Repair Mod 1 PDF

REPAIR AND REHABILITATION
OF STRUCTURES
(13.805.8)
Prepared By:
Aneena Babu
Assistant Professor,
Department Of Civil Engineering,
Mbcet
SYLLABUS
Module – I
Causes of deterioration in concrete structures – errors in design,
construction operations, earthquakes, erosion, chemical reaction,
corrosion and durability.
Causes of deterioration in steel structures – corrosion, abrasion, loosening
of connections, fatigue, impact, earthquakes and environmental problems.
Preventive measures, maintenance and inspection.
Module – II
Diagnosis and assessment of deterioration, visual inspection, non
destructive tests, Ultrasonic pulse velocity method, Rebound hammer
method, Pull out tests, Windsor probe test and crack detection techniques.
Module – III
Methods of repair of cracks, repairing spalling and disintegration,
repairing concrete floors and pavements, repairing of corrosion damage of
reinforced concrete, repair of steel structures.
Module – IV
Strengthening of existing structures, guniting, jacketing, use of chemicals,
application of polymers, ferrocement and fibre concretes, Pre-stressing,
surface coatings, painting, water proofing, grouting, special repairs.
REFERENCES
1. Sidney M. Johnson, Deterioration, Maintenance and Repairs of Structures, McGraw
Hill Book Company, New York, 1965.
2. Kaminetzky D., Design and Construction Failures- Lessons from Forensic
Investigations, Galgotia Publication, New Delhi, 2008.
3. Jacob Feld and Kenneth L. Carper, Construction Failures, Wiley Interscience,1996.
4. Vidiveli B., Rehabilitation of Concrete Structures, Standard Publishers, 2009.
5. Modi P. I. and C. N. Patel, Repair and Rehabilitation of Concrete Structures, PHI,
2016.
6. Varghese P. C. and C. N. Patel, Maintenance, Repair &Rehabilitation & Minor Works
of Buildings, PHI, 2014.
7. Guha P.K., Maintenance and Repairs of Buildings, New Central Book Agency, 2011.
8. Richardson Barry, Defects and Deterioration in Buildings: A Practical Guide to the
Science and Technology of Material Failure, Taylor& Francis, 2002.
9. Stephen E. Petty, Forensic Engineering: Damage Assessments for Residential and
Commercial Structures, CRC Press, 2013.
10. Delatte N. J., Beyond Failure: Forensic Case Studies for Civil Engineers, ASCE,
2008.
MODULE 1
References:
1) Modi P. I. and C. N. Patel, “Repair and Rehabilitation of Concrete
Structures, PHI, 2016.
2)R. Dodge Woodson, “ Concrete Structures – Protection, Repair and
Rehabilitation”, Butterworth-Heinemann, 2009
MODULE-I
LECTURE - 1
References:
DETERIORATION IN CONCRETE-
CAUSES
1. Earthquake
• Mechanism:
• Shock waves- different transmission rate through several
materials
• Symptoms:
• Spalling or cracking of concrete
• Prevention:
• Minimized by proper design procedures and attention in
detailing
• Use of angular coarse aggregate than rounded aggregates
CAUSES
2. Chemical Reactions
Acid attack
External chemicals Aggressive water

attacking concrete attack
Sulphate attack
Chemical
Reactions
Internal chemical Alkali- silica
reactions between
constituents of
concrete Alkali-carbonate
rock
CAUSES
• 2. a) Acid Attack
• Mechanism:
• Reaction between acids and product of hydration of
cement
• Acid reaching reinforcing steel
• Symptoms:
• Disintegration of concrete evidenced by loss of cement
paste and aggregate from matrix
• Rust, staining, cracking and spalling of reinforcing steel
• Prevention
• Dense concrete with low water cement ratio
• Surface coating or treatment
CAUSES
• 2. b)Aggressive water attack
• Mechanism:
• Soft or aggressive waters (with low dissolved
minerals) will leach calcium from cement paste
• Symptoms:
• Roughness
• Prevention:
• Non-Portland cement based coating
CAUSES
• 2. c) Sulphate Attack
• Mechanism:
• Sulphate ions attack concrete
• Sulphate reacts with calcium hydroxide forming calcium
sulphate (Gypsum)
• Gypsum combines with hydrated calcium-aluminate forming
calcium-sulfoaluminate (ettringite)
• Results in increase in volume
• Symptoms:
• Map or pattern cracking
• General disintegration of concrete
• Prevention:
• Dense high-quality concrete with low w/c ratio
• Sulphate resistant cement
CAUSES
An example of a
structure damaged
by
sulphuric
aggression
CAUSES
• 2. d) Alkali-carbonate rock reaction
• Mechanism:
• Carbonate rock aggregate reactive in concrete
• Symptoms:
• Swelling of concrete
• Prevention:
• Avoid reactive suspected aggregates
CAUSES
Pattern cracking
caused by ACR
CAUSES
• 2. e) Alkali-silica reaction
• Mechanism:
• Aggregates containing silica reacts to form solid non
expansive calcium-alkali-silica complex or alkali-silica
complex
• Symptoms:
• Swelling of concrete
• Prevention:
• Avoid reactive suspected aggregates
CAUSES
Deterioration due to
alkali aggregates
reaction
MODULE-I
LECTURE - 2
References:
CAUSES
3. Construction errors
• Adding water to concrete
• Cause:
• Addition of water - increase slump
• Water added - finishing of structural member
• Effects:
• Concrete with lowered strength and reduced durability
• W/c ratio of the concrete increases, the strength and
durability will decrease
• Scaling, crazing, and dusting of the concrete
CAUSES
• Improper alignment of formwork
• Effects
• Discontinuities on the surface of the concrete
• Critical in areas subjected to high velocity flow of

water, where cavitation-erosion may be induced
CAUSES
• Improper consolidation
• Effects
• Result in - bug holes, honeycombing, and cold joints
Bug Holes Honeycombing Over consolidation

CAUSES
• Improper curing
• Expected characteristics not attained - impares durability.
• Symptoms:
• Various types of cracking and surface disintegration
• Failure to achieve anticipated concrete strengths,
structural cracking may occur
CAUSES
• Improper location of reinforcing steel
• Cause
• This section refers to reinforcing steel that is improperly
located or is not adequately secured in the proper
location
• Effects
• structural cracking or failure.
• Durability- As the concrete cover over the steel is
reduced, it is much easier for corrosion to begin
CAUSES
• Movement of formwork
• Cause
• Induce Cracking And Separation Within The Concrete
• Effects
• A crack open to the surface will allow
access of water to the interior
of the concrete.
• An internal void may give rise to
freezing or corrosion problems
if the void becomes saturated
CAUSES
• Settling of concrete
• Cause
• Heavier components of the concrete -settle under
gravity
• This situation may be aggravated by the use of highly
fluid concretes
• Effects
• If any restraint tends to prevent this settling, cracking or
separations may result.
• These cracks or separations may also develop problems
of corrosion or freezing if saturated
CAUSES
• Vibration of freshly placed concrete
• Cause
• weakens properties.
• Effects
• If subjected to forces, concrete matrix may
disrupt during setting
MODULE-I
LECTURE - 3
References:
CAUSES
• 4. Design Errors
Inadequate
structural design
Design Errors
Poor design
details
CAUSES
• Inadequate structural design
• Mechanism:
• Concrete is exposed to greater stress than it is capable of
carrying
• Symptoms:
• Error resulting in formation of high compressive stress
will lead to spalling
• Error resulting in formation
of high tensile stress will lead
to cracking
• Prevention:
• Careful review of all structural
design calculations
CAUSES
• Poor design details
• Abrupt changes in section
• Symptoms
• Cracking because of stress concentrations
• Prevention
• Use of relatively thin sections rigidly tied into
massive sections or patches and replacement
concrete that are not uniform in plan dimensions
CAUSES
• Abrupt changes in section
CAUSES
• Insufficient reinforcements at re-entrant corners
and openings
• Causes
• Increased stress concentration at corners
• Symptoms
• Cracking of concrete
• Prevention
• Provide additional reinforcement in areas
where stress concentrations are expected
to occur
DETERIORATION IN
CONCRETE- CAUSES
• Insufficient reinforcements at re-entrant corners
and openings
CAUSES
• Inadequate provision for deflection
• Causes
• Loading of members or sections
beyond the capacities for which
they were designed
• Symptoms
• Cracking of walls or partitions
due to loadings
CAUSES
• Inadequate provision for deflection
CAUSES
• Inadequate provision for drainage
• Causes
• Ponding of water
• Symptoms
• Leakage may result in damage
to the interior structure
• Staining and encrustations on
the structure
CAUSES
• Insufficient travel in expansion joints
• Causes
• Inadequately design
• Symptoms
• Spalling of concrete adjacent
to the joints
• Prevention
• The full range of possible temperature differentials that a
concrete may be expected to experience should be taken
into account in the specification for expansion joints
CAUSES
• Incompatibility of materials
• Causes
• The use of materials with different properties
(modulus of elasticity or coefficient of thermal
expansion) adjacent to one another
• Symptoms
• Cracking or spalling as the structure is loaded or as
it is subjected to daily or annual temperature
variations
CAUSES
• Neglect of creep effect
• Causes
• Inadequate provision for deflections
• Neglect of creep in pre-stressed concrete members may
lead to excessive prestress loss
• Symptoms
• Cracking as loads are applied
CAUSES
• Inadequate joint spacing in slabs
MODULE-I
LECTURE - 4
References:
CAUSES
5. Erosion
• Provokes the removal of material from the surface.
• Two types: Abrasion & Cavitation
5 a) Abrasion
• Mechanism
• Due to repeated rubbing and grinding of debris,
equipment, gravels etc.
• Symptoms
• Smooth and may contain localized depressions
• Prevention
• Improvements in materials used
• Hydraulic model studies of the structure
CAUSES
5 b) Cavitation
• Mechanism
• When water flow is fast enough (>12.2m/s) and where
there is surface irregularity in concrete
• Symptoms
• Pitting and roughness
• Prevention
• Improvements in materials used
• Hydraulic model studies of the structure
CAUSES
6. Corrosion of embedded metals
Due to chemical
agents
Corrosion of
embedded metals
Due to electrolytic
attack
CAUSES
6 a) Corrosion due to chemical agents:
• Mechanism
• Reinforcement exposed to circulating air or water
• Volume of oxide produced = 8 times volume of parent
metal
• Symptoms
• Concrete cover - cracking and spalling
• Prevention
• Adequate cover
• Avoid ponding water
CAUSES
6 a) Corrosion due to electrolytic attack:
• Mechanism
• Difference in moisture content, chloride content or dissimilar
metals in contact – result in electrical potential difference -
corrosion cell
• Cross-sectional area reduced- load carrying capacity reduced
• Rust formation- volume increase
• Symptoms
• Rust
• Cracks- Straight parallel lines
• Prevention
• Low permeability concrete
CAUSES
Deteriorated structure
due to corrosion
of the reinforcement
rods.
CAUSES
7) Environmental effects
7 a) Dampness:
• Rising of moisture from ground, Action of rain, Exposed tops of
walls, condensation
• Damp building – mosquitos
• Metal corrosion
• Timber decay
• Patches on wall
• Electrical fittings damaged- short circuit
• Softening and crumbling of plaster
• Efflorescence
CAUSES
7 b) Variation in atmospheric temperature
• Changes shape and volume- if change restrained- stresses
created – cracks occur
• Dissimilar materials in contact- different co-efficient of thermal
expansion
• Provide joints to relieve restraints
• Use insulation
CAUSES
7 c) Freezing and thawing
• Empty space available in concrete insufficient to

accommodate additional solid due to freezing
• Symptoms:
• Scaling and extensive disintegration
• Prevention:
• Minimise moisture exposure, cement with low w/c ratio etc.

CAUSES
7 d) Weathering
• Moisture absorbed - exposed to sub-freezing temperatures-
freeze and expand - cracks
• Symptoms:
• Cracks
• Prevention:
• Dense and sound concrete
• Air entraining cement
MODULE-I
LECTURE – 5
ACL
References:
DETERIORATION IN STEEL-
CAUSES
1. Corrosion
• Conversion of metal by natural agencies into compound
forms
• Electro-chemical reaction convert metallic iron into an

oxide or other compound
• Symptoms: Pitted, oxidised surface, showing scales of

oxide and reddish brown rust.
• Steel flakes off easily and area is reduced.

CAUSES
2. Abrasion
• Abrasion associated with working of moving parts in
contact, members subjected to wave action or members
immersed in moving fluid
• Symptoms: worn smooth appearance of abraded surface
• Example: groins or piled structures in surf zone

CAUSES
3. Loosening of connections
• Rivets and bolts in steel structures subjected to impact or
shock loading tend to loose with time
• Induces slip in the joints, causes distortion of structure,

creates areas of extreme stress concentration
• Connections need to be checked periodically

CAUSES
4. Fatigue
• Fracture of a member due to repetitive, fluctuating loads
occurring at stresses at or below usual allowable design
values
• Symptoms: Small fractures oriented perpendicular to line of

action
• Difficult to detect
• Repair of fatigue cracks requires restoration of lost strength

by plating etc.
CAUSES
5. Impact
• Characterized by local distortion of affected members
usually in the form of a crimp or a bow of short
wavelength
• Repaired by strengthening the member by plating or

encasing
MODULE-I
LECTURE – 6
References:
PREVENTION OF DETERIORATION
OF STEEL STRUCTURES
1. Keeping the structure clean

• Corrosion accelerated by debris or dirt.
• Accumulation of dirt hide underlying defects
• Sweep, blow or hose off the dirt

OF STEEL STRUCTURES
2. Painting
• Surface Preparation:
• Surface should be cleaned before painting
• Solvent cleaning to remove grease, oil and dirt.
• Removal of scale and rust by hand scrapping or wire brushing if

loose and by use of power tools if more adherent
• Very tight scale and rust must be removed by pickling, blast

cleaning (sand or shot) or flame cleaning.
OF STEEL STRUCTURES
2. Painting
• Application:
• Prime coat applied before recontamination.
• Surface should be dry and neither too cold not too hot
• Each coat of paint must be dry before applying the next coat
• Painting by brush or spray

OF STEEL STRUCTURES
2. Painting
• Inspection:
• The painted surface should be checked after each coat for the
occurrence of pinholes, holidays and blisters.
• Thickness of several coats should also be checked
• Electrical flow detectors
• Repainting:
• New paint should be compatible with existing paint
• Do not apply several successive repainting without removing
the old coatings.
OF STEEL STRUCTURES
3. Other coatings
• Bituminous paints:
• This paint is manufactured by dissolving asphalt or vegetable
bitumen in oil or petroleum
• Zinc Coating
• Used where longer life protection is desired
OF STEEL STRUCTURES
4. Encasement
• Thin coatings must be renewed at frequent intervals
• Permanent or semi-permanent protection - encasing entire

member with concrete or plastic or by sheating it with non-
ferrous metals or other non-corroding materials.
OF STEEL STRUCTURES
4 a) Concrete Encasement
• Concrete commonly used for encasing steel
• Frequently used for protection of
water front structures in tide zone,
buried pipe structures etc.
• In addition to corrosion protection,
concrete encasement is used for
preventing damage due to abrasion and fire protection.
OF STEEL STRUCTURES
4 a) Concrete Encasement
• Concrete coating may be sprayed on or cast using forms.
• Thickness of concrete cover should be adequate
• Good bond between steel and concrete
• Steel surface should be cleaned and concrete should be dense
• Beam wrapping (wire mesh) must be provided
• Cannot protect from steel corrosion due to electrolysis
OF STEEL STRUCTURES
4 b) Reinforced Bituminous Coatings

• Coating the metal surface with hot coal-tar primer and
enamel and covering it with spiral wound wrappings of felt
or other suitable material saturated with a water proofing
bituminous mixture.
• The fabric reinforce and prevent injury to coating
• Provide excellent protection against corrosion.

OF STEEL STRUCTURES
OF STEEL STRUCTURES
4 c) Other Coatings
• Packing of urethane foam covered with polysulfide liquid
• 18-gauge sheathing of nickel-copper alloy

OF STEEL STRUCTURES
5. Corrosion Resistant Alloys

• Includes copper-bearing steel for atmospheric exposures
• Use of copper-bearing or high strength low alloy steels is

advantages in buried or subaqueous installations
• Alloys high is silicon, chromium or nickel have superior

corrosion resistant properties
OF STEEL STRUCTURES
6. Sacrificial Metal
• This term denotes the thickness of the metal which is
provided over and above the requirements of stress.
• The purpose is to provide an allowance for corrosion loss in
excess of the structural requirements of the section.
• Usual procedures is :
• Calculate the member size based on stress
• Estimate the rate of loss of metal due to corrosion.
• Increase the thickness of metal by an amount equal to rate of
loss x desired service life.
OF STEEL STRUCTURES
7. Cathodic Protection
• Corrosion in aqueous environments is electrochemical in nature
and is due to a current passing from anodic areas of metal in the
solution and returning to the metal at cathodic areas.
• This type of corrosion can be prevented by applying a counter
current on the metal in sufficient amount to neutralise the
electric currents.
• Cathodic protection consists of electric connection of an anode
to the structure to be protected, thus serving the function by
neutralising the corroding current and forming layers of
insoluble reaction products on the new cathodic areas.
OF STEEL STRUCTURES
7. Cathodic Protection (contd…)

• Protects buried steel, submerged portions of marine
structures, interiors of water tank etc.
• Cathodic protection will not prevent corrosion unless the

metal to be protected is surrounded by electrolyte such as
water or damp soil.
OF STEEL STRUCTURES
7. Cathodic Protection (contd…)
OF STEEL STRUCTURES
8. Armoring
• Means for protecting structure against abrasion.
(Eg. Concrete encasement)
• Other means include wrought iron protection plates,

claddings of hard metals, use of abrasion resistant paint
coatings
OF STEEL STRUCTURES
9. Influence of design details

• All parts of structure should be accessible for maintenance if
not accessible, the member should be encased or provided
permanent protection.
• Select structural shapes that will have a minimum exposure

surface
• Avoid shapes that will catch dirt or debris.

THANKYOU !

Repair Mod 1 PDF

Uploaded by

Copyright:

Available Formats

Repair Mod 1 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Repair Mod 1 PDF

Uploaded by

Copyright:

Available Formats

REPAIR AND REHABILITATION

External chemicals Aggressive water

• Improper alignment of formwork

• Discontinuities on the surface of the concrete

• Critical in areas subjected to high velocity flow of

Bug Holes Honeycombing Over consolidation

• Empty space available in concrete insufficient to

• Scaling and extensive disintegration

• Minimise moisture exposure, cement with low w/c ratio etc.

• Electro-chemical reaction convert metallic iron into an

• Symptoms: Pitted, oxidised surface, showing scales of

• Steel flakes off easily and area is reduced.

• Symptoms: worn smooth appearance of abraded surface

• Example: groins or piled structures in surf zone

• Induces slip in the joints, causes distortion of structure,

• Connections need to be checked periodically

• Symptoms: Small fractures oriented perpendicular to line of

• Repair of fatigue cracks requires restoration of lost strength

• Repaired by strengthening the member by plating or

1. Keeping the structure clean

• Accumulation of dirt hide underlying defects

• Sweep, blow or hose off the dirt

• Solvent cleaning to remove grease, oil and dirt.

• Removal of scale and rust by hand scrapping or wire brushing if

• Very tight scale and rust must be removed by pickling, blast

• Painting by brush or spray

• Permanent or semi-permanent protection - encasing entire

4 b) Reinforced Bituminous Coatings

• The fabric reinforce and prevent injury to coating

• Provide excellent protection against corrosion.

• 18-gauge sheathing of nickel-copper alloy

5. Corrosion Resistant Alloys

• Use of copper-bearing or high strength low alloy steels is

• Alloys high is silicon, chromium or nickel have superior

7. Cathodic Protection (contd…)

• Cathodic protection will not prevent corrosion unless the

(Eg. Concrete encasement)

• Other means include wrought iron protection plates,

9. Influence of design details

• Select structural shapes that will have a minimum exposure

• Avoid shapes that will catch dirt or debris.

You might also like