10/03/2016 GuidelinesonRepairandRehabilitationofStructures|CPWDENGINEERSASSOCIATIONBlog

GuidelinesonRepairandRehabilitation
ofStructures

MAR4
PostedbyCPWDEngineersAssociation
SamirSurlaker&SunnySurlaker,MCBauchemieIndiaPrivateLimited

Introduction

VersatilityofConcreteisanestablishedfactonaccountofitsmouldabilityanddurability.This
makesitattractiveforuseinvariedexposureconditions.Vulnerabilityofconcreteto
deteriorationhasalwaysbeenacauseofdeepconcern.ConcreteCoverplaysakeyroleinthis
phenomenon.Generally,theprocessofdeteriorationbeginsalmostimmediatelyafterthecasting.
Basicallyfrommaterialsciencepointofview,thedurabilityofconcretestructureisadirect
functionofachievingspecifiedcovernotonlyindimensionsbutalsoinquality.Consideringa
mixofcomplicatedconstruction,quickcompletiondeadlines,speedofconstructionand
economy,itbecomesvirtuallyimpossibletocastspecifiedcovertoreinforcement.Theoutermost
layerofconcretethereforebecomestheweakestone.Ifformworksarenotimpermeableand
slumpofconcreteisnotadequate,thecementpastedoesnotcoverthereinforcementoptimallyto
renderitpassivetocorrosion.Thisfacilitatesdeteriorationandthesubsequentneedforrepairs.

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Sincecoveristhefirstlineofdefensetoinhibitcorrosion,repairandrehabilitationisrecreationof
coverwiththehighestprotectionquotient.Wethereforeneedtousethelatesttechnologieslike
polymers,fibres,etc.tolowerthepermeability,minimizethecracksandprovideadequate
bonding,tostopfurtherdeterioration.Givenactualworkingconditions,itisdifficulttocreatea
coverthatwillberesistanttocarbonationorchlorideingress.Toremovethislacunafromthe
system,itispreferabletoresorttoprotectivecoatingthatworkonprinciplestoequivalentcover
toensuredurabilityofrepairs.Therefore,thelaststepofConcreteRepair,whichisanti
carbonationorchlorideingressresistantcoating,ensuresthedurabilityofRepairs.

CauseofDeterioration

Ithasbeenestablishedthattheincreasingenvironmentalstressisoneofthekeyfactorscausing
concretedamage.Figure1showsthisprocess,duetocarbonationattack.Itisrecognizedthatsteel
embeddedinaheavilyalkalinemediumlikeconcretewithpHvaluesfrom9upwardswillnot
rust.Theconcreteshydrationprocessensurestheconcretesalkalinity,producingapHvalueof
morethan12.6,whichrendersthesteelsurfacepassivetocorrosion.Duetothis,eventhe
occurrenceofsmallcracks(upto0.1mminwidth)orblemishesintheconcreteneednot
necessarilyleadtodamage.Environmentalinfluencesandcarbondioxideinparticular,will
reducetheconcretespHvalue(carbonation)andwillremovethepassivatingeffect.In
conjunctionwithexistinghumidity,theresultiscorrosionofthereinforcement.

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BasicPrinciplesfortheProtectionandRepairof
ConcreteStructures

Defectsanddamageoccurringinconcretestructurescanbeascribedtovaryingcauses,which
frequentlyoverlap.EuropeanStandardEN1504providesanexcellentguidelinesummaryof
possiblecausesofconcretedeterioration.Thefirstpointsemphasizedinthestatisticalrecordof
causesofdamagearepoorworkmanshiponthepartoftheconcreteproducerandenvironmental
stress.Withregardtopoorworkmanship,theprincipalfactorsconcernedhereareanexcessive
water/cementratio,defectiveconcretecoveranddefectivecuring.Takingthesefactorsinto
consideration,specifiersshouldissuemorestringentguidelinesinrespectofconcretecover.Ithas
becomewidelyacceptedinspecialistcirclesthatparticularimportanceshouldbeattributedto
sufficientcuringoftheconcretewithaviewtoensuringitsdurability.Thesenewdevelopments
willconsiderablyimprovethedurabilityofnewlyerectedconcretestructures,thoughtheydonot
ofcourseaffectthequalityofalreadycompletedconcretebuildings,whichisthemajorityofour
infrastructure.Otherfactors,ofcourseincludehighermechanical,chemical,thermaland
biologicalloads.

TheProcessofRemediation

Whenastructureshowssignsofdistressordeterioration,thefollowingstepsshouldbetakenin
principle.Theconditionsurveyistobeconductedandthefieldinvestigationsaretobedone.The
stepsareasunder:PreliminaryInvestigation,detailedInvestigation,Diagnosis,Layingout
specificationsforrepairs,SelectionofMaterials,SurfacePreparations,ActualRepairs,Periodical
maintenance,MaintenanceofReportsetc.forfuturerepairs.
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maintenance,MaintenanceofReportsetc.forfuturerepairs.

Inthesesteps,thechoiceofprocedure,basepretreatmentandmaterialsforconcreterepairwill
dependontheexistingdegreeofdeterioration,themechanismofdeterioration,itscausesand
anticipatedfuturestress.Acorrectdiagnosismustthereforebearrivedatpriortorepair.The
reasonsforevidentdefectsordamagemustbeexploredasthoroughlyaspossible.Followingthis
athoroughQAsystemneedstobeestablishedtoensurethedurabilityofrepairs.Toprovide
buildingownersandarchitectswithahighlevelofreliabilityintermsofdurableprotectionand
repairwork,MChasdevelopedQualityAssuranceSystemsbasedonthefollowingcriteria:

Longyearsofexperience,professionalcompetenceandtechnicalequipmentforassessmentof
defects,damageandforestablishmentofrepairmeasures.
Dependingonenvironmentalorstructuralstressconcernedandonextentofdamage,
protectiveandrepairsystemadaptedtothestructureinquestionandinvolvingsuitableand
reliableproductsfortherepairofconcretestructureswillberecommendedfromarangeof
successfullytestedandestablishedmaterials.
Experiencedprofessionalfirmswhoarethoroughlyfamiliarwiththematerialconcerned
shouldonlycarryoutprotectiveandrepairwork.Forthesereason,MCpassesonthe
experienceandknowledgeofitsstafftoprofessionalapplicators.Thecompanywilladvise
suchfirmsbeforeandduringtheperformanceofrepairwork.

Protection:1 Protection:2
Awellestablishedrepairsystemforconcretestructuresinbuildingconstructionisdescribedin
detailbelow.Hintsarealsogivenonalternativesfrequentlyrequiredduetoconditionsatthe
structuresinquestion.InBrief,Figure3showstheprocedureofeffectiveconcreterepair.The
stepsarediscussedindetailbelow.

TheMCConcreteRepairSystem

SurfacePreparation:Theexistingbasemustbefirm&stableandfreefromoils,andfats,
impuritiesofallkindincludingform/mouldoilresidueswhichmustberemovedalongwithany
cementlaitance.Sandblastingorwirebrushingareeffectivewaterfreemethodstoclean
reinforcement.Useofacidicrustremoversandwaterisnotrecommendedtoprotectthe
reinforcementfromfurthercorrosion.Thebaseshouldbelightlymoistenedbeforecommencing
workandshouldbeslightlydampbutstillabsorbentandneversaturatedwithwater.

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ProtectionofExposedReinforcement:Allexposedreinforcementcleanedtobaremetalmustbe
protectedimmediatelyaftersandblastingbyusingZentrifixKMHpolymermodifiedone
componentcorrosioninhibitorandbondcoat.Inharsherconditions,azincrichmateriallikeMC
DURZKEcanbeused.

TreatmentofCracks:Thesealingofcracksinconcreteisaspecialmeasureinitself,which
becomesabsolutelyessentialintheeventofthefollowingwidthsofcracks:Morethan0.3mmin
dryareas/roomsorMorethan0.2mmonbuildingsintheopenorMorethan0.1mmwherethe
structurehasahighcorrosionrisk.LowviscosityepoxyresinslikeMCDUR1264canbeusedto
treatfinecracks.MCDUR1264producesastructurallyperfectbondinthecaseofnonmoving
cracks.ForbiggercracksCentricretemineralinjectiongroutisalsoavailable.Thisinjectionmust
becarriedoutbeforeapplicationofthefinaltreatment.

ConcretePCCRepair:Alldefectiveareastobefilledarefirstpretreatedwithabondcoat.
ZentrifixKMHoramixtureofZentrifixdrymortarandamixingliquidconsistingofapolymer
component,NafufillBB2/NafufillSBRandwatercanbeused.Thismixingliquidisaddedtothe
drymortaruntilagroutingconsistencyisachieved.Theresultantgroutisthenthoroughly
brushedintothebase.Whiletheadhesivebondisstillfresh,Zentrifixrepairmortarisappliedto
itwetonwet.TheZentrifixrepair,mortarcanalsobeimprovewiththepolymercomponent
NafufillBB2/NafufillSBRinordertoensuregoodadhesiontothebase,topreventshrinkage
crackingandtoimproveresistancetotemperaturechanges.

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Rep:1 Rep:2
Whereconditionsonsitemakeitimpossibletoworkwetonwet,ascudcoatofsuitable
compositioncanalsobeappliedasadhesivebond.Zentrifixmortarsareappliedinoneoperation
atrepairdepthsupto25mm,andinseverallayerswheresuchdepthsexceed25mm.Thefine
fillingdescribedindetailbelowcanbeappliedafteragapofatleast12hours.Forlargerhoney
combsandjacketingpurposesreadytouse,highstrengthmicroconcreteslikeEmcekrete/
Expacrete/EmcekreteTypeAcanbeused.

FineFilling:Toachieveavisuallyuniformsurfaceandtoprovideadditionalpreventive
protectiontherepairedconcretesurfaceshouldbefinefilled.Thisisdonewithafinedrymortar,
concretecosmeticZentrifixFF02/Nafuquick,andamixingliquidcomposedofwaterandorthe
polymercomponentNafufillBB2.Dependingonthestructureinvolved,itcanbeusedin
overheadworkorasafinefillerunderelastic,crackbridgingsystems.

ImpregnationtoprovideHydrophobicQualities:Asanadditional,protectivemeasure,
particularlyinthecaseofporoussubstratessusceptibletofractures(e.glightweightconcrete),a
hydrophobicimpregnationagentcanbeapplieduptosaturationpointtothesurfacesfirsttreated
byafinefinish,usingEmcephobSX/EmcephobACetc.Thisimpregnationwillensurethatthere
willbenoinfiltrationleadingtomoreextensivedamageifhairlinecracksfromorifthesurface
protectionissubjectedtomechanicaldamage.

ConcreteSurfaceProtection,Carbonationinhibitor,Colouredfinishes:Oncompletionofthe
workdescribedabove,theentireconcretesurfacemustbeprovidedwithafinalsealorfinal
coating.Thisismandatorytomaintainstatusquoofcorrosion.Suchsurfacetreatmentsperform
severaldutiesattheonetime.Firstly,alltheconcreteisprotectedfromfurtherstressdueto
aggressivepollutantsintheairandfromprogressivecarbonation.

ThesecoatingsystemsmusthavetoahighCO2resistanceiftheyaretobeeffectiveinprotecting
againstcarbonationand,ontheotherhand,theymustnothaveanegativeeffectonthebuildings
watervapordiffusionrate.TheEmcecolorflex/Betonflairprotectivesystemhasproveditselftobe
particularlysuitableforthispurpose.
SystemsonaTwocomponentEpoxy/PUResinBase:SystemsbasedonMCDURreaction
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SystemsonaTwocomponentEpoxy/PUResinBase:SystemsbasedonMCDURreaction
resinshaveproventobebestforstructuressubjectedtoseverechemicalstresse.ginproduction
areas,waterclarificationplant,factoryfloors,multistoreycarparksandmanyotherstructures.It
shouldbenotedherethatsystemsofthiskind,basedontwocomponentreactionresins,showa
thermalexpansionbehaviordifferentfromthatofconcrete.Allowancemustbemadeforthisfact
intherepairofstructuresintheopenairandofobjectsexposedtoseverestressfromchangesin
therepairofstructuresintheopenairandofobjectsexposedtoseverestressfromchangesin
temperature.MCDURresinsystemsprovideimportantadditionalpropertiesincomparisonwith
systemsbasesonhydraulicbindingagentsparticularlywherechemicalormechanicalloadis
severe.

Conclusion

Corrosiondamagetothereinforcementinconcreteandtheresultantspallingofsectionsof
concretealongwithotherconcretesurfacedamageisfarmoreseriousthanbeingjustaneyesore:
itconstitutesaseriousrisktotheusefullifeoftheconcretestructureandevenbecomeadangerto
occupantsandpasserby.Theguidelinesprovidedaboveindicatepossiblewaysofproviding
reliablerepairwithwellestablishedproductsandsystems.MCproductsfortherepairofconcrete
structureshaveproventhemselvesinpracticeformorethan20yearsinIndianconditions,and
manybuildingsandstructurescannowbereferredtoasevidenceoftheirquality.Inadditionto
qualityoftherepairmaterial,professionalhandlingofthesematerialsandaknowledgeof
concretetechnology,constructionphysicsandtheirinterrelationshipsonthepartofthose
applyingthetreatmentisofdecisiveimportance.Itisthereforeessentialtoreservetheexecution
ofconcreterepairssolelytoexperiencedandtrainedprofessionalfirms.Ithasalsobeenshown
that,besidescarefulexecutionandobservationofallspecificationsrelatingtothedurabilityof
concretestructures,preventiveprotectioncanprovideaddedassurance.Particularlyworthyof
noteinthisconnectioniscuringofthefreshconcretewithproductswhichwillprovidelongterm
protectionagainstCO2andotherairpollutants,thuspreventingcarbonationoftheconcrete
surface.Referenceisalsomadetoprovenprotectivesystemsforstructuresespeciallyatrisk,like
theEmcephobSystemforpreventiveprotection,Emcecolorflex/Betonflairforanticarbonation
coatsandthevariousMCDURliquidplasticsforprotectionofconcretecorrosivematerials,acids,
salts,andotherchemicaleffectsseverechemicalattack.MCstechniciansarealwaysreadyto
adviseinexpertappraisalofaparticularstructureandintheselectionofsuitablemeansof
protection.

AbouttheAuthors

Mr.SamirSurlakerisaCivilandStructuralEngineerfromVJTIwithover30yearsofNational 7/10
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Mr.SamirSurlakerisaCivilandStructuralEngineerfromVJTIwithover30yearsofNational
andInternationalexperienceandexposureinConstructionChemicals,RehabilitationStrategies,
InjectionSystemsetcGermany,Europe,MiddleEastandIndia.HeiscurrentlytheManaging
DirectorofMCBauchemie(India)PvtLtd,ajointventurewithMCBauchemie,Germany
manufacturingover100constructionchemicals.

SunnySurlakerpassedhisB.E.inCivilEngineeringfromVJTIMumbaiin2005andalsoholdsa
MastersinCivilEngineeringfromUniversityofMichigan,AnnArbor,USA.Heiscurrentlythe
HeadofAdmixtureDivisionwithMCBauchemieIndiaPrivateLimitedajointventurewithMC
Bauchemie,Germanymanufacturingover100constructionchemicals.Hehasalsoworked
extensivelyinGermanyandBrazilwithMCBauchemie.BeforethathewasaMaterialSpecialist
withtheGlobalMultinationalAMECEarthandEnvironmental,inPhoenix,Arizona,USA.

AboutCPWDEngineers'Association

ItisagreatpleasuretoinformyouthatCPWDEngineersAssociationhaslauncheditsBloggingpage.
Nowthispagewillbringtoyoulatestdevelopments/activitiesofourMembers.Alleffortsarebeingmadeto
ensurethatthiswebsitecaterstotherequirementofCPWDEngineerssofarastheirvariousinformation
throughthisAssociationisconcerned.Incourseoftimethispagewouldbethemostusefulsourceof
informationandwouldreducethegapbetweentheEngineersandthisAssociation.Pleasemustinformto
othermemberstoo.Thispageisaddedforvariousinterestingthings,ImportantNews&Activitiesof
Association.
ViewallpostsbyCPWDEngineersAssociation
PostedonSun,Mar4th,2012,inCivilEngineering.Bookmarkthepermalink.7Comments.

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Comments3

Rueben|Wed,Dec4th,2013at6:14AM
Hifantasticwebsite!Doesrunningabloglikethisrequirealotofwork?
IhavenounderstandingofcodinghoweverIhadbeenhopingto
startmyownbloginthenearfuture.Anyways,shouldyou
haveanyideasortipsfornewblogownersplease
share.IknowthisisoffsubjectbutIjust
hadtoask.Kudos!

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StructuralsealantIndia|Fri,Jan4th,2013at5:21PM
Hi.

Thanksforsharingyourinfo.IreallyappreciateyoureffortsandIwillbewaitingforyour
furtherwriteupsthanksonceagain.

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mpkediyal|Mon,Mar5th,2012at11:51AM
thanksforputtingsuchtypeofarticles,

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