Repair and Retrofitting of Concrete Structures
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pdilankitNPTEL Online Certification Course on
Retrofitting and Rehabilitation of Civil Infrastructure
Module-C: General Repair and Retrofitting of
Concrete Structures
EL
PT
Week 3: Lecture C.1
Considerations for Repair and
N
Retrofitting
Swati Maitra
Assistant Professor
Ranbir and Chitra Gupta School of Infrastructure Design and Management
IIT Kharagpur
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
Concepts Covered
Considerations for Repair and Retrofitting
Steps for Repair and Retrofitting
Shoring and Scaffolding
EL
Surface Preparation
PT
N
Repair Materials
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 2
Considerations for Repair and Retrofitting
Deterioration and Performance over Time
Minimum Acceptable
Performance Level
Deterioration
Performance
Deterioration curve
EL
Service Life Performance curve
PT
N
Time Maximum Acceptable
Deterioration Level
Decreases the strength
Decreases the durability
Increases the rate of deterioration
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 3
Considerations for Repair and Retrofitting
Deterioration, Repair and Performance over Time
Minimum Acceptable
Performance Level
Deterioration
Performance
Deterioration curve
EL
Service Life Performance curve
PT
Repair
N
Time Maximum Acceptable
Deterioration Level
Increases the durability
Does not increase the strength
Slows down the rate of deterioration
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 4
Considerations for Repair and Retrofitting
Deterioration, Retrofitting and Performance over Time
Minimum Acceptable
Retrofitting Performance Level
Deterioration
Performance
Deterioration curve
EL
Performance curve
PT
N
Time Maximum Acceptable
Deterioration Level
Increases the strength
Increases the durability
Increases the level of performance
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 5
Considerations for Repair and Retrofitting
Existing Infrastructure
Initial Inspection General Visual
Regular Visual
EL
Periodic Inspection
PT
Detailed Investigation NDT & Coring
N
Evaluation Analysis of Test
Results
Repairing Retrofitting
Framework for Repairing & Retrofitting
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 6
Considerations for Repair and Retrofitting
Repair / Retrofitting in terms of
Functionality – functional performance
Structural Safety – load carrying capacity (flexure, shear, axial, torsion),
fatigue resistance, ductility etc.
EL
Serviceability – deflection, level difference, vibration, noise
PT
Appearance – aesthetics, surface characteristics, crack
N
width, crack density
Durability – long term performance
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 7
Considerations for Repair and Retrofitting
Important Stages for Repair and Retrofitting
Determine the cause(s) of damage
Evaluate the extent of damage
Evaluate the need for repair/retrofitting
EL
Select the repair/retrofitting method and the corresponding material(s)
PT
Prepare the existing structure suitable for repair/retrofitting
N
Implement the repair/retrofitting method
Cure and finish the process for usage
Evaluate the structure after retrofitting
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 8
Considerations for Repair and Retrofitting
Challenges of Repair and Retrofit of Existing Structure
Realistic assessment of the present condition of the structure
Extent of repair/retrofitting to be done
Selection of proper repair/retrofitting method and material
EL
Deterioration after repair/retrofit
PT
Access to the structural component to be repaired/retrofitted
N
as the structure is still in use
Skilled manpower
Cost
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 9
Steps for Repair and Retrofitting
Fixing suitable support and formwork – necessary for application of the
selected repair and retrofitting method
Surface preparation – sand blasting, removal of dust and debris by air blasting,
water blasting, brooming etc., cleaning and primering/ coating of corroded
EL
steel reinforcements
PT
Application of appropriate measure – apply the suitable repair and retrofitting
N
method using the selected materials
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 10
Shoring
Means of providing support temporarily to get stability of a
structure under certain circumstances during construction,
repair or alteration
Adopted when Stability of a structure is endangered due
EL
to
PT
unequal settlement during construction or during any Shoring
period of its service life
N
[Link]
removal of a defective portion of the structure
remodeling of walls, changing positions of windows etc.
alterations in adjacent buildings
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 11
Shoring
Shoring made of Timber and/or Steel tubes. Timber to be surface coated
Shoring to be designed based on the load it has to sustain and duration of load
Shoring may be internal or external, sometimes on both sides of the wall for
EL
additional stability
PT
No time limit for Shoring – may be kept for long as necessary
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 12
Shoring
Types of Shoring
Raking or Inclines Shores
angle of shores 60⁰ to 75⁰, for external supports
EL
Flying or Horizontal Shores
PT
restraint against tilting, overturning
N
Dead or Vertical Shores
provided on ground supporting vertical loads
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 13
Shoring
Roof Terrace Wall
Props or Struts Needle
1st Floor
Dead or
Vertical
Shores
EL
Ground
Floor
PT
Ground level
Dead or Vertical Shoring
N
Single Raking or Inclined
Timber Shore Two structures supported with a single
Flying or Horizontal Timber Shore
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 14
Shoring
EL
PT
Inclined and Horizontal Shoring
Hydraulic Vertical shoring
[Link]
N
Vertical shoring
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 15
Scaffolding
To provide access areas for repairing / retrofitting / constructing structures
at longer heights
Temporary structure on the outside of a structure, made of wooden planks
and metal poles
EL
PT
Used by workmen for repairing / construction / retrofitting / painting etc.
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 16
Scaffolding
Scaffolding for repair
and retrofitting
EL
PT
[Link] [Link]
dangers-of-scaffolding/ [Link]
N
Source: Author
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 17
Surface Preparation
Surface repair involves the process of conditioning
the existing concrete to receive repair materials
Conditioning is required to remove deteriorated,
contaminated, or damaged concrete to provide
EL
surfaces that will promote bonding of the repair [Link]
[Link]/p
PT
ractical-
materials
guide/surface
-preparation- Surface preparation
concrete-
repair/5827/
N
The surface preparation process is one of the most
critical phases of retrofitting work
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 18
Surface Preparation
General surface preparation procedure [Link]
Step 4
Step 1
Clean the surface of any
Locate area to be
exposed reinforcing steel
repaired. Hammer
and the existing
sounding or chain
concrete. It is critical to
drag are generally
achieve an adequate
used when locating
bond between the repair
EL
delamination.
and the existing Step 5
concrete. SSD “saturated surface dry” or
PT
damp concrete is ideal prior to
Step 2 placing repair material.
Remove deteriorated
N
concrete using Step 3
acceptable methods. Prepare surface
Surfaces of existing repair boundaries to
concrete expected to prevent feather
receive the repair edged conditions.
material must be sound, Done by saw cutting
clean, and free of bond the perimeter to
inhibiting materials. recess the edge
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 19
Surface Preparation
Concrete removal methods: Partial depth
Chipping action due to round
chisel that rotates freely
EL
Removal of the surface
PT
due to water pressure
N
Pneumatic chipping hammer
[Link]
accessories/product/12096606/chicago-pneumatic-construction-equipment-chicago-
pneumatic-cp4133-chipping-hammer
[Link]
services/robotic-hydro-demolition
Hydro removal
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 20
Surface Preparation
Concrete removal methods: Partial depth
Milling of top pavement surface
EL
PT
Rotary milling machine
[Link]
Hand held device used to remove
the top surface
N
Pneumatic scabbler
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 21
Surface Preparation
Concrete removal methods: Full depth
Selective demolition method that involves removing
damaged or low-strength concrete while keeping intact the
healthy concrete
Full depth concrete removal using high pressure water
EL
PT
[Link]
toolbox-learn-how-to-use-hand-tools-off-your-
skid-steer-or-track-loader/
N
Hydro demolition
[Link]
concrete_cleans_rebar
Full depth concrete removal using
repeated vertical movement of hammer Handheld pneumatic breaker
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 22
Surface Preparation
Concrete removal methods: Full depth
Hydraulic splitting means controlled demolition.
Hydraulic splitting eliminates both shocks and vibrations
associated with large impact tools
EL
PT
N
Splitters
[Link]
Use in road and bridge demolition,
indoor foundation breaking, light rock Pneumatic/hydraulic mounted
breakers
breaking [Link]
hydraulic-rock-breaker-for-sale_994985.html
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 23
Repair Materials
Desirable Properties of Repair Materials
Low shrinkage
Quick Setting / hardening properties
Good bond strength with existing substrate
Sufficient strength and compatible mechanical properties
EL
Adequate Workability
PT
Minimal curing requirement
N
Should allow relative movement
Air and Water impermeability
Non-hazardous and non-polluting
Durable and Cost effective
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 24
Repair Materials
Cement mortar
Polymer modified mortars
Epoxy resins
Low viscosity epoxy sealing compounds
EL
Epoxy mortar
PT
Sealers and Coatings
Polyurethane and Methacrylic Acrylate Resins
N
Silane and Siloxane sealing compounds
Chemical compounds
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 25
Repair Materials
Mixture of cement and sand
May also contain supplementary cementitious materials and
chemical admixtures
Should be consumed within 30 minutes after adding water
EL
Cement Mortar
PT
[Link]
mortar/ [Link]
Chemicals/1062605/products/polymer-modified-
repair-mortar/212657803
N
Mixture of mortar and polymer/latex in
dispersed form
Polymer latexes consisting of very small
diameter particles based on elastomeric and
thermoplastic materials emulsified in water Polymer Modified Cement
Mortar
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 26
Repair Materials
Mixture of epoxy resin and hardener in specified proportion
Epoxy resin generally created by transforming liquid polyethers into
infusible solids through a special curing process. Result of a
chemical reaction between epichlorohydrin and bisphenol-A
Hardener – aliphatic and aromatic amines and polyamides
EL
PT
Epoxy resins [Link]
[Link] com/concrete-bonding-
anchoring-adhesives/
N
Additional diluents are added
for lowering the viscosity
Coal Tar Epoxy system
Rubber Modified Epoxy system
Low viscosity epoxy sealing
compounds
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 27
Repair Materials
Mixture of epoxy and sand or epoxy, sand and coarse aggregates in
specified proportions
EL
PT
N
Epoxy mortar
[Link]
Numerous compositions with
methacrylate-based formulations, poly-
siloxane-based resin formulations etc. Sealers and Coatings
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 28
Repair Materials
Silanes and siloxanes - the two most common types of
water repellents
Both derived from silicone molecule. Silicone is a generic
name for a wide variety of polymeric chains constructed
[Link]
around a molecular structure of Si–O–Si [Link]/ap-
EL
1400-silane-
siloxane-
waterproofing/
PT
Silane and Siloxane
sealing compounds
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 29
Summary
Considerations for Repair and Retrofitting
Steps for Repair and Retrofitting
Shoring and Scaffolding
EL
PT
Surface Preparation
N
Repair Materials
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 30
THANK YOU
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 31
NPTEL Online Certification Course on
Retrofitting and Rehabilitation of Civil Infrastructure
Module-C: General Repair and Retrofitting of
Concrete Structures
EL
PT
Week 3: Lecture C.2
Repair Techniques
N
Swati Maitra
Assistant Professor
Ranbir and Chitra Gupta School of Infrastructure Design and Management
IIT Kharagpur
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
Recap of Lecture C.1
Considerations for Repair and Retrofitting
Steps for Repair and Retrofitting
Shoring and Scaffolding
EL
PT
Surface Preparation
N
Repair Materials
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 2
Concepts Covered
Repair techniques
Surface Preparation near corroded reinforcements
Repair of cracks by sealing and grouting methods
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 3
Surface Preparation near corroded reinforcement
Concrete surface preparation, when corroded reinforcement is encountered
Corroded Surface after removal
reinforcement of loose concrete
EL
PT
N
Emmons, H., Peter. (1994). Concrete Repair and Maintenance
Illustrated: Problem Analysis; Repair Strategy; Techniques, R.S.
Means Company, Inc., Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 4
Surface Preparation near corroded reinforcement
Perimeter of repair area is cut by saw or other
methods approximately at 90º angle to the surface
Surface of Concrete removed to
EL
steel cleaned expose corroded bars
PT
N
Concrete removed
under corroded bar
Emmons, H., Peter. (1994). Concrete Repair and Maintenance
Illustrated: Problem Analysis; Repair Strategy; Techniques, R.S. Means
Company, Inc., Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 5
Cleaning of reinforcing steel
Concrete to be Special coatings by
removed around alkaline slurry coating,
full circumference cathodic protection, epoxy
of the bar coating may be applied to
add additional protection
to the reinforcing bars
EL
PT
Emmons, H., Peter. (1994). Concrete Repair and
Maintenance Illustrated: Problem Analysis; Repair Strategy;
Techniques, R.S. Means Company, Inc., Kingston
Heavy oxides and other
N
Bars damaged
bond inhibiting materials during removal
removed by needle operations are
scalers, high pressure required to be
water cleaning, abrasive repaired or
blast cleaning, power replaced
wire brushing
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 6
Cleaning of reinforcing steel
Needle scalers are pneumatic tools utilizing small diameter steel
rods powered by an internal piston. Steel rods hit the intended
surface, causing removal of surface materials
EL
Needle Scalers
PT
[Link]
preparation-tools/concrete-metal-scalers/needle-scalers
N
Water mixed with sand cleans concrete
and steel surfaces, removing unsound
materials that results in a roughened
surface, promoting a better bond with
coating or repair materials High pressure water cleaning
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 7
Cleaning of reinforcing steel
Abrasives mixed with pressurized air and projected through a
nozzle to clean steel or concrete surface
EL
Abrasive blast cleaning
PT
[Link] [Link]
water-jets/ g/better-brushes-better-technique-better-cleaning
N
Power wire brushing
Power brush finishing employs wire, elastomer bonded wire, or non-
metallic (cord, natural fiber or synthetic) brushing wheels in automatic
machines, semi-automatic machines and portable air tools to smooth or
roughen surfaces, remove surface oxidation and weld scale
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 8
Replacement of reinforcing steel
Emmons, H., Peter. (1994). Concrete Repair and
Reinforcing Steel Repair (From Section Loss) Maintenance Illustrated: Problem Analysis; Repair
Strategy; Techniques, R.S. Means Company, Inc.,
Kingston
Affected Length
Loss of Section Supplemental bar over affected
length. New bar should be
mechanically spliced to affected bar
EL
If the reinforcing steel has lost more than 25% of its cross section or placed parallel to existing bar
(or 20% if two or more adjacent bars are affected), then
Complete bar replacement
PT
reinforcing steel repair is generally required
N
Supplemental Bar
Required Lap Required Lap
Affected Length
Note: When damage to reinforcing steel is uncovered, it is good
practice to perform a structural review of situation
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 9
Concrete removal geometry for repair
Partial depth
EL
Section Elevation
Beam / Rib Full depth
PT
Slab / Wall
Elevation NSection Emmons, H., Peter. (1994). Concrete Repair and
Maintenance Illustrated: Problem Analysis; Repair
Column corner Strategy; Techniques, R.S. Means Company, Inc.,
Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 10
Bonding repair materials to existing concrete
Considerations for development of adequate bond
Clean and sound substrate
Roughened profile of substrate for mechanical interlocking actions
EL
Open pore structure in substrate
PT
Repair material/bonding agent with sufficient paste for absorption into
substrate pores
N
Application of repair material with sufficient pressure to
facilitate contact between the two surfaces
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 11
Bonding repair materials to existing concrete
Bond characteristics
between new and existing
concrete
EL
PT
N
Emmons, H., Peter. (1994). Concrete Repair and Maintenance
Illustrated: Problem Analysis; Repair Strategy; Techniques, R.S.
Means Company, Inc., Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 12
Concrete Repair
Repair of cracks
Repair of patches
Repair of leakages
Replacement of structurally weak concrete
EL
PT
Replacement of spalling / delaminated concrete
N
Replacement of carbonated concrete surrounding
reinforcement
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 13
Repair Techniques
Sealing Drilling and Plugging
Surface Coating Pre-placed Aggregate Concrete
Dry Packing Routing and Sealing
Grouting Stitching and Stapling
EL
Gravity Filling Shotcrete
PT
Surface Impregnation Ferro Cement
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 14
Repair of Cracks in Concrete by Sealing
Impregnation of Sealants into the cracks
Surface coating
Surface
EL
coating Impregnation of
Epoxy into crack
PT
N
Steel
Source: Author
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 15
Repair of Cracks in Concrete by Surface Coating
Depth of crack less than cover thickness
Replacement of the damaged concrete with cement mortar
Surface coating only and no Sealants into the cracks
EL
Crack without
PT
Surface coating
resin
N
Steel
Cement mortar
Source: Author
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 16
Repair of Cracked Concrete near Corroded Reinforcement
Removal of portions contaminated with chloride/ carbonation
Replacement of the section with cement mortar
EL
Corrosion in
Cement mortar steel
PT
N
Steel
Source: Author
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 17
Repair of Damaged Concrete near Corroded Reinforcement
Removal of portions contaminated with chloride/ carbonation
Application of corrosion inhibitor to reinforcement
Replacement of the section with polymer cement mortar and surface coating
EL
PT
Surface coating Polymer Cement
Mortar
N
Steel Corrosion
Impregnation Inhibitor
Source: Author
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 18
Repair of Damaged Concrete near Corroded Reinforcement
Replacement of damaged concrete with Polymer modified cement mortar
Polymer modified
cement mortar
EL
PT
N
Corroded Corroded
Steel bar Steel bar
Bad Replacement Good Replacement
Source: Author
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 19
Dry Pack and Epoxy Bonded Dry Pack
Dry cement sand mortar (1:2.5) with little water
to form a ball
Immediately packed and placed in thin layers
(8-10 mm), and compacted with hammer
EL
Epoxy can also be used as binder –
PT
Dry pack for crack sealing
Epoxy bonded dry pack [Link]
N
application/
Suitable for small areas
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 20
Dry Pack and Epoxy Bonded Dry Pack
EL
PT
[Link]
-of-concrete-repairing-dry-packing/
N
Application of Dry pack at the bottom surface of a deck slab
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 21
Grouting
Process of inserting a material at a high pressure into cavities, voids, joints,
cracks etc. in concrete or masonry to restore its monolithic nature, filling
voids, stopping leakages, restoring strength etc.
Grout is a mixture of cement, water, water reducing admixtures, expansion
EL
agents, pozzolanas, chemicals etc.
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 22
Grouting
Procedure for Grouting
Drilling of grouting holes
Instrument - jack hammer, shot drill
Arrangement of grout pipes
EL
pipes ~4.5 cm diameter, 45 – 90 cm long
PT
Cleaning of cracks
N
by injecting water at high pressure into cracks
Inserting the grout into the holes
at high pressure of about 0.65 kg/cm2
Adequate curing after grouting
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 23
Grouting
Grouting on concrete surface
EL
PT
[Link]
repair/pressure-grouting/
N
[Link]
grouting-Compaction-grouting-can-be-used-for-the-
following_fig2_339536616
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 24
Techniques for Grouting
Cement Grouting
Epoxy Injection Grouting
EL
Chemical Grouting
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 25
Cement Grouting
Cement grout is a composite material generally
consisting of water, cement and sand
Cement grouting or slurry grouting is used to fill
underground voids, underpin foundations, to
strengthen granular soils and materials
EL
PT
Grout pipes Cement Slurry
[Link]
N
Placement of grout pipes
for grouting
[Link]
grouting/
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 26
Cement Grouting
Cement grouting application
When cracks are dormant
When cracks are active but cause of cracking has been determined
and remedial action has been taken
EL
When honeycombing is present in concrete structures
PT
N
When masonry is hollow
When deep leached mortar joints are present
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 27
Epoxy Injection Grouting
Epoxy resin and a low viscosity liquid hardener is injected
into the cracks with pressure to fill up the voids and cracks
Useful for repair of small crack as narrow as 0.05 mm
EL
Steps for Epoxy Grouting
Cleaning of the cracks
PT
Epoxy injection through small
channel
N
[Link]
Sealing the crack surface using small channels / ports into
the seal
Injecting epoxy through the channels to fill up the cracks
Removing the surface seal after curing of the epoxy
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 28
Epoxy Injection Grouting
Channels fixing for
epoxy grouting
EL
[Link]
PT
N
Source: Author
Source: Author
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 29
Epoxy Injection Grouting
Epoxy grouting application
Epoxy grout is waterproof and almost completely resistant to stains
Does not crack, shrink or discolour; making it ideal for applying in wet areas
Highly resistant to the harsh chemicals
EL
PT
Does not need to be sealed, due to its non-porous nature
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 30
Chemical Grouting
Chemical grout - pure solution with no particles in
suspension, e.g. Hydrophilic Polyurethane
Grouting Material
Solution grouts commonly used are acrylamides,
EL
polyurethanes, acrylates, epoxies and sodium
PT
silicates Stabilization of sand to prevent
foundation movement
N
[Link]
Major purpose to keep the soil in place by
stabilization, eliminating differential settlement of
structures over it
Also for the purpose of controlling water leakage
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 31
Chemical Grouting
[Link]
EL
PT
N Stabilization and strengthening
of sand
Strengthening of sand to increase bearing capacity
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 32
Gravity Filling of Cracks
Sealing of cracks of width 0.03 to 2.0 mm by gravity filling using low viscosity
monomers and resins
Cleaning of crack surface by air/ water blasting and allowed to dry for several
days
EL
Resin is poured onto the surface and spread with brooms, rollers or
PT
squeegees which slowly recedes into the cracks
N
Excess material to be broomed off
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 33
Surface Impregnation using Vacuum Method
Creating partial vacuum (by a vacuum source) within the concrete and
excess water is sucked out and then introducing the repair material, like
resin of very low viscosity
Resin (Methyl Methacrylate, Expanding Vinyl Ester Gel etc.) enters into
EL
cracks, microcracks (width up to 5 microns), voids, capillary system
PT
Complete filling up of cracks & voids
N
Upon curing, results into strong and sound concrete
Improved bonding due to lack of air voids
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 34
Surface Impregnation using Vacuum Method
Equipment - Vacuum Pump, Water Extractor, Filtering Pad, Screed Board Vibrator
Dewatering through vacuum results into good workability and high strength
Low permeability
EL
Smooth surface with reduced shrinkage
PT
Reduce corrosion type of distresses as moisture is evacuated
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 35
Surface Impregnation using Vacuum Method
The heavily used A40
motorway in London was
repaired on a January
night. Polyethylene film
EL
was laid and sealed, and
operators were connecting
PT
the vacuum lines to
N
evacuate and dry the Surface Impregnation using vacuum
concrete before applying method
the resin.
[Link]
object?id=00000153-8b93-dbf3-a177-9fbb2db10000
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 36
Summary
Repair techniques
Surface Preparation near corroded reinforcements
Repair of cracks by sealing and grouting methods
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 37
THANK YOU
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 38
NPTEL Online Certification Course on
Retrofitting and Rehabilitation of Civil Infrastructure
Module-C: General Repair and Retrofitting of
Concrete Structures
EL
PT
Week 3: Lecture C.3
Repair Techniques
N
(contd…)
Swati Maitra
Assistant Professor
Ranbir and Chitra Gupta School of Infrastructure Design and Management
IIT Kharagpur
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
Recap of Lecture C.2
Repair techniques
Surface Preparation near corroded reinforcements
Repair of cracks by sealing and grouting methods
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 2
Concepts Covered
Repair techniques (contd…)
Repair of cracks by various grouting methods
Shotcrete
EL
Ferro-cement
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 3
Drilling and Plugging of Cracks
Applicable when cracks run approximately in straight lines and are accessible
from one end
Often used to prevent vertical cracks in retaining walls
Drilling down the length of the crack and grouting it to form a key
EL
A hole is drilled (diameter 50 to 75 mm), cleaned and filled with grout
PT
N
Grout key prevents transverse movements of the sections
of concrete adjacent to crack and reduces loss of material
or leakage
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 4
Drilling and Plugging of Cracks
Key with precast concrete
or mortar
Hole drilled in stem of wall,
following down the crack
EL
PT
N
[Link] Repair of Retaining wall by drilling and plugging
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 5
Pre-Placed Aggregate Concrete
Useful when conventional concreting is difficult, e.g. areas of heavy
reinforcements, under water concreting
Clean graded coarse aggregates densely pre-packed into the formwork
Grout is forced through pipes or tubes into the voids of pre-packed aggregates
EL
Grout – mixture of cement, sand, pozzolana, superplasticizer
PT
N
Coarse aggregates need to be washed and screened before
placing to remove all fines and deleterious materials
Grouting starts from the bottom of pre-packed aggregates
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 6
Pre-Placed Aggregate Concrete
Grouting through pre-placed
coarse aggregates of the
retaining wall
EL
[Link]
aggregate-concrete-pac/3591/
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 7
Pre-Placed Aggregate Concrete
EL
PT
Grouting through pre-placed coarse
aggregates of the structure
N
[Link]
construction/preplaced-aggregate-
concrete
Flowable grout mixed and pumped into formed cavity, filling
space between aggregate
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 8
Routing and Sealing of Cracks
Repair by enlarging the crack along its exposed face
Filling and sealing the crack with suitable joint
sealant
Sealant - epoxies, urethanes, silicones, polysulfides,
EL
asphaltic materials, polymer mortars
PT
Routing and sealing of cracks on
a road surface
Applicable for horizontal, vertical or curved surfaces [Link]
N
having narrow to wide cracks
Simple technique, cost effective
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 9
Routing and Sealing of Cracks
At the crack, a groove is made (6 to 25 mm) using
a concrete saw-cutter / right-angled grinder
Cleaning of the groove by air blasting / sand
blasting / water blasting and then dried
EL
Sealant is placed into the dry groove and allowed
PT
to cure Crack sealed road surface
[Link]
N
A bond-breaker may be provided at the bottom of
the groove to allow the sealant to change shape,
without causing stress concentration
Bond breaker – polyethelene strip or tape
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 10
Routing and Sealing of Cracks
EL
PT
Repair of crack by sealing: (a) original crack; (b) routing; (c) sealing
N
Effect of Bond breaking [Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 11
Repair of Cracks by Stitching and Stapling
Stitching
Holes are drilled in concrete on both sides of the crack
Insertion of steel bars into the hole from one end to another end
Filling up the hole by suitable grout material / epoxy resin
EL
PT
Stapling
N
Groove is cut on concrete surface perpendicular to the crack
Insertion of steel bars from the top
Filling up the groove by suitable grout material / epoxy resin
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 12
Repair of Cracks by Stitching and Stapling
EL
PT
Note: Holes are alternated to each side of the crack
spaced 20-30 in. on center. Must start hole proper
distance from crack to get intersection at mid-depth
N
[Link]
_Joint_and_Crack_Sealing_and_Repair_for_Concrete_P
avements
Stitching and stapling on
cracked concrete surface
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 13
Repair of Cracks by Stitching and Stapling
Stitching and stapling on
cracked concrete roads
EL
[Link]
PT
[Link]
N
Source: Web Source: Web
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 14
Thin Polymer Overlay
Used to improve the abrasion resistance of hardened
surface
Used to improve waterproofing and protective surface
Polymer overlay applied in less than 10 mm thickness
EL
Polymer overlay comprises of primer coat and sealant
PT
[Link] Polymer overlay on
[Link]/bridge-decks/
a road surface
Primer coat - vinyl ester resin
N
Sealant - vinyl ester resin + silica filler / titanium dioxide
pigment / carbon black pigment etc.
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 15
Thin Epoxy Overlay
Used to improve the abrasion resistance of concrete
surface
Used to improve waterproofing and protective surface
Epoxy overlay 2 – 3 mm thickness (resin + hardener)
EL
Faster strength gain Epoxy overlay
PT
[Link]
Epoxy overlay sometimes require
preservation/bridge-overlays/epoxy-overlay-t-526
N
protective coating
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 16
Protective Seal Coat on entire Surface
Protective layer used as seal coat on hardened surface
Protection from ingress of water and harmful chemicals
Adhesion to surface, compatibility with alkaline
atmosphere
EL
Capacity to cover surface irregularities with ease of
PT
application Seal coating on road surface
[Link]
N
May contain some pigments to improve aesthetics
Seal coat of polyurethane, epoxy, alkydes, chlorinated
rubber, acrylic emulsions etc.
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 17
Shotcrete
Also called ‘Gunite’ or ‘Pneumatically applied concrete or mortar’
Deposition of materials in layers over the surface under pressure without
supporting formwork
Useful for restoring spalled surfaces
EL
PT
Dry mix process or Wet mix process
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 18
Shotcrete – Dry Mix Process
Thoroughly mixing the dry materials
Feeding of the materials in a mechanical feeder or gun
Carrying the material by compressed air through a hose to a special nozzle
EL
Introducing water at nozzle point and intimately mixing with other ingredients at
the nozzle
PT
N
Jetting the mixture from the nozzle at high velocity on to the
surface to receive the shotcrete
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 19
Shotcrete – Dry Mix Process
EL
PT
N
[Link]
[Link] Schematic diagram of Dry Mix Process
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 20
Shotcrete – Dry Mix Process
EL
PT
N
Dry Mix Shotcrete applied on a curved surface
Source: Web
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 21
Shotcrete – Wet Mix Process
Thoroughly mixing all the ingredients including water
Feeding the mixture into the delivery equipment
Delivering the mixture by compressed air up to the nozzle
EL
Jetting the mixture from the nozzle at high velocity on to the surface to receive
PT
the shotcrete
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 22
Shotcrete – Wet Mix Process
EL
PT
N
[Link] Schematic diagram of Wet Mix Process
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 23
Shotcrete – Wet Mix Process
EL
PT
Wet mix Shotcrete applied on a surface
N
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 24
Advantages of Shotcrete
Shotcrete undergoes placement and compaction simultaneously
Dense, homogeneous, high strength and waterproof
Can be applied on any type and any shape of surfaces like vertical, horizontal,
curved etc.
EL
Fibers can be added as an ingredient for shotcrete
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 25
Ferro-Cement
Thin-walled concrete, thickness ranging between 12–30
mm for crack/surface repair
Hydraulic cement mortar reinforced with a minimum 2
layers of continuous and orthogonally woven wire mesh
EL
4 – 6 mm apart
PT
Ferro cement application
Cement mortar is admixed with plasticizers and polymers [Link]
[Link]
N
to seal the cracks
Wire mesh is mechanically connected with the concrete
surface by nails fixed with suitable epoxy bonding system
Protective layer against water and environment
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 26
Ferro-Cement
Hand plastering, semi-mechanized and guniting
Normally Portland Cement and fine aggregates (>2.36 mm) are used in
Ferro cement in the ratio of 1:2 or 1:3 with w/c of 0.40 to 0.45
Plasticizer / Admixtures / Fly ash
EL
Reinforcement – Skeleton Steel or Wire Mesh
PT
Special technique for compacting ferro-cement layers using
N
orbital vibrators to ensure proper encapsulation of wire
mesh in cement mortar
Water curing
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 27
Ferro-Cement
Skeleton Steel – Steel bar of about 8 mm diameter spaced at 75 to 100 mm c/c.
Tied reinforcement or welded wire fabric
Wire Mesh – Galvanized wire of 0.5 to 1.5 mm diameter and spaced at 6 to 20
mm c/c. Formed by Welding / Weaving / Twisting the wires
EL
PT
N
Application of Ferro-cement
[Link] [Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 28
Ferro-Cement
Versatile, can be formed in any shape
Flexibility in cutting, drilling, jointing
Fire resistant, Impermeable, Low cost
EL
Low durability
PT
Low strength
Chances of Corrosion of wire mesh
N
Labour intensive
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 29
Summary
Repair techniques
Repair of cracks by various grouting methods
Drilling and Plugging, Pre-placed Aggregate Concrete,
Routing and Sealing, Stitching and Stapling,
EL
Thin Epoxy Overlay, Thin Polymer Overlay
PT
Shotcrete
N
Ferro-cement
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 30
THANK YOU
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 31
NPTEL Online Certification Course on
Retrofitting and Rehabilitation of Civil Infrastructure
Module-C: General Repair and Retrofitting of
Concrete Structures
EL
PT
Week 3: Lecture C.4
Repair Techniques
N
Swati Maitra
Assistant Professor
Ranbir and Chitra Gupta School of Infrastructure Design and Management
IIT Kharagpur
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
Recap of Lecture C.3
Repair techniques
Repair of cracks by various grouting methods
Drilling and Plugging, Pre-placed Aggregate Concrete,
EL
Routing and Sealing, Stitching and Stapling,
Thin Epoxy Overlay, Thin Polymer Overlay
PT
N
Shotcrete
Ferro-cement
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
Concepts Covered
Repair techniques (contd…)
Corrosion Treatments of Steel reinforcements
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
Repair Techniques
Chemical and Electrochemical Methods for Treatment of Corrosion
in Steel Reinforcement
Cathodic Protection
Chloride Extraction
EL
Re-alkalization
PT
Corrosion Inhibiting Admixtures
N
Reinforcement Coatings
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 4
Cathodic Protection
Corrosion occurs because of electro-chemical reaction between two dissimilar
elements in electrical contact in presence of oxygen and moisture. Due to the
difference in electro-chemical potential, anodic and cathodic reactions take
place. Flow of corrosion current from anodic to cathodic regions of the steel
reinforcement
EL
PT
Fe Fe++ + 2e- (anodic reaction)
N
4e- + O2 + 2H2O 4(OH)- (cathodic reaction)
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 5
Cathodic Protection
Principles of Cathodic Protection
Based on the nature of flow of corrosion current. A direct current is applied in
opposition to the corrosion current
Cathodic protection involves placing the reinforcement in a concrete structure
EL
within a circuit in such a manner that the steel becomes polarized and acts as
PT
the cathode. As a result, it does not undergo corrosion at a significant rate
N
Two approaches of Cathodic protection
Impressed Current Technique
Galvanic Cathodic Protection
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 6
Impressed Current Cathodic Protection
Involves connecting the steel reinforcement (which requires treatment) to a
metal or carbon component and applying a direct current between the
reinforcement and the component
The reinforcement becomes the cathode in an electrochemical cell and the
EL
other conductive material (like titanium, certain zinc or aluminium alloys,
PT
conductive titanium-based ceramics and carbon) becomes the anode
N
Since it is the anode that will undergo corrosion, the steel,
being the cathode, remains intact
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 7
Impressed Current Cathodic Protection
EL
PT
N
Working Principle of
Impressed Current Cathodic Protection
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 8
Impressed Current Cathodic Protection
The anode is made from a conductive material
that is inert and, thus, not vulnerable to corrosion
The circuit is completed by the diffusion of ions
through the concrete pore solution, with anions
EL
such as hydroxide and chloride ions (if present)
migrating from the cathode to the anode, and
PT
cations, including calcium, sodium and potassium Impressed current cathodic protection
N
ions, moving towards the cathode Dyer, Thomas. (2014). Concrete
Durability, CRC Press, Taylor &
Francis Group, Florida
Passivation of steel gets strengthened due to build up
of alkalinity at the cathode (production of OH- ions)
2H2O + O2 + 4e- 4(OH)-
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 9
Galvanic Cathodic Protection
Galvanic Corrosion
Electro-chemical form of corrosion in which the close proximity of two different
metals are in contact and water containing an electrolyte leads to one of the metals
corroding
Which metal will corrode that depends on the strength with which each metal’s
EL
atoms are bound to each other
PT
Depends on metal’s standard electrode potential, which is the potential difference
N
between a metal electrode and a hydrogen electrode across
an electrolyte solution
A more +ve standard electrode potential denotes a material is
more active or anodic and thus is more prone to corrosion
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 10
Galvanic Cathodic Protection
In this technique, a potential difference is not required
to be actively applied – passive form of protection
Instead, the potential difference is produced by
connecting the reinforcing steel to an electrode made
EL
from a metal that is more anodic, leading to galvanic
corrosion, in which the more anodic electrode
PT
corrodes sacrificially and the steel remains largely Galvanic cathodic protection
N
unaffected
The absence of an applied electrical current thus is
usually more economical when compared with
impressed current technique
Dyer, Thomas. (2014). Concrete
Durability, CRC Press, Taylor &
Francis Group, Florida
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 11
Galvanic Cathodic Protection
System consists of
Strip or mesh type sacrificial anode, based on Zinc or Aluminium or Magnesium
alloys. Anode must be in contact with concrete like sheeting attached to the
surface, mesh held in place by permanent formwork, thin layers applied using
EL
thermal spraying or blocks held in shallow cavities in concrete
PT
Ion conductive backfill (hydro-gel or polymer system)
N
Embeddable reference electrodes
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 12
Chloride Extraction
Electrochemical chloride extraction (ECE) is a technique that reverses the
movement of chloride ions into concrete through the application of a potential
difference between an electrode at the concrete surface and the reinforcing
steel
EL
The configuration is similar to that of Impressed current cathodic protection
PT
technique, although a temporary external electrode is used and the voltage
N
used is higher (approximately 10 - 40 V), as compared
to the potential differences of a few hundred millivolts for
cathodic protection
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 13
Chloride Extraction
Principles of Electrochemical Chloride Extraction
When a potential difference is established between a surface electrode and the
reinforcing steel, -ve ions migrate towards the anode
A potential difference
EL
Electrolyte solution
Working Principle of
is applied between [Ca(OH)2 ]
Electrolytic Chloride Extraction
Tank
+
PT
the steel bar and the Mesh
-
mesh with a direct
N
current power source Cl-
Cl-
CaCl2 is formed,
Cl- Cl-
Cl-
Cl-
Cl- Cl-
Cl- Cl-
which can be drained
off from the tank
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 14
Chloride Extraction
Chloride / Hydroxyl ion ratio > 0.6, protective
passivating layer starts breaking down –
Chloride Threshold (approx. 0.4% Chloride by
weight of Cement)
Original Concrete
EL
External anode (Titanium coating) is temporarily
PT
attached to the concrete surface and reactions
are driven by a DC power supply
Chloride Removal Technique
N
Chloride ions are negatively charged and move
from the steel surface towards the external
anode
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 15
Chloride Extraction
During the electrolysis process, the production of hydroxide ions at the
reinforcing steel surface results into a high pH level indicating a highly alkaline
concrete environment after completion of the process
This alkaline environment protects the steel against future chances of corrosion
EL
PT
N
Free chloride
concentrations at different
distances from a
Dyer, Thomas. (2014).
Concrete Durability, reinforcement bar with
CRC Press, Taylor &
Francis Group, Florida time during ECE
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 16
Re-alkalisation
Nondestructive electro-chemical treatment to restore the alkalinity of
carbonated concrete for prevention of further corrosion of reinforcements
Usually done on carbonated concrete, where pH levels within a structural
element have dropped, or threaten to drop, causing carbonation
EL
Application of an electric field between the reinforcement and an anode system
PT
embedded in an electrolytic source and temporarily placed on the concrete
N
surface
Instead of using a power supply, a sacrificial external
electrode, e.g. Aluminium alloy, can also be used in the
configuration (similar to galvanic cathodic protection)
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 17
Re-alkalisation
Principles of Re-alkalisation
Electrochemical technique that is used to produce hydroxide ions at the
reinforcement (as occurs during cathodic protection and chloride extraction) and
cause the migration of alkali metal ions toward the steel to passivate its surface
EL
Here, the electrolyte used is normally K2CO3 or Na2CO3, which permeate the
PT
concrete and further increase levels of alkalinity in the concrete pore solution
N
Electro osmosis and migration of ions take place.
Electrolysis at steel surface produces alkaline environment
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 18
Re-alkalisation
EL
PT
N
Working Principle of Re-alkalization Treatment
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 19
Re-alkalisation
The increase in OH- at the surface is the result of their production at the
reinforcement surface
The increase in Na+ is the result of the migration of ions from within the
concrete and from the electrolyte solution used in the treatment
EL
Evidence for Na2CO3 Electrolyte Na2CO3
Change in the concentration
of OH-, Na+ and CO32- at the
PT
electrolyte having reached reinforcement undergoing
re-alkalisation
N
the reinforcement is the
(relatively small) increase
in CO32− ion concentration
Dyer, Thomas. (2014). Concrete Durability,
CRC Press, Taylor & Francis Group, Florida
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 20
Re-alkalisation
After treatment, the pH is considerably higher mostly due to the production of OH-
The pH around the reinforcement may typically decrease with time, due to the
diffusion of ions caused by the differences in concentrations of ions at different
locations in the concrete
EL
Generally stabilize at pH Electrolyte Na2CO3
PT
10.5, adequate for
N
passivation
Profiles of pH and Na concentrations
in an untreated carbonated specimen
and a re-alkalised specimen after
treatment for 33 days
Dyer, Thomas. (2014). Concrete Durability, CRC Press,
Taylor & Francis Group, Florida
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 21
Corrosion Inhibiting Admixtures
Agents that increase the chloride threshold level (which causes de-passivation)
and also slows down the corrosion, once de-passivation has occurred
Corrosion Inhibitors – Inorganic and Organic compounds
Inorganic Corrosion Inhibitors like Calcium Nitrite [Ca(NO2)2], Sodium Nitrite,
EL
Sodium Molibdate, Sodium Flurophosphate
PT
Organic Corrosion Inhibitors like Malonic acid, Disodium Glycerophosphate,
N
amine compounds
Act as anodic or cathodic inhibitors
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 22
Corrosion Inhibiting Admixtures
Anodic Inhibitors (inorganic compounds) oxidize Fe(OH)2 into Fe(OH)3,
removes nitrite ions and thus lowering the [Cl-] / [NO2-] ratio
Cathodic Inhibitors (organic compounds) forming a protective layer at the
EL
steel surface, thus limiting the chloride and oxygen to reach the
PT
reinforcement
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 23
Reinforcement Coatings
Two types – Impermeable material and Sacrificial coating
Impermeable coating – Application of Epoxy Resin
Sacrificial coating – Galvanized treatment. Coating the surface of steel with a
thin layer of Zinc (~ 10 to 250 μm thickness )
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 24
Reinforcement Coatings
Epoxy coating
Isolate steel from contact
with oxygen, moisture,
and chloride, thus
EL
preventing corrosion of
PT
steel reinforcement
N
Thickness of epoxy
coating ~ 0.3 mm Epoxy coating of existing
reinforcement
[Link]
methods/5835/
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 25
Reinforcement Coatings
Sacrificial coating – Galvanized treatment
Zinc being more anodic than steel, it undergoes corrosion and steel remains
uncorroded
Under conditions of relatively low chloride concentration and pH level typical of
EL
concrete, Zinc is passivated and thus acts also as a physical barrier to the
PT
reinforcement against chlorides
N
Chloride concentration required to depassivation of zinc is
much higher
Corrosion products of zinc being non-expansive, so
cracking is reduced and thus further protection of steel
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 26
Reinforcement Coatings
EL
PT
Galvanized reinforcing steel
N
[Link]
p/2017/06/30/galvanized-rebar/
Epoxy coated steel bars
[Link]
epoxy-coated-rebar/
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 27
Summary
Corrosion Treatments of Steel Reinforcements
Cathodic Protection
Chloride Extraction
EL
Re-alkalisation
Corrosion Inhibiting Admixtures
PT
Reinforcement Coatings
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
THANK YOU
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 29
NPTEL Online Certification Course on
Retrofitting and Rehabilitation of Civil Infrastructure
Module-C: General Repair and Retrofitting of
Concrete Structures
EL
PT
Week 3: Lecture C.5
Strengthening of Structural
N
Components
Swati Maitra
Assistant Professor
Ranbir and Chitra Gupta School of Infrastructure Design and Management
IIT Kharagpur
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
Recap of Lecture C.4
Corrosion Treatments of Steel Reinforcements
Cathodic Protection
Chloride Extraction
EL
Re-alkalisation
Corrosion Inhibiting Admixtures
PT
Reinforcement Coatings
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
Concepts Covered
Conventional Strengthening Techniques
Attachment of Steel to Concrete and Crack Stabilization
Strengthening of Structural Components
EL
Advantages and Limitations of Strengthening with Steel
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
Conventional Strengthening Techniques
Strengthening - upgrading the capacity of a structure over its original design
Strengthening of structural concrete by
‘Replacing’ poor quality or defective material by better quality material
EL
‘Attaching’ additional load-bearing materials
PT
‘Re-distribution of the loading actions’ on the structural system
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 4
Conventional Strengthening Techniques
New load-bearing material
Highly quality concrete
Reinforcing steel bars (longitudinal, lateral, stirrups, etc.)
EL
Thin steel plates, straps, tendons
PT
Fiber reinforced polymer composites (sheets, plates, bars etc.)
N
Various combinations of these
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 5
Conventional Strengthening Techniques
Strengthening Techniques
Section Enlargement
New additional concrete and reinforcing steel
Bonded to existing concrete to act monolithically
EL
Composite Construction
PT
Placement of additional plates / structural shapes of
N
steel / other material to increase the stiffness or load
carrying capacity
Load transfer in the composite member by the use
of adhesives, grouts, mechanical anchors etc.
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 6
Conventional Strengthening Techniques
Post-tensioning
Placement of tension components either Internally within the member or
externally to the member by jacking
Tension components – steel plates, rods, tendons, strands etc.
Provides the member an active load carrying capability, relieves
EL
overstressing, reducing deflections etc.
PT
Stress-Reduction
N
By cutting new expansion joints, jacking displaced
structure, installing isolation bearings, removal of
portions of structure
Reduces stress in a member or structure
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 7
Conventional Strengthening Techniques
Internal Grouting
Pressure injection of flowable materials into cracks, voids, discontinuities
to regain the structural properties and strength
Materials for grouting - Polymers, cement-based materials etc.
EL
External Grouting
PT
Pump materials outside the structure, to fill voids between the structure
and the surrounding soil
N
To provide necessary load transfer between the
structure and soil or to displace unwanted settlement
Materials for grouting – cement based materials,
chemicals etc.
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 8
Attachment of steel to concrete
Steel is utilized to
strengthen connections or to
provide additional tensile
capacity
EL
Different techniques of
Attachment by mechanical attachment of steel to concrete
connections / adhesives /
PT
Emmons, H., Peter. (1994). Concrete Repair and Maintenance Illustrated: Problem
Analysis; Repair Strategy; Techniques, R.S. Means Company, Inc., Kingston
combinations
N
Attachments permitting load
transfer (shear, tension, or
compression) between the
steel and the concrete
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 9
Crack Stabilization
EL
PT
Emmons, H., Peter. (1994). Concrete Repair and
Maintenance Illustrated: Problem Analysis; Repair
N
Strategy; Techniques, R.S. Means Company, Inc.,
Kingston
Improper Crack Treatment
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 10
Crack Stabilization
Proper Crack Treatment
EL
PT
Emmons, H., Peter. (1994). Concrete Repair and
Maintenance Illustrated: Problem Analysis; Repair
N
Strategy; Techniques, R.S. Means Company, Inc.,
Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 11
Strengthening of Structural Components
Beams and Girders – Shear and Flexural Strengthening
Slabs – Flexural Strengthening
Columns – Axial and Confinement Strengthening
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 12
Beam Shear Strengthening
Techniques for increasing beam shear capacity
Internal Post-tensioning
External Post-tensioning
EL
Internal Steel reinforcement
PT
External Steel reinforcement
N
Section Enlargement
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 13
Beam Shear Strengthening
Internal and External Post-Tensioning
EL
Drilled hole
through member
PT
Internal Post-Tensioning N External Post-Tensioning
Emmons, H., Peter. (1994). Concrete Repair and Maintenance Illustrated: Problem Analysis; Repair Strategy; Techniques, R.S. Means Company, Inc., Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 14
Beam Shear Strengthening
External Post-Tensioning Emmons, H., Peter. (1994). Concrete Repair and Maintenance
Illustrated: Problem Analysis; Repair Strategy; Techniques, R.S.
Means Company, Inc., Kingston
EL
Shear Crack
PT
N
Shear Crack epoxy
grouted before post-
tensioning
Post-tensioned rods on
each side of beam
External Post-Tensioning
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 15
Beam Shear Strengthening
Emmons, H., Peter. (1994). Concrete Repair and Maintenance Illustrated: Problem
Internal Steel Reinforcement Analysis; Repair Strategy; Techniques, R.S. Means Company, Inc., Kingston
Addition of internal steel
reinforcement
EL
Existing Stirrups
PT
Diagonally
Drilled Shear Cracks
N
Holes
Existing
Stirrups
Steel bars
placed in
drilled holes
and grouted
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 16
Beam Shear Strengthening
External Steel Reinforcement
Shear Cracks
EL
PT
Steel Plate Bonding
External
N
Steel Stirrups
Cracks grouted with
epoxy
Addition of external steel reinforcement
Emmons, H., Peter. (1994). Concrete Repair and Maintenance Illustrated: Problem Analysis; Repair Strategy; Techniques, R.S. Means Company, Inc., Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 17
Beam and Slab Flexure Strengthening
Techniques for increasing beam and slab flexural capacity
Concrete Encasement or Section Enlargement
Concrete Overlays
EL
Externally Bonded Steel Plate
External Post-tensioning
PT
Near Surface Mounting
N
Span Length Shortening
Supplemental Support
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 18
Beam and Slab Flexure Strengthening
Concrete Encasement and Overlay
Overlaying from top, side
Beam Encasement
Overlay and soffit
Using suitable formwork,
shotcrete
Increase in dead load
EL
PT
Existing Beam
N
Concrete Overlays and Encasement
Emmons, H., Peter. (1994). Concrete Repair and Maintenance Illustrated: Problem Analysis; Repair Strategy; Techniques, R.S. Means Company, Inc., Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 19
Beam and Slab Flexure Strengthening
EL
PT
N
Beam Encasement or Section Enlargement
CPWD Handbook (2002). Repair and Rehabilitation of RCC Buildings
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 20
Beam and Slab Flexure Strengthening
Concrete Overlay at top and
bottom of Slab
EL
PT
CPWD Handbook (2002).
N
Repair and Rehabilitation
of RCC Buildings
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 21
Beam and Slab Flexure Strengthening
Externally Bonded Steel Plate
Plate bonded at top and bottom
EL
Steel plate bonded with Epoxy
Bridge live load adhesive
capacity increase with
PT
bonded steel plates
Threaded rod
N
provides additional
shear capacity and
erection support
Epoxy adhesive
Steel plate
Emmons, H., Peter. (1994). Concrete Repair and
Maintenance Illustrated: Problem Analysis;
Repair Strategy; Techniques, R.S. Means
Company, Inc., Kingston Epoxy adhesive pressure grouted into Plate-Concrete interface
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 22
Beam and Slab Flexure Strengthening
Correction of deflected member
Installation of with Bonded Steel Plate
Lifting of steel plate
deflected
slab
EL
PT
N
Section through
deflected slab
Epoxy adhesive
Bonded steel plate
Emmons, H., Peter. (1994). Concrete Repair and
Maintenance Illustrated: Problem Analysis; Repair Anchor used for erection of plate
Strategy; Techniques, R.S. Means Company, Inc.,
Kingston
and additional shear capacity
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 23
Beam and Slab Flexure Strengthening
EL
PT
[Link]
Steel Plates at the tension faces of the beam
N
CPWD Handbook (2002). Repair and Rehabilitation of RCC Buildings
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 24
Beam and Slab Flexure Strengthening
External Post Tensioning
High strength steel strands are used to increase the strength of damaged
concrete structures
Tendons are pulled and connected to anchor points
EL
Anchoring by shear transfer mechanism or by end bearing assembly with side
PT
mounted or soffit mounted and bolted
N
High fatigue and impact resistance
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 25
Beam and Slab Flexure Strengthening
External Post Tensioning
EL
Stressed Tendon immediately allows the
beam to carry loads
PT
External Post-Tensioning
N
External Post-Tensioning
Emmons, H., Peter. (1994). Concrete Repair and Maintenance Illustrated: Problem
Analysis; Repair Strategy; Techniques, R.S. Means Company, Inc., Kingston
Tensioning of external PT tendons
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 26
Beam and Slab Flexure Strengthening
External Post Tensioning
End
Anchorage
Externally mounted
Emmons, H., Peter. (1994). Concrete Repair and Maintenance
post-tensioned strand
Illustrated: Problem Analysis; Repair Strategy; Techniques, R.S. on each side of beam
EL
Means Company, Inc., Kingston
PT
Externally Post-Tensioned
Concrete Beams
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 27
Beam and Slab Flexure Strengthening
External Post Tensioning
Difficulty in providing anchorage in post-tensioning strands
Difficulty in providing lateral stability
Corrosion of steel strands
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 28
Beam and Slab Flexure Strengthening
Near Surface Mounting (NSM)
Addition of tensile reinforcements
perpendicular to the plane of the crack
A shallow groove or slot is saw-cut across
EL
the crack, larger than the diameter of bar,
PT
and is cleaned NSM Steel bars in Concrete beam
N
Insertion of cementitious grout / epoxy resin
into the cleaned slot as a bonding agent
Steel bars are placed in the slot and the
surface is levelled
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 29
Beam and Slab Flexure Strengthening
Span Length Shortening
EL
PT
Emmons, H., Peter. (1994). Concrete Repair and
Maintenance Illustrated: Problem Analysis; Repair
N
Strategy; Techniques, R.S. Means Company, Inc.,
Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 30
Beam and Slab Flexure Strengthening
Supplemental Support
EL
Supplementary
Support
PT
N
Emmons, H., Peter. (1994). Concrete Repair and Maintenance Illustrated: Problem Analysis; Repair Strategy; Techniques, R.S. Means Company, Inc., Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 31
Wall Strengthening
Existing Retaining Wall
Masonry or Concrete
New Concrete
EL
Strengthening of Retaining Wall by
Retaining Wall
Section Enlargement
cast next to
PT
the Existing
Wall
N Emmons, H., Peter. (1994). Concrete Repair and
Maintenance Illustrated: Problem Analysis; Repair
Strategy; Techniques, R.S. Means Company, Inc.,
Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 32
Wall Strengthening
Wall buckled from excessive Soil
Pressure Strengthened by using
additional Steel Frames
EL
PT
Emmons, H., Peter. (1994). Concrete Repair and
Maintenance Illustrated: Problem Analysis; Repair
N
Strategy; Techniques, R.S. Means Company, Inc.,
Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 33
Strengthening of Columns
Increase in axial capacity – section enlargement with additional reinforcement
Increase in ductility – additional stirrups, concrete jacketing, steel jacketing
Increase in shear capacity connection – addition of shear collars
EL
Increase in moment capacity connection – addition of steel plates, shear walls
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 34
Strengthening of Columns
Section Enlargement
EL
PT
N
Emmons, H., Peter. (1994). Concrete Repair and Maintenance Illustrated: Problem Analysis;
Repair Strategy; Techniques, R.S. Means Company, Inc., Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 35
Strengthening of Columns
EL
PT
N
CPWD Handbook (2002). Repair
and Rehabilitation of RCC Buildings
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 36
Strengthening of Columns
RCC Jacketing
EL
PT
N
CPWD Handbook (2002). Repair and Rehabilitation of RCC Buildings
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 37
Strengthening of Columns
Steel Jacketing
Lateral confinement of concrete columns using Steel Jackets or Straps laid
intermittently along the height of the column
EL
PT
N
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 38
Strengthening of Columns
Inadequate Shear capacity at
column-slab connection Shear Capacity Strengthening
Using Shear Collars
Erection of friction-fit Shear Collar steel or concrete
Shear Collar
Non-shrink grout to be applied after
erection for uniform load transfer
EL
PT
N
Placement of
Non-shrink grout
after erection
Punching shear stresses
reduce due to increase
in effective area of shear
transfer interfaces
Emmons, H., Peter. (1994). Concrete Repair and Maintenance Illustrated: Problem Analysis; Repair Strategy; Techniques, R.S.
Means Company, Inc., Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 39
Strengthening of Columns
Beam-Column Moment Capacity Strengthening
using Steel Plates, Concrete Shear Walls Concrete
Shear wall
added to
existing
columns and
beams
EL
Steel Plate
assembly
PT
compositely
fastened to
existing
N
concrete
members
Emmons, H., Peter. (1994).
Concrete Repair and Maintenance
Illustrated: Problem Analysis;
Repair Strategy; Techniques, R.S.
Means Company, Inc., Kingston
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 40
Advantages of Strengthening with Steel
Compatible material with high strength
No need of closing the operation of the structure
Practically no change in the original dimension of beams and columns
EL
Easy mechanism for placing and erection at site
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 41
Limitations of Strengthening with Steel
Steel is susceptible to environmental attack, so chances of Corrosion with
natural exposure to environment
Difficulty in handling and cutting of steel plates at the site due to heavy
weight
EL
Difficulty in splicing of steel plates and formation of joints due to limited
PT
delivery length of steel plates
N
Difficulty of field welding due to heavy weight
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 42
Limitations of Strengthening with Steel
Need for a larger than structurally necessary jacket thickness to ensure that
the shells do not buckle while lifting into places
Steel being isotropic and having a high stiffness is not the best material for
use in concrete confinement since a large portion of the axial load is taken by
EL
the steel tube than that of concrete, the efficiency of confinement is reduced
PT
through separation
N
Failure of the epoxy at the epoxy-concrete interface
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 43
Summary
Conventional Strengthening Techniques
Attachment of Steel to Concrete and Crack Stabilization
Strengthening of Structural Components
Beam Shear Strengthening
EL
Beam and Slab Flexure Strengthening
PT
Wall Strengthening
N
Column Strengthening
Advantages and Limitations of Strengthening with Steel
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
THANK YOU
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 45
NPTEL Online Certification Course on
Retrofitting and Rehabilitation of Civil Infrastructure
Module-C: General Repair and Retrofitting of
Concrete Structures
EL
PT
Week 3: Lecture C.6
Strengthening of
N
Structural Components
Swati Maitra
Assistant Professor
Ranbir and Chitra Gupta School of Infrastructure Design and Management
IIT Kharagpur
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
Recap of Lecture C.5
Conventional Strengthening Techniques
Attachment of Steel to Concrete and Crack Stabilization
Strengthening of Structural Components
Beam Shear Strengthening
EL
Beam and Slab Flexure Strengthening
PT
Wall Strengthening
N
Column Strengthening
Advantages and Limitations of Strengthening with Steel
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
Concepts Covered
Strengthening of Structural Components
Strengthening of Foundation
Slab-jacking
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
Strengthening of Foundation
Section Enlargement of Footing
Underpinning
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 4
Strengthening of Footing
Section Enlargement with Reinforcements
EL
PT
N
Source: Web
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 5
Strengthening of Footing
EL
PT
N
Source: Web
[Link]
for-Highway-Structures%3A-Buckle-
Friedland/79f05ceea341931e3f1315ce07ddb837eb6e404e/figure/30
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 6
Strengthening of Footing
EL
PT
Drilled hole through
member Concreting in extended portion
N
Arrangement of reinforcement
Insertion of Dowel bars
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 7
Strengthening of Foundation
Underpinning
Method of supporting the structure while carrying out repairs and
alterations or providing a new or additional foundation without disturbing
the stability of existing structures
EL
Process of modifying an existing foundation by providing an extra support
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 8
Strengthening of Foundation
Need for Underpinning
To strengthen a shallow footing, when a structure with deep foundation is to
be constructed adjacent to the shallow footing
To protect an existing structure from the danger of excessive or differential
EL
settlement
PT
To improve the bearing capacity of foundation area
N
To provide a basement / additional load for an existing
structure
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 9
Underpinning
Steps before Underpinning
Proper evaluation of the existing structure
Necessary repair including grouting, crack sealing and adequate shoring
before underpinning
EL
PT
Methods of Underpinning
N
Pit Method
Pile Method
Chemical Method
Other Method, like, cement grouting, vibro-floatation etc.
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 10
Underpinning – Pit Method
Deepening and enlarging existing foundation by removing soil from beneath
the foundation and replacing it with concrete / reinforced concrete and grout
material
Needs proper shoring to prevent settlement
EL
Often results into moderate deformation of structure
PT
Simple and low cost method
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 11
Underpinning – Pit Method
EL
PT
[Link]
ngs/underpinning-methods-
procedure-foundation-
N
strengthening-repair/2092/
Underpinning by Pit Method
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 12
Underpinning – Pit Method
EL
PT
Pit Method of Underpinning with Cantilever needle
N
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 13
Underpinning – Pile Method
Strengthening existing foundation by installing piles
through pre-drilled holes
High load carrying capacity
Low settlement, low noise and vibration
EL
Underpinning piles, Micro piles, Jack piles
PT
[Link]
erpinning-methods-procedure- Underpinning by Pile Method
N
foundation-strengthening-repair/2092/
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 14
Underpinning – Pile Method
Underpinning Piles – normally provided in pairs, one on each side of load
bearing wall or in groups around the sides of columns
Micro piles - small diameter piles, high strength with steel casing, installed
from ground surface by rotary drilling
EL
Jack Piles – precast piles. Underlying ground is preloaded before the load of
PT
the structure is finally transferred by means of jacking between the tilted
N
existing structure and the new underpinning
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 15
Underpinning of Wall
EL
PT
N
Typical section of Underpinning Bay
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 16
Underpinning of Wall
EL
PT
N
Elevation of Underpinning Bay
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 17
Jack Pile Underpinning
It is done where the
[Link]
traditional underpinning is
ng-methods-procedure-foundation-
strengthening-repair/2092/
uneconomical because of
the depth of suitable Typical section of
Jack Pile Underpinning
bearing capacity of subsoil
EL
PT
Advantage - it is vibration-
N
free and flexible because
the pile depth can be
adjusted to suitable subsoil
conditions encountered
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 18
Needle and Pile Underpinning
Used where the
traditional or Jack pile
underpinning techniques
are unsuitable for the
existing foundation
EL
condition
PT
N
Needle and Pile Underpinning Sections
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 19
Pynford Stool Method of Underpinning
Stage I – Holes formed Stage 2 – Stools inserted
Stage 3 – Brickwork
between pinned stools
Used when the
in wall to receive steel or and pinned to soffit of removed to leave wall existing foundation
precast concrete stools brickwork over opening supported on pinned stools
soil has poor bearing
capacity
EL
PT
N
Pynford Stool method of Underpinning (Stages 1 to 3)
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 20
Pynford Stool Method of underpinning
Stage 4 – Reinforcement Stage 5 – Formwork Stage 6 – Formwork
fabricated and placed erected and beam removed, beam allowed to
around pinned stools cast cure before being pinned
to underside of wall
EL
PT
N
Pynford method of Underpinning (Stages 4 to 6)
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 21
Root Pile or Angle Piling
Root Pile or Angle Piling
EL
method of Underpinning
PT
N
[Link]
pinning-methods-procedure-foundation-
strengthening-repair/2092/
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 22
Underpinning Column
EL
PT
[Link]
N
methods-procedure-foundation-strengthening-
repair/2092/
Typical details of Underpinning Columns
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 23
Underpinning Column
EL
PT
N
Underpinning Column with kentledge load
[Link]
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 24
Underpinning – Chemical Method
Foundation soil is consolidated by employing Chemicals
Perforated pipes are driven in an inclined way beneath the foundation to
cover the entire area of footing
After installation of pipe, sodium silicate mixed with water is inserted
EL
through pipes and then the pipes are withdrawn
PT
Chemical reaction takes place between the chemicals and the soil is
N
strengthened by consolidation
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 25
Slab-jacking
The process of raising slab-on-grade or
filling the voids underneath, or both, by
injecting a cementitious / non-cementitious
/ asphaltic grouting material under
pressure
EL
PT
Used to level and align concrete slabs-on- Slab-jacking in progress
grade that have shifted / moved /
N
[Link]
misaligned due to settlement, erosion,
flooding or shrinkage of soil / base layer
below the slab
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 26
Slab-jacking
Prior to slab-jacking, soil conditions need to be determined
Holes are to be drilled in staggered pattern ~ 1.5 to 3.0 m c/c for inserting the
grouting materials
If the soil is tight below the slab, a void may be created to start slab-jacking.
This will distribute the pressure of the grout over a larger area, resulting in
EL
more control and an increase in lifting area
PT
Grout pressure need to be monitored by pressure gauges mounted near the
N
pump discharge and also near the grout discharge nozzle
After completion, the grout holes need to be finished
with a repair mortar to level the surface
Resurfacing the slab can be done with a polymer-modified
cementitious material for more uniform appearance
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 27
Slab-jacking
American Concrete Institute (2010). Field
Guide to Concrete Repair Application
Procedures (ACI RAP-11)
Void created below the slab to
EL
initiate Slab-jacking
PT
N
Typical layout of Slab-jacking holes
Pumping of grout in drilled
Typical Cracking pattern in a slab hole indicating grout flow
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 28
Slab-jacking
Benefits of Slab-jacking
Can be done on any weather
Material injected below the slab provides a strong base
Little or no change in landscaping
Not expensive
EL
PT
Possible Problems of Slab-jacking
Additional weight of slab-jacking grout may cause further soil settlement
N
If the soil settlement has not terminated, the jacked slab
will continue to settle
Consequently, sub-surface erosion and continued
shrinking of supporting soil may result
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 29
Slab-jacking
EL
PT
Cracked and sinking driveway restored by Slab-jacking Sinking walkway raised and levelled by Slab-jacking
[Link] [Link]
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 30
Summary
Strengthening of Structural Components
Strengthening of Foundation
Section Enlargement of Footing
Underpinning
EL
PT
Slab-jacking
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
References
Dyer, Thomas. (2014). Concrete Durability, CRC Press, Taylor & Francis Group, Florida
CPWD Handbook (2002). Repair and Rehabilitation of RCC Buildings
Emmons, H., Peter. (1994). Concrete Repair and Maintenance Illustrated: Problem Analysis;
Repair Strategy; Techniques, R.S. Means Company, Inc., Kingston
EL
American Concrete Institute (2010). Field Guide to Concrete Repair Application Procedures (ACI
RAP-11)
PT
International Concrete Repair Institute (2006). Guideline for the Selection of Strengthening
N
Systems for Concrete Structures (ICRI 330.1-2006)
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C
THANK YOU
EL
PT
N
IIT Kharagpur Retrofitting and Rehabilitation of Civil Infrastructure Module C 33
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