Unit III

Maintenance and Repair Strategies

Maintenance and
Rehabilitation of Structures
10 PSE E04

Maintenance and Repair Strategies

Maintenance and Repair Strategies

Definition
Maintenance
to keep a structure well so that it doesn't get
damaged

Repair
to restore a damaged structure

Retrofitting
to strengthen a structure

Rehabilitation
to return a structure to a useful state by repair,
alteration, and modification

Example for Rehabilitation

Situation:
A beam has spalling of concrete

Analysis:
The cause of the problem is analysed

Problem:
Spalling of concrete due to corrosion of steel
reinforcement.

Solution:
Corrosion protection is made and then patch is
provided.

Example for Retrofitting

Situation:
A beam has cracks at the base

Analysis:
The cause of the problem is analysed

Problem:
Deflection has occurred due to insufficient cross
section of the beam.
Cracks have appeared due to large deflection

Solution:
Increase the cross-section of the beam by jacketing

Maintenance and Repair Strategies

Facets of Maintenance
1. Planned Maintenance
Executed to keep the structure in useful
condition, as scheduled at the time of design of
a structure
Example: white washing, cleaning, inspection

2. Preventive Maintenance
Executed to prevent failure which may recur
within the life of a structure
Recurring planned maintenance
Example: cleaning, white washing, avoiding
water stagnation

Facets of Maintenance
3. Predictive Maintenance
Executed when minor damages are noticed so
as to prevent their progression.
Example: Grouting of minor cracks

4. Corrective Maintenance
. Executed when a structure is damaged to bring
it to an acceptable standard
. Repair works
. Example: treatment for rising damp

Maintenance and Repair Strategies

Importance of Maintenance
Three components of a structure:
Civil engineering components
Mechanical components
Electrical components

All the components undergo ageing.

They need maintenance.

Importance of Maintenance
Maintenance keeps up a building's
appearance and extends its life
Maintenance ensures proper
functioning and efficiency of
equipments within the structure
Maintenance ensures the usability of
a structure under human acceptable
conditions

Importance of Maintenance
Maintenance ensures that historic
places will be in a fit state to be
handed over to future generations
Maintenance will reduce need for
repair, which will in turn reduce
waste and energy
Maintenance is cheaper than repair
or rehabilitation

Maintenance costs at various ages

of a structure

Example for importance of

Maintenance
Regular inspection enables
Timely identification of deteriorated
building elements due to weathering like
loose mosaic tiles, plaster of external
walls and spalled concrete
Avoid threatening to public safety
Avoid the need of large repair works

Maintenance and Repair Strategies

Preventive measures on various

aspects
In residential structures(usually RC
structures)
Avoid/minimise design and construction
errors
Providing appropriate drainage facilities
Periodic cleaning
Visual inspection
Periodic technical inspection

Preventive measures on various

aspects
In industrial structures(steel
structures)
Cathodic protection
Multi-layer protective coatings
Periodic inspection

Preventive measures on various

aspects
In hydraulic structures
Controlling aquatic weeds
Monitoring the water quality
Control of silt formation
Surveying the solid deposition
Avoid cracking of the lining and eventual
eruption of concrete slabs through
proper design and construction

Preventive measures on various

aspects
In roads
Removal of loose material on the
surface
Refilling of small holes with the base and
sub-base material
Good drainage by maintaining the
shoulder drains
Prohibition of traffic on shoulders

Preventive measures on various

aspects
Seismic Strengthening (when seismic
zone is upgraded)
Modification of roofs and floors
Inserting new walls
Strengthening existing walls
Strengthening reinforced concrete
members
Strengthening of foundations

Maintenance and Repair Strategies

Causes of deterioration
(RC structures)
Based on the properties of the
structure
Permeability
Voids
Micro cracks
Macro cracks

Causes of deterioration
(RC structures)
Based on the environmental conditions
Penetration of water
Penetration of aggressive chemicals
Carbonation
Chloride ingress
Sulphate attack
Alkali - silica reaction
Freeze - thaw effect
Temperature changes

Maintenance and Repair Strategies

Assessment procedure for

evaluating a damaged structure
Condition survey (CPWD)
Examination of a structure of concrete for the purpose of
identifying and defining area of distress
Undertaken so as to provide fruitful outcome at optimum
effort and cost
History of a project from its inception to completion and
subsequent life is recorded

Periodic structural inspections are carried out based

on the following frequency:
every 10 years for buildings where at least 90% of its
floor area is used solely for residential purposes
every 5 years for all other buildings
As per Singapore BCA

Objectives of Condition Survey

To identify
Causes of distress
Sources of distress

To assess
The extent of distress
The residual strength
Its rehabitability

To prioritise the distressed elements

according to seriousness for repairs
To select and plan effective remedy

Stages of Condition Survey

Preliminary Inspection
Planning
Visual Inspection
Field and laboratory testing

Maintenance and Repair Strategies

Preliminary Inspection
To assess and collect
Background history of the distressed
structure
Notes and records of earlier repairs, if any
All other possible information
Practical restrictions
Safety requirements for assessment
Approximate time required for
assessment

Planning
Preparation of field documents
Drawings
Floor plans
Worksheets for recording data

Grouping of structural members

Based on position
Based on exposure
Based on protective finishes provided

Classification of damage
Cosmetic repair
Superficial repair
Patch repair
Principal repair
Major repair

Visual Inspection
Qualitative method of evaluation of
structural soundness
Quick scan of the structure to assess its
general state of health
Record of visual inspection is essential for
preparation of bill of materials for repair
items
Camera, binoculars, magnifying glass,
gauge for crack width measurement are
used

Limitations of Visual Inspection

Difficulties in the conduct of a visual inspection
Some of the main structural elements in a building
may have been covered up by architectural finishes

Professional judgement to determine which

areas should be exposed for inspection
Reference is made to structural layout plans to
determine the critical structural elements
Without proper judgement, the inspection
would not be effective

Maintenance and Repair Strategies

Testing Techniques
Property under
investigation

Test

Insitu concrete strength

Rebound Hammer Test

Ultrasonic Pulse Velocity
Windsor Probe
LOK/CAPO test
Core cutting and testing
Load test

Windsor Probe

Windsor Probe
Penetration resistance equipment
Gunpowder actuated driver, hardened alloy
probe, loaded cartridges, depth gauge and
accessories
Driver fires the probe into the concrete
Exposed length of probe is measured by
depth gauge
Damage may be caused in slender members
Not affected by local surface conditions

Windsor Probe

Windsor Probe

Windsor Probe

LOK test

CAPO test

LOK/CAPO test
Equipment is designed to specified geometry
to provide results that closely correlate to
compressive strength of concrete
This correlation is achieved by measuring the
force required to pull a steel disc or ring,
embedded in fresh concrete, against a circular
counter pressure placed on the concrete
surface concentric with the disc or ring.
For hardened concrete, an expandable steel
ring is used

LOK/CAPO test

Core cutting and testing

Cylindrical cores are cut by rotary
cutting tool with diamond bits
Appearance of the core is recorded
Core is soaked in water, capped with
molten sulphur to make its ends
plane
Core is then tested in moist condition

Core cutting and testing

Tests conducted on the core
Strength
Density
Depth of carbonation
Chemical analysis
Water/gas permeability

Core cutting and testing

Core cutting and testing

Testing Techniques
Property under
investigation
Chemical Attack

Test
Carbonation test
Chloride test
Sulphate test

Carbonation test
Aim:
To determine depth of concrete affected due to combined attack of
atmospheric carbon di oxide and moisture causing a reduction in level
of alkalinity of concrete.

Procedure:
Hole is drilled to different depths upto cover concrete thickness.
Dust is removed by blowing air.
0.2% solution phenolphthalein is sprayed with injection syringe and
needle.
phenolphthalein pH indicator of concrete

Inference:
Change in colour of concrete to pink indicates that the concrete is in
good health
No colour change indicates that concrete is affected by carbonation
Depth of carbonation is estimated based on change in colour profile

Chloride test
Rapid chloride test kit 4
Recent commercial testing instrument
Samples are collected from various
depths(every 5mm) by drilling
Powdered samples(about 1.5g) are mixed
with special chloride extraction liquid
Electrical potential of the liquid is measured
by chloride-ion sensitive electrode.
From calibration graph, chloride content is
determined

Corrosion prone Locations based on

Chemical Analysis
(Source: ICJ, June 1998)
Test Results

Interpolations

pH value

Chloride content

> 11.5

Very low

No corrosion

> 11.5

> 0.15% by
weight of
cement

Corrosion prone

< 11.5

> 0.15% by
weight of
cement

Increased risk of
corrosion

Testing Techniques
Property under
investigation
Corrosion Potential
Assessment

Test
Cover-meter/ Profometer
measurement
Half cell Potentiometer
Resistivity Meter
Permeability ( Water and
Air)

Cover meter survey

(Covermaster & Profometer)
Aim:
To determine existing cover thickness
To identify the location and diameter of
rebar

Principle:
Non destructive pulse-induction
Digital method

Profometer

Interpretation of Cover Thickness

Survey
Test Results
Cover
Cover concrete
thickness
quality
Required
Good

Interpolations

Required

Bad

Relatively no
corrosion prone
Corrosion prone

Very less

Good

Corrosion prone

Half cell Potentiometer

Corrosion Risk by Half cell

Potentiometer
Half cell potentiometer
reading (mV)
Cu CuSO4
Silver Silver
Electrode
chloride
electrode
< -350
< - 700
-200 to -350
-500 to -700
> -200
> -500

Probability of
corrosion
being active

> 95%
50%
< 5%

Resistivity Measurement

Resistivity Measurement
Aim:
To determine the resistance of concrete

Procedure:
Known current applied between two
outer probes 100 mm apart
Voltage drop between two inner probes
50 mm apart is measured and
resistance value R in ohm-cm is
determined

Corrosion Risk from

Resistivity

Resistivity (ohm-cm) Corrosion Probability

> 20000

Negligible

10000 to 20000

Low

5000 to 10000

High

< 5000

Very high

Corrosion probability based on

Resistivity and Potential difference
Test Results
Resistivity
Potential
(ohm)
(mV)
>10000
> -200
< 10000

-200 to -350

5000

-200 to -350

< 5000

< -350

Low (high
conductivity)

Higher
potential
gradient

Interpolations

No corrosion relatively
cathodic
Initiation of corrosion
relatively anodic
Presence of corrosion
anodic
High intensity corrosion
fully anodic
High rate of corrosion

Modified Figg Permeability test

(Porosiscope-Plus)

Modified Figg Permeability

test
Aim:
To determine the air or water permeability of the surface layer
of the concrete.

Procedure:
In both the air and water permeability test, a hole of 10 mm
diameter is drilled 40 mm deep normal to the concrete surface
A plug is inserted into this hole to form an airtight cavity in the
concrete
In the air permeability test, the pressure in the cavity is
reduced to 55 kPa using a hand operated vacuum pump and
the pump is isolated
The time for the air to permeate through the concrete to
increase the cavity pressure to 50 kPa is noted and taken as
the measure of the air permeability of the concrete

Modified Figg Permeability

test
Water permeability is measured at a head of 100
mm
A two-way connector is used to connect this to a
syringe and to a horizontal capillary tube set 100
mm above the base of the cavity
Water is injected through the syringe to replace all
the air and after one minute the syringe isolated
with a water meniscus in a suitable position
The time for the meniscus to move 50 mm is
taken as a measure of the water permeability of
the concrete

Testing Techniques
Property under
Test
investigation
Fire Damage Assessment Differential Thermal
Analysis
X-ray Diffraction
Thermo-Gravimetric
Analysis

Differential Thermal Analysis

Aim:
To study the physical and chemical
changes that occur in a material when it
is heated

Principle:
When a material is slowly heated, its
temperature rises but when the material
undergoes any endothermic reaction,
like, losing water, losing CO2, change in
crystalline structure, its temperature
remains constant.

Differential Thermal Analysis

Procedure:
Sample and inert materials are heated in separate crucibles
Difference of temperature between the two is recorded by
thermocouples
Thermocouples generate electrical signal whenever there is
change in temperature difference between the reference
and sample
When there is no endothermic reaction, no change in
differential temperature and hence no electrical signal is
generated
When any endothermic reaction occurs, there is differential
temperature and electrical signal is generated
The results are presented in the form of curves

Differential Thermal Analysis

Inference:
Endothermic peak due to Calcium hydroxide
is found at 500C
Endothermic peak due to conversion of
silica is found at 570C
Various fire damaged samples are subjected
to DTA and the peak temperatures are noted
By comparing the DTA curve of the sample
with known compounds, qualitative
composition of the sample can be judged

X-ray Diffraction
Aim:
To determine the extent of deterioration in concrete that has
been subjected to fire
To determine the temperature to which concrete that has
been subjected

Principle:
When a monochromatic X-ray beam falls on a crystal it gets
reflected by the various crystalline planes in the substance
Interference occurs among the various refected beams
resulting in a diffraction pattern consisting of dark and bright
fringes
The composition of a sample can be determined by comparing
the fringe patterns with that of already known crystals

Testing Techniques
Property under
investigation
Structural
Integrity/Soundness
Assessment

Test
Ultrasonic pulse velocity

Impact Echo Test

Radiography

Radiography
Aim:
To
To
To
To

determine the location and size of reinforcement

check for the existence of voids
determine the areas of poor compaction
check for voids in grouting in prestressing ducts

Procedure:
Photograph is taken, showing details of the inside of a
concrete member
Gamma rays used for elements upto 500 mm thickness and
high energy X-rays used for elements more than 500 mm
thickness
Safety precautions have to taken against usage of gamma
rays and X-rays

Conclusion
In majority of cases, the causes of problems are be
due to
Lower cover thickness
Permeable cover concrete
High chloride levels
Alternate wetting and drying

All possible factors be noted during an

investigation, so that unusual features of the
environment or the concrete can be identified and
the necessary solution is sought
The remedial solutions may range from minimal
patch repair to drastic replacement

 Reference :
Handbook on Repair and Rehabilitation
of RCC buildings, CPWD