Evaluation and Repair of Concrete Buildings

The Tale of Two High-Profile Projects

Randall Poston, PhD, PE, SE, NAE

• Sr. Principal – Pivot Engineers
• President – American Concrete
Institute

31 de outubro de 2019 - São Paulo/SP

Repair is a large segment of the
industry

$20 Billion Dollars Spent

Annually (Vision 2020)
Repairs are needed to:

Address structural distress

Repairs are needed to:

Remediate material deterioration

Repairs are needed to:

Enhance durability of existing elements

Repairs are needed to:

Correct serviceability issues

Repairs are needed to:

Address construction defects

Repairs are needed to:

Allow new use of old structures

The repair industry was the wild west of the construction
industry
with the good…
the bad...
and the ugly.
ACI 562 was developed to improve repair
practice
ACI 562 Outline

General
Criteria

Assessment and Evaluation

Repair Design

Construction and Quality Assurance

ACI 562 Repair Process:
1) Assessment and Evaluation
2) Repair Design
3) Construction and Quality Assurance
ACI 562 Repair Process:
1) Assessment and Evaluation
- Identify the probable cause(s)
- Define loads and anticipated exposure
- Define the extents of the problem
- Define the extent of required repairs
ACI 562 Repair Process:

2) Repair Design
- Select repair methodology
- Material selection to ensure
compatibility
- Durability considerations
ACI 562 Repair Process:

3) Construction and Quality Assurance

- Reliable repair execution
- Address temporary conditions
- Inspection and testing requirements
The Tale of Two High-Profile
Projects
 Case #1
Game of Miles and Inches
 s
i le
M
0
15
1.75 miles (2.8 Km)
of exposed slab
edges
6 Years after construction
completed
ACI 562 Repair Process:
1) Assessment and Evaluation
2) Repair Design
3) Construction and Quality Assurance
ACI 562 Repair Process:
1) Assessment and Evaluation
2) Repair Design
3) Construction and Quality Assurance
Assessment and Evaluation:
- 100% Visual Assessment
- Forensic Evaluation
31 locations had evidence of concrete distress
N N

West East
Forensic Investigation
15%
N
of exposed slab edges evaluated
N

West East
The Problem:
Top of Slab
Slab Edge

Edge Reinforcing Bar

Drip Edge
The Problem:

Slab Edge Reinforcing Bar

Minimum Concrete
Cover
Evaluation of Findings:

86% of slab edges did not meet code

requirements for concrete cover
Evaluation of Findings:

Cl-
were not a culprit
ACI 562 Repair Process:
1) Assessment and Evaluation
2) Repair Design
3) Construction and Quality Assurance
The Repair:
Top of Slab
Existing Slab
Edge
Reinforcing Bar with
Inadequate Cover

Existing Reglet
The Repair:
Remove Existing
Concrete with
Chipping Hammer

Remove
Existing Bar
The Repair:
New Concrete

Longitudinal GFRP Dowel

GFRP Bar Bar
The Repair:
The Repair:
Sealant Joint Waterproof Coating
 Stainless Steel
Helical Anchor

GFRP Dowel
Crack Treatment
Load Transfer Considerations:
1 Roughened Surface

2 GFRP Dowel

3 Stainless
Steel Anchors
 Durability Considerations:
2 Sealant Joint
1 Waterproof Coating

3 Inert GFRP
Reinforcement

4 Admixed
Corrosion
Inhibitor
5 Increased
Width
ACI 562 Repair Process:
1) Assessment and Evaluation
2) Repair Design
3) Construction and Quality Assurance
The demolition exposed PT anchors
Wind-driven rain can cause premature PT corrosion

(farhadatx)
Specifications required temporary protection
and a mock up to demonstrate adequacy
Most protection systems
but some worked
failed,
Robust QA/QC is critical for success of repairs
 Four Inspection Points:

Concrete Reinforcement Concrete Coating

Removal and Formwork Placement Installation

1 2 3 4

Surface Preparation Pre-Placement Placement Final Condition

Comprehensive material testing
requirements
• Compressive Strength
Frequent
• Slump

• Shrinkage
Less Frequent
• Pull-Bond Strength

• Chloride Content
Infrequent
• Modulus of Elasticity
The bond is critical:
Existing Substrate
New Concrete

Bond Line
Pull Bond Strength Testing
Pull Bond Strength Testing
 25%
N = 145
Specified Minimum Average = 215 psi
(120 psi) Std. Dev. = 85 psi
20%

15%
Frequency

10%

5%

0%
0 50 100 150 200 250 300 350 400 450 500

Pull-Bond Test Result (psi)

91 of pull-bond tests met the
%
requirements
25%
N = 145
Specified Minimum Average = 215 psi
(120 psi) Std. Dev. = 85 psi
20%

15%
Frequency

Further
10%
Assessment
Needed
5%

0%
0 50 100 150 200 250 300 350 400 450 500

Pull-Bond Test Result (psi)

Sometimes assessment led to rejection
 Case #2
The “Dangerous” Building
 Office Building

EJ
Transit Mall
North Block
EJ
•Cracked drywall in office building
•Cracked basement walls
•Separated columns at expansion joint
10 Years after
construction
completed
Long List of Defects:
Included in the RFP
• Office Building
• Slab deflections
• Punching shear strength
• Column strength
• Shear wall strength
• Shear wall boundary elements
• Foundations
• Low strength concrete
• Transit Mall
• Slab flexural strength
• Slab punching shear strength
• Column strength
• Foundations
• North Block
• Slab punching shear
• Cracked basement walls
• Current Code Strength Repairs
Long List of Defects:
Included in the RFP Not Included in the RFP
• Office Building • “Sensitive” Owners
• Slab deflections • “Determined” Building Department
• Punching shear strength • “Angry” Peer Reviewer
• Column strength • “Challenging” Owner’s
• Shear wall strength Representative
• Shear wall boundary elements
• Foundations
• Low strength concrete
• Transit Mall
• Slab flexural strength
• Slab punching shear strength
• Column strength
• Foundations
• North Block
• Slab punching shear
• Cracked basement walls
• Current Code Strength Repairs
ACI 562 Repair Process:
1) Assessment and Evaluation
2) Repair Design
3) Construction and Quality Assurance
ACI 562 Repair Process:
1) Assessment and Evaluation
2) Repair Design
3) Construction and Quality Assurance
Assessment and Evaluation:
- Forensic Evaluation
- Material Testing
- Structural Analysis
Assessment and Evaluation:
Non-Destructive Destructive
Distress Impact Observation
Radar Pull Bond Petrography
Echo Opening
Punching
¢ ¢ ¢ ¢
Shear
Column
¢ ¢ ¢
Flexure
Transit Slab
¢ ¢ ¢ ¢
Flexure
Office Slab
¢ ¢ ¢
Deflections
Non-Destructive Testing
Observation Openings
Material Testing
Evaluation of Findings:
1- Inadequate punching shear capacity
Evaluation of Findings:
2- Deficiency in column
flexure
Evaluation of Findings:
3- Flexure and Punching Deficiencies in Transit Mall
Evaluation of Findings:
4- Excessive Deflections in Office Building
ACI 562 Repair Process:
1) Assessment and Evaluation
2) Repair Design
3) Construction and Quality Assurance
1- Punching Shear Repair
2- Column
Strengthening
3- Transit Mall Repairs
3- Transit Mall Repairs
4- Deflection
Remediation
ACI 562 Repair Process:
1) Assessment and Evaluation
2) Repair Design
3) Construction and Quality Assurance
Robust Quality Control Program
The Soft Side of Concrete Repairs
(Not covered by ACI 562)
 “Repair”
• Commonly:

Scientific, technical in nature…

“Put it back together”

 “Repair”
• Commonly: • Alternatively:

Scientific, technical in nature… Psychological…

“Put it back together”

“Can I trust this building?”
Public Opinion
Public Opinion
Success = When Carpet is Biggest
Battle
Project Completion
Project Completion
Summary
Summary:
• Concrete repairs present unique technical
and non-technical challenges
• Successful repairs require correct diagnosis,
proper design, and reliable diagnosis
• ACI 562 aims to improve the reliability of
repairs and enhance the performance of
the repairs.
Summary:
• A comprehensive investigation is the
corner stone of a reliable repair.
• Design of repairs and material selection
should consider structural strength and
durability
• Comprehensive QC program is integral for
repair reliability.
Questions?