CON REP NET

PERFORMANCES OF CONCRETE
REPAIRS IN PRACTICE

Graham Tilly, Gifford and Partners

 STRUCTURES

90

80
70

60

50
Number

40

30
20

10

0
Buildings Bridges Dams Power Car parks Other
stations
 Ages of Structures

60

50

40
Number

30

20

10

0
0-10 11-20 21-30 31-40 41-50 51-60 61-70 71-80 81-151
Years (to 2003)
 ENVIRONMENTS

80
70
60
50
Number

40
30
20
10
0
Urban Rural Highway Coastal Industrial
WP2 Past Performances

DETERIORATION AND
REPAIR
 Number

0
20
40
60
80
100
120
Co
rro 140
sio
n

Fr
os
t

Cr
a ck
s

De AA
t er R
io
r at
ed
co
nc
r et
Po e
or
co
Types of Original Deterioration

ns
t ru
ct
io
n

Ot
he
r
 Ages of Structures when Repaired

60

50

40
Number

30

20

10

0
0-10 11-20 21-30 31-40 41-50 51-60 61-70 71-100
Years (to 2003)
 Types of Repair

140

120

100

80
Number

60

40

20

0
Patch Coating Crack Strengthen Sprayed Electro- Other
injection concrete chemical
 Patches

80
70
60
50
Number

40
30
20
10
0
Cementitious Polymer modified Other
 Coatings

50
45
40
35
30
Number

25
20
15
10
5
0
Barrier Hydrophobic Anti- Other
carbonation
 PERFORMANCES OF REPAIRS

Successful
Evidence of deterioration
Failed
 Performances of all Repairs

120

100

80
Number

60

40

20

0
Successful Evidence of Failed
deterioration
Repair Performances, BCA 1997
60

50

40
Per cent

30

20

10

0
Good Fair Poor Failure
 Performances of Patches

35
30
25
Number

20
15
10
5
0
Cementitious Polymer Other
modified
Successful Evidence of deterioration Failed
 Performances of Coatings

35

30

25

20
Number

15

10

0
Successful Evidence of Failed
deterioration
 Performances of Repairs to Corrosion

20
18
16
14
12
Successful
Number

10 Evidence of failure
8 Failed

6
4
2
0
Patch Patch + coating Crack injection
 Performances in Relation to Ages of Repairs

40

35

30

25
Successful
Number

20 Evidence of failure
Failed
15

10

0
0-5 6-10 11-15 16-20 21-52
Years
Failure of Patch Repair
Failure of sprayed coating
Continued ASR
WP2 Past Performances

MODES AND CAUSES OF

FAILURE
 Modes of Failure

35

30

25

20
Number

15

10

0
Corrosion Cracking Debonding AAR Other
 Number
Inc
or

0
5
10
15
20
25
30
35
40
45
re
ct 50
de
sig
n

Ma
t er
Po ial
or
W
or
km
an
sh
W ip
ro
ng
dia
gn
os
is

W
Causes of Failure

ea
th
er

Un
k no
wn

Ot
h er
Deterioration and Repair Model
Repair Performances
Damage Level Detection
 SUMMARY

229 Case Histories Analysed

Disappointing Repair Performances

25% fail in 5 years
75% fail in 10 years
95% fail in 25 years
 Summary Continued

Modes of Repair Failure :

continued corrosion, cracking, debonding

Causes of Repair Failure:

wrong diagnosis, wrong design, wrong
material and poor workmanship
 Recommendations
Repair materials should be compatible
with the substrate

Repair materials should be flexible

Repair materials should be forgiving