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 III
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-III
LECTURE -17
References:
1) https://www.slideshare.net/NayanaD123/crack-repair- techniques
2) R. Dodge Woodson, “ Concrete Structures – Protection, Repair and
Rehabilitation”, Butterworth-Heinemann, 2009
3) https://theconstructor.org/concrete/methods-of-crack-repair/886/
4) https://civildigital.com/repair-techniques-cracks-concrete-crack-
repair/
5) Modi P. I. and C. N. Patel, “Repair and Rehabilitation of Concrete
Structures, PHI, 2016.
 PROCEDURE FOR REPAIR OF
CRACKS
1. Determine whether cracks are active or dormant
• Done by means of periodic observations utilizing crack
width gauge or Tell tales or vernier callipers
• If magnitude of movement, measured over a reasonable
period of time is sufficient to displace the telltales, treat the
crack as active
 PROCEDURE FOR REPAIR OF
CRACKS
• Determine whether cracks are active or dormant (Cont..)
• The crack width gauge is specifically designed to assist those who survey
and report on damaged buildings
• Quick and easy measurement.
• Supplied in an ever ready case.
• Manufactured in rigid durable
acrylic.
• Calibrated to edge scale which
simplifies crack measurement
in corners and awkward
locations.
 PROCEDURE FOR REPAIR OF
CRACKS
1. Determine whether cracks are active or dormant (Cont..)
• Tell-Tales consist of two plates which overlap for part of their
length.
• One plate is calibrated in millimeters and the overlapping plate is
transparent and marked with a hairline cursor.
• As the crack width opens or
closes, one plate moves relative
to the other.
• The tell-tales are fixed with
screws and adhesive across
the crack to be monitored.
 PROCEDURE FOR REPAIR OF
CRACKS
2. Determine the cause of cracking
3. Select a method of repair
• Are the cracks active or dormant?
• What is the primary purpose of repair? Is it just to reduce
excessive leakage or must be cracks be water proof? Is
strengthening required?
• How do the cracks occur? Are they pattern cracks isolated cracks?
• What is the magnitude and direction of anticipated future
movements?
PROCEDURE FOR REPAIR OF CRACKS
2. Select a method of repair (Cont..)

ACTIVE
CRACKS
Mode of
Pattern Isolated Occurance
Cracks Cracks

Not Not Strengthening

Required Required Requirement
Required Required

Improbable Extensible 1. Redesign the Blanketing

Occurance overlay structure and Applicable
provide an expansion methods of repair
joint
2. Stitching
3. External Stressing
PROCEDURE FOR REPAIR OF CRACKS
2. Select a method of repair (Cont..)

DORMANT
CRACKS

Pattern Cracks Isolated Cracks Mode of Occurance

Required Not Required Strengthening

Requirement

None Minor Severe None Minor Severe Water condition

1. Rout or Seal
Improbable 1. Rout or Seal Overlay
2. Judicious Neglect Applicable
occurance 2. Judicious Neglect
3. Autogenous Healing
3. Autogenous
4. Overlay methods of repair
Healing
4. Overlay
PROCEDURE FOR REPAIR OF CRACKS
2. Select a method of repair (Cont..)

DORMANT
CRACKS

Pattern Cracks Isolated Cracks

Required Not Required

None Minor Severe

None Minor Severe

1. Epozy 1. Ext stress+ Ext. stress+ 1. Rout or Seal 1. Rout or Seal

2. Stitching Epoxy epoxy 2. Jud. Neglect 2. Jud. Neglect Blanketing
3. Auto. Heal 2. Auto. heal 3. Auto Heal 3. Auto. Heal
4. Ext. Stress 4. Epoxy 4. Epoxy
5.Grout 5.Grout
6. Blanketing 6. Blanketing
 MODULE-III
LECTURE - 18
References:
1) https://www.slideshare.net/NayanaD123/crack-repair- techniques
2) R. Dodge Woodson, “ Concrete Structures – Protection, Repair and
Rehabilitation”, Butterworth-Heinemann, 2009
3) https://theconstructor.org/concrete/methods-of-crack-repair/886/
4) https://civildigital.com/repair-techniques-cracks-concrete-crack-
repair/
5) Modi P. I. and C. N. Patel, “Repair and Rehabilitation of Concrete
Structures, PHI, 2016.
 CRACK REPAIR TECHNIQUES
1. Bonding with Epoxies
2. Routing and sealing
3. Stitching
4. External stressing
5. Overlays
6. Grouting
7. Blanketing
8. Autogenous healing
BONDING WITH EPOXIES
• Injecting epoxy bonding compounds in high pressure into
cracks
• PROCEDURE
1. Drill into the cracks
2. Flush out cracks by injecting water/other solvents
3. Dry the surface
4. Epoxy injection in to holes
5. Curing of epoxy
6. Remove surface seal by grinding
BONDING WITH EPOXIES
ROUTING AND SEALING
• Simplest , most common , inexpensive method
• For both fine and larger isolated cracks
• This method involves enlarging the crack along its
exposed face and sealing it with a suitable joint sealant
• Most used for floors and pavements
• In road pavements hot tar used as sealant
• Side effects –
• chemical attack
• corrosion of rebars
• swelling
ROUTING AND SEALING
• Preparing a groove at the surface with a depth 6- 25mm.
Concrete saw, hand tools or pneumatic tools may be
used
• Groove is cleaned by air blasting, sand blasting or water
blasting and dried
• Sealant is placed into the groove and allowed to cure
ROUTING AND SEALING
STITCHING
• Stitching may be used when tensile strength must be
reestablished across major cracks.
• Stitching involves
• Drilling holes on both sides of the crack
• Grouting in U-shaped metal units with short legs called
• Staples or stitching dogs
STITCHING
STITCHING
STITCHING
• Following points should be observed:
• This method of strengthening will stiffen the structure
locally. This may accentuate the restraints causing cracking
and reactivate the condition
• Stitching the crack will tend to cause the problem to
migrate elsewhere in the structure
• Where there is a water problem, the crack should be sealed
as well as stitched so that the stitches are not corroded
• Where possible, stitch both sides of concrete
• If stitching is to supplement the strength of existing section,
the deformations must be compatible
 MODULE-III
LECTURE - 19
References:
1) https://www.slideshare.net/NayanaD123/crack-repair- techniques
2) R. Dodge Woodson, “ Concrete Structures – Protection, Repair and
Rehabilitation”, Butterworth-Heinemann, 2009
3) https://theconstructor.org/concrete/methods-of-crack-repair/886/
4) https://civildigital.com/repair-techniques-cracks-concrete-crack-
repair/
5) Modi P. I. and C. N. Patel, “Repair and Rehabilitation of Concrete
Structures, PHI, 2016.
EXTERNAL STRESSING
• The development of cracking is due to the tensile stress,
thus can be arrested by suppressing this stress
• Cracks can be closed by inducing a compression force to
over come the tensile stresses
• The compressive force is applied by
1. Pre-stressing wires or rods
2. Wedging – by opening the cracks and filling with
expanding mortar, by jacking and grouting or by actual
driving wedges
EXTERNAL STRESSING
BLANKETING
• Blanketing is similar to routing and sealing used on a
larger scale and is applicable for sealing active as well
as dormant cracks.
• Following are the types of blanketing joints
• Type I
• Type II
• Type III
• Type IV
BLANKETING
• Type I
• The first type of blanket joints use elastic sealants
• They return to their original shape, when not under an
externally induced stress
• A bond breaker should be used at the bottom of the chase,
so that the sealant is free to deform.
BLANKETING
• Type II

• Use sealant materials that are known as mastic sealants

• Their details are similar to that of an elastic sealant, except

that the bond breaker is omitted and the sealant is bonded
to the bottom as well as to the sides of the chase.
BLANKETING
• Type III
• It is a mortar plugged joint
• A recess in the form of a trapezoid to accommodate the
mortar plug is made
• This recess is filled with mortar
BLANKETING
• Type IV
• A water cripped bar is used
 MODULE-III
LECTURE - 20
References:
1) https://www.slideshare.net/NayanaD123/crack-repair- techniques
2) R. Dodge Woodson, “ Concrete Structures – Protection, Repair and
Rehabilitation”, Butterworth-Heinemann, 2009
3) https://theconstructor.org/concrete/methods-of-crack-repair/886/
4) https://civildigital.com/repair-techniques-cracks-concrete-crack-
repair/
5) Modi P. I. and C. N. Patel, “Repair and Rehabilitation of Concrete
Structures, PHI, 2016.
OVERLAYS
• Used to seal cracks
• Used when large no of cracks, treating each crack is
expensive
• Active cracks – overlays done with materials which are
extensible but not flexible
• Eg : Polymeric membrane with top coat of tar

• Dormant cracks – any type of overlays may be used

• Eg: polymer modified Portland cement mortar or concrete, or
by silica fume concrete
OVERLAYS
• Overlays may be placed, troweled, screeded, or sprayed in
one or more layers onto the concrete surface.

• The additional dead load of overlays is to be considered in

the analysis of an existing structure

• Overlays can be designed to act compositely with the

existing structure and additional reinforcement in the form
of welded-wire fabric, and reinforcing steel or fibers may
be added.
OVERLAYS
• For an overlay to perform properly, the surface to which it
is bonded should be clean, sound, and appropriately
roughened.

• Bonded overlays are not used where there is active

cracking or structural movement.

• Before placing the overlay, the surface must be thoroughly

cleaned and made free of laitance, weak material, grease or
oil and a bond coat consisting of finer material of overlay or
an epoxy adhesive is applied immediately before placing
the overlay.
OVERLAYS
GROUTING
• Similar to epoxy injection

• Epoxy not used where fire resistance and cold weather

• Grouting is effective alternative

• When the crack is straight line

• Drill out the length of crack

• grout it to form a key

• This method is effective in stopping water leaks

GROUTING
PROCEDURE
1. Holes are drilled in structure along cracks and in an ar
ound hollow spots.
2. If there are several cracks, holes can be drilled in a
staggered manner at 500 to 750mm spacing in both di
rections
covering adequately the area proposed to be grouted. H
oles spacing can be altered as per site conditions.
3. G.I. pieces (12 to 20mm dia x 200mm) with one end t
hreaded or PVC nozzles are fixed in the holes with rich
cement mortar.
GROUTING
PROCEDURE
4. All the cracks and annular space around G.I. pipes are
sealed with rich cement mortar.
4. All the cracks are cut open to a ‘V’ shaped groove,
cleaned & sealed with rich cement mortar.
5. All the grout holes should be sluiced with water using
the same equipment a day before grouting as per
following sequence; so as to saturate the masonry.
GROUTING
PROCEDURE
7. All holes are first plugged with proper wooden plugs or
locked in the case of PVC nozzles. The bottom most plug
and the two adjacent plugs are removed and water
injected in the bottom most hole under pressure.
8. When the clear water comes out through the adjacent
holes the injection of water is stopped and the plugs in the
bottom most hole and the one immediately above are
restored.
9. The process of grouting of concrete cracks is repeated with
other holes till all the holes are covered. On the day of
grouting all the plugs are removed to drain out excess
water and restored before commencing grouting.
AUTOGENOUS HEALING
• Autogenous healing is the natural process of crack repair that
can occur in concrete in the presence of moisture
• The repair is by a combination of mechanical blocking by
particles carried into the crack with the water and the
deposition of calcium carbonate from the cementitious material
• Autogenous healing occurs by the carbonation of calcium oxide
and calcium hydroxide present in the cement by CO2 present in
the air and water
• The resulting CaCO3 and Ca(OH)2 crystals precipitate
accumulate and grow through and out from cracks
• Develop a mechanical and chemical bonding between crystals
and between surface and crystals
 MODULE-III
LECTURE - 21
References:
1) http://www.cipremier.com/e107_files/downloads/Papers/100/26/10
0026073.pdf
2) Sidney M. Johnson, “Deterioration, Maintenance and Repair of
Structures”, Mc Graw-Hill Book Company. New York, 1965.
REPAIRING SPALLING AND
DISINTEGRATION
1. Jacketing

2. Guniting

3. Prepacked concrete

4. Drypack

5. Replacement of concrete

6. Overlays
REPAIRING SPALLING AND DISINTEGRATION

1. JACKETING
• Primarily applicable to the repair of deteriorated columns,
piers and piles

• Consist of restoring or increasing the section of existing

member by encasing it in new concrete

• Protects section against further deterioration by providing

additional strength to the member

• The form for the jacket should be provided with spacers to

assure clearance between it and the existing concrete
surface.
REPAIRING SPALLING AND DISINTEGRATION

1. JACKETING
• The form may be temporary or permanent and may
consist of timber, wrought iron, precast concrete or gauge
metal, depending on the purpose and exposure.

• Filling up the forms can be done by pumping the grout, by

using pre packed concrete

• The grout should be placed as soon as possible after the

rinsing operation and under an air pressure, sufficient to
assure a smooth and continuous flow
REPAIRING SPALLING AND DISINTEGRATION

1. JACKETING
• The forms should be filled to overflowing, the grout
allowed to settle for about 20 minutes, and the forms
refilled to overflowing.

• The outside of the forms should be vibrated during

placing of the grout.

• The top of the jacket should be finished with a collar of

concrete in such a manner that a smooth transition
between repaired and existing work will result.
REPAIRING SPALLING AND DISINTEGRATION

2. GUNITING
• Gunite is also known as shotcrete or pneumatically applied
mortar.

• Used where the deterioration is relatively shallow

• Can be used on vertical and overhead, as well as on

horizontal surfaces

• Gunite is a mixture of Portland cement, sand and water, shot

into the place by compressed air.
REPAIRING SPALLING AND DISINTEGRATION

2. GUNITING
• The existing surface must be made rough to afford a good
keying effect.

• Anchor bolts tying the new work to the old concrete are
essential.

• A layer of galvanized welded wire mesh can also be

provided.

• The mesh is connected to the hook bolts and the existing

reinforcing bars, with galvanized tie wire
 REPAIRING SPALLING AND DISINTEGRATION

3. PRE PACKED CONCRETE

• This method is particularly useful for carrying out the
repair under water and elsewhere where accessibility is a
problem.

• Prepacked concrete is made by filling forms with coarse

aggregate and then filling the voids of the aggregate by
pumping in a sand-cement grout.

• As the grout is pumped into the forms, it will fill the voids,
displacing any water in them, and form a concrete mass.
 REPAIRING SPALLING AND DISINTEGRATION
4. DRY PACK
• Drypacking is the hand placement of a very dry mortar
and the subsequent tamping of the mortar into place,
producing an intimate contact between the new and
existing works.
• Because of the low water-cement ratio of the material,
there is little shrinkage, and the patch remains tight.
• Drypacking is used for filling small, relatively deep holes,
such as those resulting from the removal of form ties, and
narrow slots cut for repair of cracks.
• The usual mortar mix is 1 :2.5 to 1 :3.
 REPAIRING SPALLING AND DISINTEGRATION
5. REPLACEMENT OF CONCRETE
• This method consists of replacing the defective concrete
with new concrete of conventional proportions, placed in
a conventional manner.
• This method is a satisfactory and economical solution
where the repair occurs in depth (at least beyond the
reinforcement), and where the area to be repaired is
accessible.
• This method is particularly indicated where a water-tight
construction is required and where the deterioration
extends completely through the original concrete section.
 REPAIRING SPALLING AND DISINTEGRATION

6. OVERLAYS
• In addition to seal cracks, an overlay may also be
used to restore a spalled or diSintegrated surface.

• Overlays used include mortar, bituminous

compounds, and epoxies.

• They should be bonded to the existing concrete

surface.
 MODULE-III
LECTURE - 22
References:
1) https://www.masterbuilder.co.in/repair-and-rehabilitation-of-corrosion-
damaged-concrete-structures/
2) Sidney M. Johnson, “Deterioration, Maintenance and Repair of Structures”, Mc
Graw-Hill Book Company. New York, 1965.
3) http://www.comsiru.uct.ac.za/sites/default/files/image_tool/images/333/R
esearch/Downloads/Mono_5_pdf.pdf
4) Mackechnie, JR, & Alexander, MG. “Repair principles for corrosion-damaged
reinforced concrete structures.” Research Monograph No. 5. University of
Cape Town: Department of Civil Engineering, 2001
REPAIR OF CORROSION DAMAGE OF RCC

• STEPS IN EXECUTING REPAIR

• The first step - strengthen the structure by performing
structural analysis and designing a suitable location for the
temporary support.
• The second step - remove the cracked and delaminated
concrete - clean the concrete surface and steel bars. After
rust is removed by brush or sand blasting, the steel bars
should be painted with epoxy coating or replaced; additional
steel rods shall be added if necessary. Then new concrete can
be poured.
• The final step is to coat the concrete member with concrete
surface coating as external protection.
 REPAIR OF CORROSION DAMAGE OF RCC
• MATERIALS
• Polymer Concrete
• Increase in strength up to 140 N/mm2 obtained using
polymer in concrete.
• Increase in tensile strength of concrete is also achieved by
polymer impregnation.
• The durability of polymer impregnated concrete is
substantially increased when exposed to freeze-thaw cycles.
• Materials (monomers and polymers) used for the
impregnation are Styrene, Polypropeleyne, Methyl
Methacrylate (MMA) and Poly Methyl Methacrylate (PMMA).
REPAIR OF CORROSION DAMAGE OF RCC

• MATERIALS
• Epoxy Grouts, Mortars and Coatings
• Epoxy resin is a product of Epichlorohydrin and Bisphenol with
or without additives such as plasticisers and dilutants.
• To get a cured epoxy resin product, a hardener (usually an
amine) is blended with the epoxy resin at ambient temperature.
• The resin mortar may be obtained by adding fillers, such as,
coarse sand or calcined bauxite grit.
• They develop excellent strength and adhesive properties, and
are resistant to many chemicals. They have good chemical and
physical stability; they harden rapidly and resist water
penetration. In all, they provide a toughness that couples
durability with crack resistance.
REPAIR OF CORROSION DAMAGE OF RCC

• MATERIALS
• Latex Modified Concrete
• These are conventional patching mixes to which is added a
synthetic latex.
• Both compressive and tensile strength are improved, while
flexibility of the patch, a major factor influencing its
durability, is increased substantially.
• Resistance to alkalies and dilute acids is good; the concrete
has low water absorption properties and freeze-thaw
stability is improved over a conventional patch.
• Bond strength of the latex modified mortar is said to be
greater than the shear strength of the old concrete.
REPAIR OF CORROSION DAMAGE OF RCC
• STRUCTURE STRENGTHENING
• One of the most dangerous and important first steps
necessary for the repair is selecting the temporary support,
which depends on the following:
• evaluating the state of the whole structure
• determining how to transfer loads in the building and its
distribution
• determining the volume of repair that will be done
• determining the type of concrete member that will be
repaired
• the repair process must be carried out by a structural
engineer with a high degree of experience who has the
capability to perform the structure
 REPAIR OF CORROSION DAMAGE OF RCC
• CLEAN CONCRETE SURFACES
• The stage of preparing a surface by pouring the new concrete is
one of the most important stages of the repair process.
• Before application of the primer coating, which provides the
bond between the existing old concrete and the new concrete
for repair, the concrete surface must be well prepared, and this
takes place according to the materials used.
• The concrete surface must be clean and not contain any oils,
broken concrete, soil, or lubricants. The surface must be cleaned
completely through sand blasting, water, or manually using
brushes.
REPAIR OF CORROSION DAMAGE OF RCC

• CLEAN STEEL REINFORCEMENT BARS

• After removal of the concrete covers and cleaning the surface,
the next step is to evaluate the steel reinforcement by measuring
steel diameter.
• If the cross-sectional area of the steel bars is found to have a
reduction equal to or more than 20%, additional reinforcing
steel bars must be added.
• In the case of beams and slabs that need to add additional
steel reinforcement bars, it is preferable to connect the steel
bars with concrete by drilling new holes in the concrete and
making the bond of the steel bars in the holes by using
adhesive epoxies.
REPAIR OF CORROSION DAMAGE OF RCC

• REPAIR STRATEGIES
• There is a proactive and reactive approach
• The suitability and cost effectiveness of repairs depends
on what level of deterioration has taken place and specific
conditions of the existing structure.
REPAIR OF CORROSION DAMAGE OF RCC
• REPAIR STRATEGIES
• PROACTIVE REPAIR STRATEGIES
• A variety of coating and penetrate systems are available that
create a barrier system to seal the surface thereby stifling
corrosion by restricting oxygen flow to the reinforcing steel.
• Application of coatings (sometimes referred to as
penetrating pore-liners) may be used to reduce the moisture
content of concrete and thereby suppress the corrosion
reaction.
• The drying action works on the fact that surfaces lined with
coatings repels water molecules during wetting but allows
water vapor movement out of the concrete to facilitate
drying.
• Coatings generally are most effective on uncontaminated
concrete, free from cracks and surface defects.
REPAIR OF CORROSION DAMAGE OF RCC
• REPAIR STRATEGIES
• PROACTIVE REPAIR STRATEGIES
• Penetrating systems with migrating corrosion
inhibitors use a chemical substance that reduces the
corrosion of metals without a reduction in the
concentration of corrosive agents.
• It is designed to soak through the concrete and protect
the reinforcing steel.
• Corrosion inhibitors work by reducing the rate of the
anodic and/or cathodic reactions thereby suppressing
the overall corrosion rate in the reinforcing steel.
REPAIR OF CORROSION DAMAGE OF RCC
• REPAIR STRATEGIES
• REACTIVE REPAIR STRATEGIES
• Once concrete begins to show signs of defects and/or
surface damage, the structural integrity is already
compromised.
• A coating or corrosion inhibitor would be insufficient
until the concrete is repaired.
• Depending on what stage of deterioration has taken
place will directly coincide with what repair method
will be required.
REPAIR OF CORROSION DAMAGE OF RCC
• REPAIR STRATEGIES
• PATCH REPAIRS
• Patch repairs all follow the same basic activities. The goal
is to clean the reinforcing steel to prevent future damage.
• To gain access to the reinforcing steel, mechanical means
are used to remove the concrete cover which can include
pneumatic hammers, hydro jetting or milling. All of the
cracked and delaminated concrete must be removed to
fully expose the corroded reinforcement.
• The corroded steel is then cleaned by sandblasting or wire
brush and an application of a protective anti-corrosion
coating to the steel is applied. At areas where the
reinforcing bar has corroded beyond 20% of the original
size, additional bar shall be spliced in to guarantee
structural integrity.
REPAIR OF CORROSION DAMAGE OF RCC
• REPAIR STRATEGIES
• PATCH REPAIRS
REPAIR OF CORROSION DAMAGE OF RCC
• REPAIR STRATEGIES
• CRACK INJECTION
• Inject epoxy under pressure into the cracks.
• The injection procedure will vary, subject to the
application and location of the crack(s), with horizontal,
vertical, and overhead cracks requiring somewhat
different approaches.
• Depending on the specific requirements of the job, crack
repair by epoxy injection can restore structural integrity
and reduce moisture penetration through concrete cracks
0.002 in. in width and greater.
REPAIR OF CORROSION DAMAGE OF RCC
 MODULE-III
LECTURE - 23
References:
1) https
CONCRETE FLOOR
MAINTENANCE / REPAIR
• REPAIRING POTHOLES IN CONCRETE FLOORS AND
SLABS
• For repairs to concrete floors and slabs that have suffered from
general wear and tear, erosion and impact damage.
CONCRETE FLOOR MAINTENANCE / REPAIR (Cont..)

• REPAIRING POTHOLES IN CONCRETE FLOORS AND

SLABS
• Saw cut around the perimeter of
the repair area.
• Break out loose and damaged
concrete leaving a sound flat base
for repair.
• Prime the sides and base of the
repair area.
• Whilst the primer is still
wet/tacky apply and compact the
repair mortar. Allow sufficient
time for the repair to gain
strength before trafficking.
CONCRETE FLOOR MAINTENANCE / REPAIR (Cont..)

• REPAIRING POTHOLES IN CONCRETE FLOORS AND

SLABS
• For repair depths of 3-50mm use
epoxy resin mortars particularly
where chemical resistance is
required.
• For repair depths of 10-100 use
cement based mortars where
applicable. Spray with water and
cover with plastic sheet to reduce
shrinkage or spray with a curing
compound.
CONCRETE FLOOR MAINTENANCE / REPAIR (Cont..)

• RESURFACING LARGE AREAS

• Remove all loose, unsound concrete

and contamination by shotblasting
(blastracking) the surface to
ensuring that the concrete substrate
is strong and open textured.
• Depending on the product to be
used either:
a) saturate the concrete with water
and after soaking remove any free
surface water. Whilst the concrete
is still damp mix the smoothing
compound and scrub it into the
surface with a stiff broom.
b) Apply two coats of primer to the
dry substrate.
CONCRETE FLOOR MAINTENANCE / REPAIR (Cont..)

• RESURFACING LARGE AREAS

• Mix and pump the resurfacing

compound over the area to the
required thickness.
• Release trapped air and assist in
levelling with a spiked roller.
• Allow to harden and traffic
CONCRETE FLOOR MAINTENANCE / REPAIR (Cont..)

• HOW TO REPAIR FULL DEPTH DAMAGED CONCRETE

FLOORS AND SLABS
• Saw cut square the perimeter of
damaged area and break out
defective concrete leaving only
sound concrete.
• Re-compact the sub-base and
replace any d.p.m.
• Drill and fix dowel bars with resin
anchor grout to tie the repair to the
existing concrete where appropriate
and place fibreboard to reform the
movement joint.
CONCRETE FLOOR MAINTENANCE / REPAIR (Cont..)

• HOW TO REPAIR FULL DEPTH DAMAGED CONCRETE

FLOORS AND SLABS
• For free standing repair place
fibreboard round the perimeter of
repair to separate it from the original.
No dowels are needed.
• Prime the sides of the repair area for
tied repairs.
• Mix and compact the repair concrete
finishing level with the traffic surface.
• Allow to harden and cut the fibreboard
to form a recessed joint if required.
• Install joint sealant and allow to cure
before trafficking.
 MODULE-III
LECTURE - 24
References:
1) https
CONCRETE PAVEMENT
MAINTENANCE / REPAIR
• Concrete is used in roads, highways and airport
pavements because of its load carrying capacity and low
maintenance
• The four common types of concrete pavements are:
• PCP Plain Concrete Pavement
• CRCP Continuously Reinforced Concrete Pavement
• JRCP Joint Reinforced Concrete Pavement
• SFCP Steel Fibre Reinforced Concrete Pavement
CONCRETE PAVEMENT MAINTENANCE / REPAIR (Cont..)

DEFINITIONS
• Base concrete : The upper (structural) layer of portland
cement concrete with varying in-situ strengths, typically 25
to 50 MPa.
• Crack : An irregular, unplanned opening in base concrete
which is essentially vertical and of various widths and which
may intersect with others, typically orientated longitudinally
(in the direction of traffic), or transversely or a combination
• Cross-stitch : A process of drilling alternately inclined holes
into concrete across a crack or joint and affixing a tiebar for
the purposes of tying adjacent concrete panels to prevent
joint/ crack from further widening.
CONCRETE PAVEMENT MAINTENANCE / REPAIR (Cont..)

DEFINITIONS
• Routing :A mechanical process where a cutting bit is
mounted on a vertical rotating shaft, with or without a
vertical oscillating action, which is manually pushed or self
propelled along the crack at a pre-set depth to form a surface
reservoir in the base concrete for the purposes of installing a
sealant
• Reservoir : A uniform rectangular (in cross section) crack
channel resulting from routing operations.
• Spall : A small broken or chipped segment of concrete
normally occurring at the edge of a joint or a crack.
CONCRETE PAVEMENT MAINTENANCE / REPAIR (Cont..)

REPAIR TECHNIQUES
• JOINT AND CRACK RESEALING:
• Joint and crack resealing minimizes the infiltration of
surface water and incompressible material into the
joint system
• It applies where the width of cracking (or
longitudinal joint opening) is at least 1 mm.
• It suggests the use of urethane as a substitute for
silicone sealant where distillate fuels are likely to be
in concentration.
CONCRETE PAVEMENT MAINTENANCE / REPAIR (Cont..)

REPAIR TECHNIQUES
• RETROFITTING CONCRETE SHOULDERS
• Retrofitting concrete shoulders adds a tied concrete
shoulder to an existing pavement.
• It is similar to dowel-bar retrofit because it decreases
the critical edge stresses and corner deflections and
reduces the potential for transverse cracking and
faulting
CONCRETE PAVEMENT MAINTENANCE / REPAIR (Cont..)

REPAIR TECHNIQUES
• DOWEL-BAR RETROFIT
• Dowel-bar retrofit increases the load transfer
efficiency at transverse cracks and joints in PCP and
JRCP pavements
• Links the slabs together so that the load is
distributed evenly across the joint
CONCRETE PAVEMENT MAINTENANCE / REPAIR (Cont..)

REPAIR TECHNIQUES
• SLAB UNDERSEALING
• Slab undersealing is a means to stabilise existing
pavement slabs by filling small voids beneath the slab
and base or base and subbase.
• The undersealing is intended to restore slab support
and does not include the lifting of the pavement slab
(slab jacking) to a prescribed elevation or to an original
profile.
CONCRETE PAVEMENT MAINTENANCE / REPAIR (Cont..)

REPAIR TECHNIQUES
• CROSS-STITCHING
• Cross-stitching is used to repair longitudinal cracks that are
in a fair condition. It increases load transfer at the crack by
adding steel reinforcement to restrict widening of the crack.
• GROOVING
• Grooving restores skid resistance to concrete pavements.
• It increases the surface friction and surface drainage
capabilities of a pavement by creating small longitudinal or
transverse channels that drain water from underneath the
tyre, reducing the hydroplaning potential.
 MODULE-III
LECTURE - 25
References:
1) https
REPAIR OF STEEL STRUCTURES
PLATING
• When abrasion or corrosion is localized – splice new metal
across area of deterioration.
• Run plates and rolled sections alongside and past the
deteriorated portion – splice them to existing sound structure.
• Convenient for repairing – cracked, buckled or local crushing
• Before installation - contact surfaces should be cleaned –
painted after plating.
• Not a permanent repair
• Should be encased- otherwise, corrosion continues
REPAIR OF STEEL STRUCTURES
2. REPLACEMENT
3. CONCRETE ENCASEMENT
THANKYOU !
JACKETING
• Primarily applicable to the repair of deteriorated columns,
piers and piles

• Consist of restoring or increasing the section of existing

member by encasing it in new concrete

• Protects section against further deterioration by providing

additional strength to the member
JACKETING TYPES
TIMBER FORMS:
• Protecting concrete from chemical reactions (marine
environments)
• Timber should be resistant to fire and appearance good
JACKETING TYPES
REINFORCED CONCRETE JACKETING (columns):
• Damaged regions of the existing members should be
repaired prior to their jacketing.
 JACKETING TYPES
REINFORCED CONCRETE JACKETING (Columns):

Properties of • Match with the concrete of the existing structure.

jackets • Compressive strength greater than that of the existing
structures by 5 N/mm2 or at least equal to that of the existing
structure.
Minimum • 10 cm for concrete cast-in-place and 4 cm for shotcrete.
width of • If possible, four-sided jacket should be used.
jacket • Narrow gap should be provided to prevent any possible
increase in flexural capacity.
Minimum • 3Afy, where, A is the area of contact in cm2 and fy is in kg/cm2
area of • Spacing should not exceed six times of the width of the new
longitudinal elements (the jacket in the case) up to the limit of 60 cm.
reinforcement • Percentage of steel in the jacket with respect to the jacket area
should be limited between 0.015and 0.04.
• At least, 12 mm bar should be used at every corner for a four
sided jacket.
 JACKETING TYPES
REINFORCED CONCRETE JACKETING (Columns):

Minimum • Designed and spaced as per earthquake design practice.

area of • Minimum bar diameter used for ties is not less than 10 mm
transverse or 1/3 of the diameter of the biggest longitudinal bar.
reinforcement • The ties should have 135-degree hooks with 10bar diameter
anchorage.
• Due to the difficulty of manufacturing 135-degree hooks on
the field, ties made up of multiple pieces, can be used.
Shear stress • Provide adequate shear transfer mechanism to assured
in the monolithic behaviour.
interface • A relative movement between both concrete interfaces
(between the jacket and the existing element) should be
prevented.
• Chipping the concrete cover of the original member and
roughening its surface may improve the bond between the
old and the new concrete.
• For four-sided jacket, the ties should be used to confine and
for shear reinforcement to the composite element.
JACKETING TYPES
STEEL JACKETING (columns):
 JACKETING TYPES
STEEL JACKETING (Columns):
Steel plate • At least 6 mm
thickness
Height of • 1.2 to 1.5 times splice length in case of flexural columns.
jacket • Full height of column in case of shear columns.
Shape of • Rectangular jacketing, prefabricated two L-shaped panels
jackets The use of rectangular jackets has proved to be successful in
case of small size columns upto 36 inch width, but has been
• less successful on larger rectangular columns. On larger
columns, rectangular jackets appear to be incapable to
provide adequate confinement.
Free ends of • Welded throughout the height of jacket, size of weld1”
jackets • 38 mm (1.5 inch), steel jacket may be terminated above the
bottom top of footing to avoid any possible bearing of the steel jacket
clearance. against the footing, to avoid local damage to the jacket and/or
an undesirable or unintended increase in flexural capacity
JACKETING TYPES
FRP JACKETING (columns):