REPAIR AND RETROFITTING OF

MASONRY STRUCTURES

EFFORTS BY:
ABHISHEK BHATT
(0506)
ANTARA MASHRUWALA
(1706)
DISHITA SHAH
(3006)
Objective:
To study different repair materials and
techniques to be adopted in various situation to
repair defective structures of brick and stone
masonry.

Repairs: Process to replace or correct

deteriorated/damaged materials and components of
a building.

Retrofitting: Upgrading of structural and non-

structural systems to provide a higher level of
resistance than existed before .
HOW DAMAGE OCCURS IN BRICK-MASONRY
STRUCTURES:

Effect of Aging on Brick-Work:

Rain Exposure
Temperature
Moisture Absorption
Chemical Alteration
Continuous Exposure to Chemicals

Construction Error:

Eccentrically Loaded Walls gives overturning effect

(Decorative Panels on one side, Support of Working platforms
on one side)

Usage of Poor quality of materials

Error due to saving in economy

 Maintenance:

Common maintenance to brick is to white wash or to

paint them at regular intervals, preferably every 2 years.

To maintain all sanitary installation in a good condition,

any leakage notice anywhere should be intended to
immediately, since a small leakage from nani-trap would
lead to a major damage in due course.

Any cracking wherever noticed should be attended

immediately either by sealing the joints with cement
mortar or by strengthening the cracks with reinforced
bands.
TYPES OF CRACKS IN MASONRY STRUCTURES:
1.Vertical cracks in sidewalls at corner
2.Vertical cracks around balconies
3.Vertical cracks below the openings in line with the window
jambs.
4.Vertical cracks at the junction of RCC column and masonry
wall.
5. Vertical cracks in the top most stories at corners of structures
having RCC slab.
6.Horizontal cracks at window lintel or sill level in the top most
story.
7.Horizontal cracks in the top most story below the RCC slab
level.
8. Horizontal cracks at eaves level in the buildings having
pitched roof with wooden joists and purlins.
 TYPES OF CRACKS IN MASONRY STRUCTURES:

Typical Earthquake Typical Earthquake Wall Cracking

Damage - Wall Damage: In-Plane above the Door
Corner Failure (1993 Wall Cracking Opening (1993
Killari Earthquake) Killari Earthquake)
GENERAL CAUSES TO DEVELOP THE CRACKS:
Poor quality of bricks.
For masonry work,use the porous stones.
Absence of grading in before the use of fine aggregate fine mortar.
If percentage of clay and silt in fine aggregate exceed 3 percent.
Due to the excessive amount of soluble sulphate.
Plumb alignment.
The position of the element in the structure.
Differential loading.
Weak mortar.
Insufficient bond.
Improper curing.
Entered dampness from ground, roof and exterior faces.
High daily temperature variations.
Atmospheric pollutions.
Lack of strength at corner and at junction of walls.
Improper binding of thick walls.
Sand / Cement Mortar:
It is the most simplest and basic repair method. It is highly
reliable but may fail under severe drying conditions.
Thus cracks will appear as a result of shrinkage in the plastic
state of mortar.
Due to this shrinkage, debonding and delaminating frequently
occurs.
Due to high water cement, ratio strength decreases.
High density of pores and capillaries allow water and acidic
vapours to more easily penetrate the repair and attack to the
reinforcement bars.

Polymer modified cementations mortars:

Polymer modified cementitious mortars are factory controlled
blend of specially graded fillers, cement and admixtures to control
strength development in set time. To reduce the shrinkage they
contain polymers to improve the low permeability, quality and to
enhance adhesion.
The thermal expansion properties are similar to normal
concrete.
Heat development is low so much larger volume repairs can be
undertaken.
Low impermeability can prevent ingress chlorides.
Epoxy resin mortars:

Epoxy technology is based on the mixing of two liquid

resins which react together to form a hard solid if
aggregates are added the resin system acts to bind them
together to create mortar.
Achieves compressive strength of 60-80 N/mm2 and
very heavy high flexural strength.
Due to good adhesion repair will never fail along
correctly prepared bond line.
More strength gain occurs in one day in normal
atmospheric conditions.
Properly compact mortar is impermeable to water.
Most epoxy mortar requires primer.
Epoxy injection:

Narrow cracks of 0.05 mm cracks are repaired by this

method.
High strength, highly viscous material can be achieved.
In this, holes are drilled at closer interval repairs are done
under external force through pumps or greasing guns.
Normal pressure should be of 1 kg/cm2.We should not apply
too much pressure which propagates the cracks.
High degree of skills and executions are required to repair
these types of cracks.
Crack stitching:

This method involves drilling holes on both sides of

crack and grouting in stitching dogs.

Stitching may be used when the tensile strength must

be re-established across major cracks.

Stitching a crack tends to stiffen the structure, causing

the concrete to crack elsewhere. therefore it may be

necessary to strengthen the adjacent section with

external reinforcement.
METHOD FOR ADVANCE RETROFIT TECHNIQUE
WITH HELICAL REINFORCEMENT

Firstly slots are cut with cutter machine of length 500 mm on

1. each side of crack. The depth of slot is 10 mm but it also
depends on the plaster surfaces.

Clear loose detritus from slots ensuring exposed brick surfaces

2. are cleaned of mortar and flush thoroughly with water, or
treated with a suitable primer.

3. Now fill the slot with grout with pressure.

Push Helical 6mm reinforcement crack stitching tie into grout

4.
to approximately two thirds of slot depth.

Finish the surface and repair the crack on the wall with
5.
appropriate filler /grout chemical.
Tuck pointing:

Defective joints can usually be repaired by tuck-pointing with

Portland cement mortar, with the help of skilled stonemason
In this method, all joints, vertical and horizontal, in the face
of the wall should be tuck-pointed.
This procedure requires removing and replacing all mortar to
a depth of at least 16mm throughout every joint. each joint is
raked to a depth not greater than 26mm unless the old mortar
is so defective then it is necessary to remove the mortar up to
greater depth.
The depth of old mortar is removed first so that sound mortar
acts as a base for new mortar.
All dust and dirt within the raked joints should be washed out.
The mortar is mixed at least 1 hour prior to use to ensure pre-
hydration which stabilizes the plasticity and workability of
mortar and minimizes any tendency to shrink after insertion
into the joint opening.
The sand/cement ratio should be about 3 to 1 by volume.
TUCK POINTING
Grouting (cement mortar):

Masonry structures can be sealed effectively with less cost by

using grout provided the cement-base stabilizing mixture contains
an intrusion aid.
The consistency of intrusion mixture is that of smooth slurry.
Before the intrusion, grout is pumped, the holes are tested by
pumping water to see the drilling is adequate and to determine
correct consistency for the slurry repairs.
Firstly plaster is removed near the cracks from inside and
outside of walls and clean the cracks thoroughly with airjet and
water.
Wet the cracks ,if dry ,by sprinkling water.
This mixture is pumped into holes previously drilled at various
interval to various depths without damaging the integrity of
structure.

Pumping the grout simultaneously into multiple series of drill

holes ensures good penetration into any fissures within the
structure and for making masonry structures watertight.
Grouting (chemical):

Chemical grouts consist of solution of two or more

chemicals (such as urethanes, sodium silicate) that
react to form a gel. This grout opposed to cement
grouts that consist of suspension of solid particles in
a fluid.

Advantages of chemical grout include applicability in

moist environment and their ability to be applied in
very fine facture.

Disadvantage is high degree of skill needed for

satisfactory use and their lack of strength.

Crack as narrow as 0.05 mm can been filled with

chemical grout.
Polymer coating:

Polymer coating is use for the job condition and can be

an effective protective coating if properly applied.

Polymer coating should be selected from the material

specifically for the intended application.

Some formulation will adhere to damp surfaces and even

under water but may required a completely dry surface.

Mixing and applying polymers below 16 degree and

above 32 degree Celsius will require special caution and
procedure.

Moisture passing through the sub grade backfill or from

rainwater can accumulate under the coating, which will
be interrupted by freezing and thawing.
Epoxy resins
Epoxy resins are excellent binding agents with high tensile
strength. The epoxy components are mixed just prior to
application. The product is of low viscosity and can be
injected in small cracks too.
The higher viscosity epoxy resin can be used for surface
coating or filling larger cracks or holes.
Epoxy mortar
Epoxy resins when combined, with sand aggregate it forms
epoxy mortar. Epoxy mortar mixture has higher
compressive strength, higher tensile strength and a lower
modulus of elasticity than Portland cement concrete.
Quick-setting cement mortar
It is a non-hydrous magnesium phosphate cement with two
components, a liquid and a dry, which can be mixed in a
manner similar to portland cement concrete.
Gypsum cement mortar
It has lowest strength at failure among these three
materials. So it is used in minor repair works in structural
application.
Mechanical anchors
Mechanical anchors provide both shear and tension
resistance. Such anchors are manufactured to give
sufficient strength.
RETROFIT:
Post earthquake improvement of the
seismic resistance of a structure including repair
of damage . Upgrading of structural and non-
structural systems to provide a higher level of
resistance than existed before the earthquake.

SURFACE TREATMENT:

Surface treatment is a common method, which

has largely developed through experience.

Surface treatment incorporates different

techniques such as ferrocement, reinforced plaster,
and shotcrete.
FERROCEMENT:

Ferrocement consists of closely spaced multiple layers of

hardware mesh of fine rods
(Figure 1 (a)) with reinforcement ratio of 3-8% completely
embedded in a high strength (15-30 MPa) cement mortar layer
(10- 50 mm thickness).
The mortar is troweled on through the mesh with covering
thickness of 1-5 mm.
Typical mortar mix consists of 1 part cement: 1.5-3 parts
sand with approximately 0.4 w/c ratio.
REINFORCED PLASTER:

A thin layer of cement plaster applied over high strength

steel reinforcement can be used for retrofitting.

The steel can be arranged as diagonal bars or as a vertical

and horizontal mesh.

In diagonal tension test and static cyclic tests, the

technique was able to improve the improvement in strength
depends on the strengthening layer thickness, the cement
mortar strength, the reinforcement quantity and the means
of its bonding with the retrofitted wall, and the degree of
masonry damage.
 Shotcrete overlays are sprayed onto the surface of a
masonry wall over a mesh of reinforcing bars.
In shotcrete the size of coarse aggregate is limited to 6mm.
With thorough mixing of aggregates and adjustment of
pressure at the nozzle should be controlled otherwise a large
proportion of coarse aggregate is lost in rebound.
Due to greater wear of nozzles during shotcrete there is a
tendency to reduce the proportion or even eliminate coarse
aggregates.
Certain additives are available which can reduce wear and
tear of nozzles.
After shotcreting proper curing is essential.
In situation where heavy construction machinery can not be
moved or is not economically viable, manual shotcreting can
also be resorted too.
In manual method layers of concrete can not exceed 35-40
mm in thickness when laid.
Mason should be trained properly to move the trowel
applying vibrations and simultaneously for compacting effect
on each layer.
Non destructive testing of shotcrete repair work should be
carried out.
GROUT AND
PROCESS : EPOXY INJECTION:
The crack or joint should be widen wherever the injection work
is to be carried out (approximately 15 mm wide x 15 mm depth)
Drill holes of about 13 mm dia upto 150 mm deep at 500 mm @
c/c.
Use compressed air to clean the hole, as well as crack to
remove dust, dirt, loose materials etc.
Use 12 mm dia specially threaded injection nipples and fix
them into the holes provided. Seal the entire surface around
the nipple with putty.
Seal the surface of the crack with putty so as to ensure that the
injected grout does not leak from the gaps & from cracked
surface.
The surface now is ready for injection.
Prepare the injection grout and load it into the injection gun.
EXTERNAL REINFORCEMENT:

A steel plates or tubes can be used as external

reinforcement for existing Unreinforced Masonry(URM)
buildings.

Steel system is attached directly to the existing

diaphragm or wall.

Two vertical members (via pin connections), which are

placed next to the existing wall (i.e. creating in-fill panel)
can be used.
CONFINING URMwith
Confined masonry USING R.C. frame
R.C., weak COLUMNS:
represents one of
the most widely used masonry construction system in Asia
and Latin America.
In China, they used such confinement in new masonry
buildings as well as it is used as retrofitting for existing
URM buildings.
The basic feature of confined masonry structures is the
vertical R.C. or reinforced masonry tie columns, which
confine the walls at all corners and wall intersections as well
as the vertical borders of doors and windows openings.
In order to be effective, tie columns should connect with a
tie beam along the walls at floors levels.
POST TENSIONING:
Post-tensioning involves a compressive force applied to
masonry wall; this force counteracts the tensile stresses
resulting from lateral loads.

There has been little application of this technique; post-

tensioning is mainly used to retrofit structures characterized as
monuments.

This is due in part to lack of knowledge about the behavior of

post-tensioning masonry.

In addition, the codification of post-tensioning masonry has

only begun recently.
(Contd..)POST TENSIONING:
Post-tensioning tendons are usually in the form of alloy steel
thread bars.

Bars typically show higher relaxation losses (2-3 times strand

losses) and much lower strength/weight ratio (VSL 1990); in
addition, a major drawback for using of steel bars is corrosion.
Fiber reinforced plastic presents a promising solution for this
problem

Tendons are placed inside steel tube (duct) either within holes
drilled along the midplane of the wall or along groves
symmetrically cut on both surfaces of the wall.

Holes are cement grouted and external grooves are filled with
shotcrete.
GROUT OR EPOXY INJECTION
IN CRACKS

1 - Plaster removed

2 - Cracks sealed after cleaning

3 - Grout ports

Strengthening of
existing masonry

1 - Brick or block wall

2 - Injection holes

3 - Grout mixture
STRENGTHENING WITH WIRE MESH AND MORTAR
STRENGTHENING WITH WIRE MESH
Two steel meshes (welded wire fabric with an elementary mesh of
approximately 50 x 50 mm) are placed on the two sides of the wall, they
are connected by passing steel each 500 to 750 mm apart, A 20 to 40
mm thick cement mortar or micro concrete layer is then applied on the
two networks thus giving rise to two interconnected vertical plates. This
system can also be used to improve connection of orthogonal
1 - Welded wire meshwalls.
- 50 mm
x 50 mm

2 - Mortar or micro-concrete
rendering

3 - Concrete roof band

4 - Cross ties at 500 to 750

mm apart
3
5 - Corner bar diameter 8 mm

CORNER REINFORCEMENT
For Large cracks and crushed concrete
For cracks wider than about 6 mm or for regions in which the concrete or
masonry has crushed, a treatment other than injection is indicated. The following
procedure may be adopted.
The loose material is removed and replaced with any of the materials mentioned
earlier, i.e., expansive cement mortar, quick setting cement or gypsum cement
mortar.

Strengthening of
existing masonry
1 - Wire mesh on front
face

2 Clamps

3 - Wire mesh on back

face

4 - Cement plaster

5 - Crack in wall
 The technique of
Splint and bandage strengthening technique
covering the wall
with steel mesh and
mortar or micro-
concrete may be
used only on the
outside surface of
external walls but
maintaining
continuity of steel at
the corners. This
would strengthen
the walls as well as
bind them together.
As a variation and
for economy in the
use of materials, the
covering may be in
the form of vertical
splints between
openings and
horizontal bandages
over spandrel walls
at suitable number
Splint and bandage strengthening technique
NEGLIGENCE AFTER REPAIRS AND
RETROFITTING
No. Negligence Reasons
1 Hair cracks are lack of curing after 4 hours from the
found on the all application of cement mortar.
ready strengthened
brick masonry walls.

2 Weld mesh are soon improper thickness of the cement

on the brick masonry mortar
walls after finishing
coat.
3 Uneven plaster works are going on without
surface are found on preparing proper level markers.
the wall.
4 Different shades are Improper mixing of cement with
found on plastered other materials and improper curing
surface.
CASE STUDY : JABALPUR EARTHQUAKE

PHOTOGRAPHS OF DAMAGE DUE TO

EARTHQUAKE

STRENGTHNING OF EXISTING
CONSTRUCTION

STRENGTHNING OF NEW CONSTRUCTION

PHOTOGRAPHS OF NEW CONSTRUCTION

AFTER EARTHQUAKE
 JABALPUR EARTHQUAKE DAMAGED
NUILDINGS

Partial Building Faillure of Brick Masonry

Collapse in the 1997 Walls in the 1997
Jabalpur Earthquake Jabalpur Earthquake
 STRENGTHENING OF EXISTING CONSTRUCTION
Seismic Deficiency
Lack of integrity (box-type action)
Cracks in the walls
Inadequate wall resistance (shear and
tensile)
Flexible floor/roof diaphragm (Corrugated Installation of RC roof band (bond beam).
metal sheets/timber)
Cracking/damage of wall corners (due to
improper interlocking of cross walls)
Description of Seismic Strengthening
provisions used
Installation of seismic belt (bandage) at the
lintel level; it consists of welded wire mesh
installed above the lintel level and
anchored to the wall. The mesh is covered
with a thin cement plaster overlay (see
Figure a)
In case of small cracks, pressure injection
of epoxy grout; in case of large cracks,
filling the gaps with cement grout and
jacketing with reinforced cement overlay.
Reinforced concrete jacketing. Difficult to
find skilled labor and materials for welded
wire mesh in rural areas
Provision of roof band is expected to
enhance the overall intergrity and improve
torsional resistance of building
Corner strengthening of wall corners -
installation of welded wire mesh anchored
to the walls with steel dowels and covered
with a thin cement plaster overlay , see
Figure b.
FIGURE A FIGURE B
STRENGTHENING OF NEW
CONSTRUCTION

Description of Seismic
Seismic Deficiency Strengthening provisions
used
Roof Reinforced concrete roof band; provision of
roof band results in an improved overall
integrity and torsional resistance of the
building.

Wall RCC lintel band; very effective, however

skilled labour and materials may not be
available, see Figures 7D, 7E and 7F

Wall Improved quality of masonry (bricks and

mortar) use of better quality bricks will
drastically improve the wall seismic
resistance; use or richer cement/sand
mortar will improve wall shear resistance.

Wall Provision of vertical reinforcement at wall

corners and intersections, see Figure 7G
(Source: IAEE 1986)
7D-An Example of New Construction 7E-Construction of RC
with Seismic Features (note RC lintel lintel band
band)

7F-Construction of RC Lintel Band -

Pouring of Concrete Completed
7G-Provision of
Vertical
Reinforcement at
Wall Corners and
Intersections
 CONCLUSION

Cost effective and safer approach will be to carry out

appropriate repair and retrofitting of the building.
It will offer the advantage of carrying out the work part by part
or room by room so that the occupants may continue to live in
the building during the repair and retrofitting work .
By doing so the cost of repair and retrofitting came to only 8 %
of the estimated cost of reconstruction.
REFERENCES:

Civil Engineering & Construction Review (Vol.14

Dec.2001)
Structural Consolidation & Strengthening of
masonry (Department of Civil Engineering, Belgium)
13th International Brick & Block masonry Conference
Deterioration & Damages in Buildings, Department
of Civil Engineering, IIT, Kharagpur
Jabalpur & Killari earthquake Damage reports &
Retrofitting Method, Department of Civil
engineering, IIT, Kanpur
QUESTION FROM OUR PRESENTATION

Why cracks or deteriorations occurs in brick

masonry structures? State any 6 techniques
by which it can be repaired? Explain any one
in detail with neat sketches.