering Joints not slurry tight
(Intrinsic)-Honey Combed Concrete-
Allowing harmful chemicals-initiate
corrosion
Manifestation- Carbonation-
depasivation- increased volume of
corrosion-increased cracking-
Accelerated corrosion-Spalling-
Reduction is bar diameter- Pushing and
buckling of the bar-failure of
reinforcement
 INTRINSIC AND EXTRINSIC CAUSES
AND STAGES OF DISTRESS

• Less Cover Thickness(Intrinsic)-

Protective cover thickness required
Manifestation- Carbonation-
depasivation- increased volume of
corrosion-increased cracking-
Accelerated corrosion-Spalling-
Reduction is bar diameter- Pushing
and buckling of the bar-failure of
reinforcement
INTRINSIC AND EXTRINSIC CAUSES AND
STAGES OF DISTRESS
• Wrong Placement of Reinforcement
(Intrinsic)-Cracking and Crushing of
Concrete to cause microcracking-Allows
harmful chemicals to enter inside
Manifestation- Carbonation-
depasivation- increased volume of
corrosion-increased cracking-
Accelerated corrosion-Spalling-
Reduction is bar diameter- Pushing and
buckling of the bar-failure of
reinforcement
 INTRINSIC AND EXTRINSIC CAUSES
AND STAGES OF DISTRESS(Chemical)
• Chloride-Depasivation of Steel-
Formation of Galvanic cells to initiate
corrosion
Manifestation- Chloride ion acts as
current carrier-depasivation- increased
volume of corrosion-increased
cracking-Accelerated corrosion-
Spalling-Reduction is bar diameter-
Pushing and buckling of the bar-failure
of reinforcement
 INTRINSIC AND EXTRINSIC CAUSES
AND STAGES OF DISTRESS(Chemical
Effect)

• Chloride Attack-Toilets, sea water,

sullage, atmospheric gases, acids
• Sulphate Attack-Soil, industrial
wastes
 INTRINSIC AND EXTRINSIC CAUSES
AND STAGES OF DISTRESS(Chemical)

• Sulphate-Formation of Calcium
Sulpho Alluminate
Manifestation- Bursting Force-
increased volume- Cracking- Weak
and Permeable Concrete-
Disintegration- Accelerated
corrosion-Spalling-Reduction is bar
diameter- Pushing and buckling of
the bar-failure of reinforcement
 INTRINSIC AND EXTRINSIC CAUSES
AND STAGES OF DISTRESS(Chemical)

• Reactive Aggregates-Formation of
expansive Gel around aggregates-
Disintegration
Manifestation- Bursting Force-
increased volume- Cracking- Weak
and Permeable Concrete-
Disintegration- Accelerated corrosion-
Spalling-Reduction is bar diameter-
Pushing and buckling of the bar-
failure of reinforcement
 INTRINSIC AND EXTRINSIC CAUSES
AND STAGES OF DISTRESS(Design
Deficiency)

• Wrong Assessment of Design Loads-

Deflection, Crushing/Cracking of
Structural Members.
• Not considering factors like shrinkage,
thermal movement and structural
behaviour.
 INTRINSIC AND EXTRINSIC CAUSES
AND STAGES OF DISTRESS
(Environmental )

• Heating/Cooling-Surface
disintegration and micro cracking
• Wetting/Drying-Increase in Capillary
porosity due to leaching away of
soluble salts.
• Abrasion of surface-Surface
disintegration and reduced cover
thickness
 HOLISTIC MODEL FOR DETERIORATION-
MODEL-1
 Deterioration process-two stages-First stage
due to loading and weathering effects-voids
become interlinked.
 Voids-Interlinked gets connected with cracks
in concrete-Provides mechanism for fluid
transport into concrete
 Penetrability increases and in second stage
the oxides, carbon dioxide, acids, chlorides
ingress increases
 Cracking, spalling, loss of mass and loss of
strength and stiffness.
CONCRETE DETERIORATION FROM ENVIRONMENT
EFFECTS (MODEL 1)
A water tight reinforced concrete structure containing
discontinuous cracks, micro cracks and pores

Environmental Action(Stage 1)
No visible damage
Weathering Effects (Cyclic heating/
Gradual loss of water tightness as cooling, wetting/drying
cracks, micro cracks and pores become
more interconnected
Environmental Action(Stage 2)
Initiation and propagation of damage
Penetration of water, oxygen and Carbon
dioxide, acids eg cl- , so4--

Expansion of concrete due to increased hydraulic pressure caused by

Corrosion of steel, Sulphate attack on cement paste, Alkali attack on
aggregate, Freezing of water
and simultaneous decrease in strength and stiffness of concrete

Cracking, spalling and loss of mass

 HOLISTIC MODEL FOR DETERIORATION-
MODEL-2
 Three stages-Loss of water tightness,
initiation of damage and propagation of
damage
 Stage-1- No noticeable weakening of

material occurs but protective barrier is

broken down due to depasivity of RCC by
CO2, chloride penetration
 Selection of materials, mix proportions and
concrete processing
 DETERIORATION OF RCC (MODEL 2)
Stage 1-
Gradual Loss
Acceptable damage limit
of water
Stage 3 tightness
Stage 2-
Stage 2 Initiation of
Damage damage
Stage 3-
Stage 1 Propagation
of damage

Service life of a structure

Service life in Years with an acceptable damage
limit
 HOLISTIC MODEL FOR DETERIORATION-
MODEL-3
 Based on water-cement ratio

 Three principal elements(a) Interconnected

porosity, Exposure to aggressive agents,

chemicals ©Intermittent presence of water
 Porous or micro cracked concrete in absence
of water though there is presence of harmful
aggressive agents like CO2
 Absence of water aggressive agents cannot

travel
TERNARY REPRESENTATIOIN OF RCC DAMAGE(MODEL 3)

Interconnected
porosity(Permeability)
Exposure to
aggressive agents

Presence of Water

Damage to RCC
 IS 456 : 2000 Section 2
Materials, Workmanship, Inspection &
Testing
Primary improvements :
Wider choice of cements, mineral admixtures
Stringent requirements for water quality
Introduction of high strength concrete
Provisions for Durability of concrete

Minimum cement content linked to exposure

Maximum cement content 450 kg/cum
Minimum grade of concrete increased
Greater flexibility in concrete mix design
Simplified acceptance criteria
 IS 456:2000 Cl. 6 – Concrete
 Grades are given in three groups
Ordinary Conc. 10, 15, 20 Mpa
Standard Conc. 25,30,35,40,45,50,55 Mpa
High str. Conc. 60,65,70,75,80 Mpa
 In 1978 ed there were only 7 grades, max.
40Mpa
Now there is a quantum jump upto 80Mpa
 For High Strength concrete, designed
parameters values may be obtained from
special literature / experimental results
 IS 456:2000 Cl. 6 – Concrete
 6.1.2 The minimum grade of concrete for
plain and reinforced concrete shall be as per
Table 5
 Minimum grade is linked to exposure
conditions
Exposure Plain conc. Reinf. Con.
Mild - M 20
Moderate M 15 M 25
Severe M 20 M 30
V. Severe M 20 M 35
Extreme M 25 M 40
 IS 456:2000 Cl. 5.2- Mineral Admixtures
 As per 1978 edition, Pozzolanic materials
conforming to relevant Indian standards
may be used with permission of the
Engineer-in-charge
 The new clause is amplified, giving list of
mineral admixtures : Fly ash
Silica fume New
Rice husk ash New
Metakaoline New
GGBFS
provided uniform blending with cement is
ensured
 POSSIBLE PROBLEMS IN ACCEPTING
CEMENT

Properties Problems Remedies

Partially
Compressive
Low Strength Replace with
Strength
Good Cement
Flash Setting,
Use
False Setting,
Setting Time Accelerators or
Low or High
Retarders
Setting Time
Use Mineral
Soundness Expansion
Admixtures
Heat of
Excessive Heat Use Pozzolanas
Hydration
 PROBLEMS ASSOCIATED WITH WATER
REDUCING ADMIXTURES
PROBLEMS Reasons
Low Ambient
Temperature
Slow Setting Excessive Dosage
Lower Cement Content
Inadequate Dosage
Inadequate Improper Grading
Workability Incompatibility with
Cement
Air Entrainment
Low Compressive
Improper Mix Design
Strength
Excessive Dosage
 PROBLEMS WITH FRESH CONCRETE

1. Low Workability
2. Bleeding
3. Segregation
4. Slow Setting
5. Fast Setting
 LOW WORKABILITY
REASONS:

 Low Water-Cement Ratio

 Angularity of Aggregate
 Low Paste Content

REMEDIES

 Use of Water Reducing Admixtures

 Use of Higher Paste Content
 Use of Mineral Admixtures
 Increasing the Water Content
 BLEEDING

REASONS:

 Lack of Fine Material

 Improper Grading
 Un-Favorable Atmospheric
Conditions
 Excessive Water Content
REMEDIES

 Increasing More Fines Such as

Pozzolanas
 Adopting Proper Grading
 SLOW SETTING

Reasons:
1. Presence of Certain Organic Materials
2. Low Ambient Temperature
3. Excessive Volume of Fly ash
4. Excessive Quantity of Naphthalene Based
Super Plasticizer
 FAST SETTING
Reasons:
 High Ambient Temperatures
 High Heat of Hydration
 Presence of an-hydrite or hemi-hydrite Gypsum

Remedies:
 Protecting Concrete from High Temperatures
 Pre-Cooling Aggregate and Water
 Minimizing C3A Content in Cement
 Adding Gypsum when Clinker reaches Normal
Temperature
 Adding Pozzolanas to Reduce Heat of Hydration
PROBLEMS IN HARDENED CONCRETE

1. Low Compressive Strength,

2. Cracking,
3. Volume Change (Shrinkage or
Expansion),
4. Honey Combing,
5. Scaling.
 LOW COMPRESSIVE STRENGTH
Reasons:
 Higher Water Demand for the Mix
 Improper Compaction
 Improper Curing
 Improper Utilization Admixtures

Remedies:
 Utilization of Water Reducing Admixtures
 Providing Adequate Compaction and
Curing
 Adopting Proper Gradation of Aggregates
 HONEY COMBING

Reasons:
 Improper Grading
 Inadequate Paste Content
 Over Vibration

Remedies:
 Adopting Proper Grading
 Providing Sufficient Paste Content
 Providing Adequate Vibration
 CRACKING

Reasons: Remedies:
 Drying  Adopting Proper Grading
Shrinkage
 Providing Adequate Curing
 Plastic
Shrinkage  Using Good Quality of
Aggregate
 Corrosion of
Steel  Adopting Precautions against
 Excessive Heat of Hydration and Other
Strain Problems
 SCALING
Reasons
 Over Troweling,
 Improper Curing or Lack of
Curing,
 Insufficient Protection of
Concrete in Cold Weather

Remedies
 Avoid Troweling of the Surface when Bleed Water
is still present,
 Provide Adequate Curing
 VOLUME CHANGE (Shrinkage)
Reasons:
 Lack of Proper Curing
 Carbonation
 Windy and Sunny Atmosphere
 Excessive Fine Material
 Excessive Water

Remedies
 Providing Adequate Curing
 Protecting Concrete from Wind and High
Temperatures
 Optimum Utilization of Cement and Water
 Utilization of Pozzolanic Materials
 TYPICAL USEFUL LIFE SPAN
Description Life Span (Yrs)
Temporary buildings at project sites 1-10

Roads-Flexible pavements 5-10

Roads-Rigid Pavements 20-30
Marine Structures 40
Residential buildings 60
Public buildings 100
Bridges, dams, tunnels 120
Monumental structures 100-200
Heritage structures More than 200
CONDITION SURVEY OF
BUILDINGS
 CONDITION SURVEY-OBJECTIVES
Examination of concrete for identifying
and defining areas of distress.
To identify causes and sources of
distress
To assess the extent of distress, the
residua strength and possibility of
rehabilitability
To prioritise distressed elements
according to the seriousness for repairs
To select and plan an effective remedy
 CONDITION SURVEY-STAGES
1) Preliminary Inspection-Assess and collect
information
 Back ground History -Clients and Owners,
occupants, general public
 Notes and records of earlier repairs

 Practical restrictions in carrying out repairs

 Safety requirements for condition surveyteam

 Extent and quantum of survey work

 Requirements of field testing, sampling

 Advise client/owner for immediate safety

measures to be taken
 To define the scope of the work
 CONDITION SURVEY-STAGES
Preliminary Inspection- Basic information
gathering
 Period of construction

 Construction details-architectural, structural

 Exposure conditions

 Designed use and present use

 Previous changes

 Record of structural changes

 Record of first occurrence of deterioration

 Details of repairs if any carried out

 Apparent causes of distress

 Photographic record
 CONDITION SURVEY-STAGES

2) Planning Stage
 Preparation of documents- survey objective-
scope and method,
 Field and laboratory testing-Tools required

 Sequence of condition survey-work schedule

 Floor plans

 Worksheets and tables for recording

 Previous condition survey

 Maintenance and repair records

 Grouping of structural members

 CONDITION SURVEY-STAGES

3) Visual Inspection Stage

 Evaluation of structural soundness

 Measurement of crack widths

 Use of binoculars, cameras

 CLASSIFICATION OF DAMAGE
 Class 0- Cosmetic- Redecoration if required
 Class 1- Superficial- Carbonation depths not
reached- Superficial repair.
 Class 2- Patch Repair- Minor structural cracks-
protective coating- crack sealing-shotcrete-
reinforcing with nominal steel fabric
 Class 3 – Principal Repair- Spalling of cover
concrete, major structural cracks- corrosion-
reduction in load carrying capacity-
Strengthening to RCC, additional reinforcement
 Class 4- Major Repair- Major structural loss-
replacement of structural members-demolition
and recasting
 ASSESSMENT PROCEDURE
 Processing of assessing structural condition
of existing building
 Assembling and systematically analyzing
information and data regarding building or
portions to determine structural adequacy
 Approach-Multilevel approach recommended.
Preliminary assessment and then follows the
detailed analysis if demanded.
 Potential Screening factors-Date of
construction, building area, acquisition cost,
importance and occupancy can be reduced
and prioritize inventory
 PRELIMINARY ASSESSMENT
 Provides initial analytical data for estimating
adequacy of existing building
 Basic Steps-Available documents review like
drawings, design criteria, soil investigations,
calculations and other information-if information
is not available then the engineers judgment
 Site Inspection-Enables the engineer to confirm
the correctness of existing design information
and assess structural condition of the building
 Evidence of structural modification,
deterioration of materials, discrepancies,
weaknesses in structural members or
connections, settlement or foundation problems
 KEY ASPECTS OF PRELIMINARY ANALYSIS
 Preliminary Analysis-Estimating if building has
adequate capacity to withstand specified structural
criteria
 Identifying structural deterioration in building

Key Aspects
 Loading and Performance Criteria
 Structural Components
 Material Properties
 Member Analysis
 Non-Structural Evaluation
 Cost-Impact study
 ASSESSMENT AND EVALUATION(General)

 Data, observations-spread sheets, mapping

drawings, notes
Broad trouble spots
1) Planning provisions and their response
2) Services-Plumbing+electrical-Concealed/exposed
3) Additions and alterations carried out by occupants
4) Congenital defects, constructions lapses and
outcome
5) Material and specifications-Workmanship and
compatibility
6) Age related wear and tear
 ASSESSMENT AND EVALUATION(General)
7) Maintenance inadequacies and related response
8) Construction history
9) Basic structural framing provisions and
deficiencies
10) Critical areas for weather resistance and their
response
11) External ground area and infrastructure support
provisions
12) House keeping-In general
13) Special elevation treatments-extent, overhangs
and its performance
14) Response of terrace for weather protection
15) Special observations, with particular reference for
priority measures for structure safety
 DEFINTIONS OF DIFFERENT R’S INVOLVED
Repair- Process of reconstruction and renewal
of the existing buildings either wholly or
partly
Retrofit-Upgrading of certain building systems
such as mechanical, electrical or structural to
improve the performance, function or
appearance
Rehabilitation-Upgrading required to meet the
present needs.It implies sensitivity to building
features and a sympathetic matching of
original construction
 DEFINITIONS OF DIFFERENT R’S INVOLVED
Renovation- Process of substantial repair or
alteration that extends a buildings useful life
Restoration-More restrictive term than
rehabilitation-Replicating the structure as
originally built
Remodeling-Same as renovation usually used
for buildings
Refurbishment-Replacement of certain
components and using whatever is alright.
STRATEGIES OF REPAIR

 Allow the structure to

deteriorate to a
minimum performance
level and then
rehabilitate to original
condition
 Maintenance is done
before minimum
condition is reached
and then bring
structure to original
condition
 DISTRESS:
A structure when it fails to perform the functions
for which it was designed
GENERAL CAUSES OF DAMAGE

 Errors in design, detailing and construction

 Use of substandard materials
 Over loading
 Lack of quality control in construction
 Movement of soil and change of temperature
 External influences such as
- Earthquake
- Wind
- Fire
- Corrosion due to environment
 Failure of earlier repairs
FACTORS CAUSING DISTRESS IN CONCRETE STRUCTURES
FAULTY DESIGN Wrong mix
Under design

INFERIOR MATERIALS Contaminated

aggregate
Contaminated water

POOR CONSTRUCTION PRACTICES Faulty formwork

Inadequate curing

ABUSE OF STRUCTURES Lack of maintenance

ENVIRONMENTAL EFFECTS Thermal, moisture

Freezing & Thawing

CHEMICAL EFFECTS Carbonation, chloride

INTERNAL STRESSES Fire, sulphate attack

MECHANICAL CAUSES Over loading,

abrasion
 CAUSES OF CRACKS IN CONCRETE

Early frost damage

Before Plastic shrinkage

hardening Plastic
Plastic settlement

Formwork movement
Constructional
Movement
Sub-grade movement
 CAUSES OF CRACKS IN CONCRETE

Shrinkage Aggregate
Physical Drying shrinkage
Crazing

Corrosion of reinforcement
Chemical Alkali-aggregate reactions
After Cement carbonation
hardening
Freeze thaw cycles
Thermal External seasonal
Temperature variations
Early thermal contraction

Accidental overload
Structural Creep
Design loads
VISUAL OBSERVATION (INSPECTION)

• Cracks
# Width, depth, length
• Rust staining
• Spalling of concrete
• Dampness
• Drainage
• Foundation
 DOCUMENTATION
• Both by drawing and photographs
# Types and pattern of cracking
# Spalling
# Abnormal distress
# Discoloration
# Deformation
• History of construction
• Original quality
• Analysis and design methods with
assumption made
• Types of materials used
 MEASUREMENT OF GEOMETRICAL
PARAMETERS

• Column, beam, slab dimensions

• Vertical alignment
• Deflections and deformations if any
Based on the visual inspection and documentation,
RCC portal frames and other structural RCC Members can
be categorized as follows to denote the extent of distress
in the members.

• Fairly damaged
• Moderately damaged
• Severely damaged
 INVESTIGATION METHOD
• Visual observations
 Documentations
 Measurement of geometrical parameters
• Experiments for evaluating material properties and
member behavior
# Non destructive testing
# Partially destructives testing
# Load tests
• Interpretation and analysis of test results
• Formulation of repair measures
• Post repair evaluation
THANK YOU