Repair Philosophy .

CONCRETE REPAIR,PROTECTION
AND STRENGTHENING SYSTEMS
Dr.S.Annamalai
Senior Principal Structural Consultant
p
Visiting professor Anna uty, Sathyabama uty
11/28/2018 12:02 AM SARRU CONSULTANTS
1
THE CULPRIT OF CORROSION!!!!
COMMON CAUSES OF CORROSION
Carbonation Chloride Attack

Sulphate Attack
11/28/2
018 2
12:02 SARRU CONSULTANTS
Th C
The Corrosion ‐
i C b
Carbonation
ti
C (OH)2 + CO
Ca(OH) CO2 C CO3 + H
CaCO H2O
4 Fe + 2 H2O + 3 O2 FeOOH
As steel corrodes the iron turns into iron oxide or rust. The rust takes up to
four times the volume as the steel. This puts pressure on the concrete and
causes cracking and spalling.
11/28/2018 12:02 AM SARRU CONSULTANTS 3
Th C
The Corrosion –
i Chl id tt k
Chloride attack
O2
H2O
e‐
2F (OH)2 + ½ O
2Fe(OH) ½ O2 F 2O3 + 2H
Fe 2H2O anode
d
Fe2+ + 2Cl‐ FeCl2
FeCl2 + H2O Fe(OH)2 + 2 H+ + 2Cl‐
e‐
½ O2 + H2O + 2 e‐ 2 OH‐ cathode
H2O
O2
Classification of Repair
Classification of Repair
Structural Defects
D
¾Localized Spalls.
E ¾Sectional Loss.
¾
¾Cracks.
F ¾Corrosion Damages.
E
C Non – Structural or Cosmetic Repairs
T ¾ Honey combing.
¾ Aggregate Finish.
S ¾ Shrinkage Cracks.
Sh i k C k
¾ Abrasion / Cavitation.
11/28/2
018 5
Objective of Repair
Objective of Repair
Structural Defects
Structural efects
TR
EA Treatment should be carried out with materials compatible with parent substrate so
h h i d ld b li hi .
that the repaired area would be monolithic
T
M
E
Non – Structural or Cosmetic Repairs
Non Structural or Cosmetic Repairs
N
Treatment can be carried out with materials that improve the aesthetics and will
T not further degrade the structure
not further degrade the structure.
11/28/2
018 6
REPAIR PROCESS
REPAIR PROCESS
ÆCRACK INJECTION
ÆCORROSION PROTECTION
Morta
r
ÆCONCRETE REFURBISHMENT
o
ÆSURFACE PROTECTION
Different Coefficients of Thermal Expansion causes
differential movemnent
11/28/2
018 7
CONCRETE INJECTION
CONCRETE INJECTION
CRACK REPAIRS ‐ STEPS
CRACK REPAIRS
Install ports
11/28/2
018 9
Method for Low Depth Crack
Method for Low Depth Crack
Low pressure syringe
L i
Method for Fine Cracks
SURFACE MOUNTED
Method for Wide Cracks
Method for Wide Cracks
Drilled hole packer injection
Crack injection ‐ Equipments
Crack injection ‐
Low Pressure Grouting using Pump
G i i
Why Compatibility?
Why Compatibility?
Maintaining Harmony With the Existing Structure
DISTRIBUTED CONCENTRATED
Bondd Strength
S h
Shrinkage
p
Coefficient of Thermal Expansion
Modulus of Elasticity
Unique Fibre
technology
• Over 50 types and lengths of fibre
were tested before the final choice
db f h fi l h i
• Unique kidney shaped fibre with
rough surface increases mechanical
rough surface increases mechanical
adhesion
• Fibre type Poly Acryl Nitrile
Fibre type Poly Acryl Nitrile
promotes chemical adhesion
between cement paste and fibre
p
11/28/2
018 19
Patch Repairs to the Vertical members
Patch Repairs to the Vertical members
Patch Repairs to the Horizontal Members
Patch Repairs to the Horizontal Members
Form and Pour Dual Shrinkage
Compensated Micro‐Concrete
Spray applied repairs for large surface area
p y pp p g
Spray Mortar
Spray applied repairs for large surface area
Surface Preparation
Surface Preparation
Surface Preparation
Surface Preparation
Surface
Su ace Preparation
epa at o
Surface Preparation
CONCRETE PROTECTION SYSTEMS
CONCRETE PROTECTION SYSTEMS
PROTECTION SYSTEM CLASSIFICATITON
PROTECTION SYSTEM CLASSIFICATITON
COATINGS
HYDROPHOBIC
IMPREGNATIONS
SEALERS
Silanes Hydrophobicity
Silanes ‐
Work by Changing the Surface Tension of the Substrate
hydrophobic surface
hydrophobic surface hydrophilic surface
h d hili f
by (OH‐functions)
silane treatment
Water
Water
silanized capillary pore capillary pore
alkoxysilane
lk il OH‐function
ADVANCE SURFACE PROTECTION SYSTEMS:
HYDROPHOBIC IMPREGNATORS
Hydrophobic impregnators is treatment of the concrete to produce a water repellent surface.

The systems is deeply penetrative and reacts chemically with the concrete and becomes an
integral part of the concrete itself.
Recommended Methods
Silane based water repellent

treatment to concrete which
is deeply
pyp penetrative and
also effective in reducing the
corrosion current upto 90%
after treatment
treatment.
Reference
Silane treated
Not Treated
Not Treated
Boundaries coated with Hydrophobic
Boundaries coated with Hydrophobic
Impregnators: Sydney Opera House
Reference: Hakura Island, Maldives
f k l d ldi
STRENGTHENING OF CONCRETE
STRUCTURES WITH MBRACE FRP SYSTEMS
11/28/2 SARRU CONSULTANTS
018 38
12:02
SOLUTIONS:TRADITIONAL METHODS OF
STRENGTHENIG
1. Jacketing with Pourable Concrete
2 Steel Plate Bonding.
2. St l Pl t B di
3. Jacketing with Sprayed Concrete
Jacketing with Sprayed Concrete
TRADITIONAL METHODS CONRETE JACKETING
TRADITIONAL METHODS: CONRETE JACKETING
11/28/2
018 40
TRADITIONAL METHODS: STEEL PLATE
BONDING
11/28/2
018 41
TRADITIONAL METHODS: JACKETING WITH
TRADITIONAL METHODS: JACKETING WITH
SPRAYED CONCRETE
11/28/2
018 42
State of the Art Technology:
State of the Art Technology:
MBrace: Adding Muscles to Structures!!!
• Strengthening of Deck Slabs & I‐Girders or Box Girders of Bridge
Structures.
• Strengthening of Columns, Beams and Slabs of Building Structures.
g g g
• Strengthening of Masonry Structures.
• Seismic Retrofitting of Structures
11/28/2
018 43
FIBER REINFORCEMENT TYPES
FIBER REINFORCEMENT TYPES
Glass Fiber
Glass Fiber Carbon Fiber
Carbon Fiber Aramid
Aramid
Sheet Sheet Fiber Sheet
11/28/2018 12:02 AM SARRU CONSULTANTS
Plate type reinforcement 44
STATE OF THE ART TECHNIQUE
STATE OF THE ART TECHNIQUE.
Fibre Reinforced Polymer Composite
+ =
What is FRP Composite??
What is FRP Composite??
A Matrix of Polymeric Material reinforced with Fibers with a high aspect Ratio
Polymer
(
(Resin)
)
Fiber
R i f
Reinforcement
t
11/28/2
018 46
System Built‐up:
System Built up: Carbon Laminate
Carbon Laminate
Peeling of the Ply
MBrace Laminate
MBrace Laminate Adhesive
System Built up: Bar System
System Built‐up: Bar System
Classification of FRP Systems
Classification of FRP Systems
Wet Lay up System: Consists of Dry
Unidirectional or Multidirectional FRP sheets
impregnated and cured at site. In thus sense it
resembles Cast in Situ Concrete.
Precured FRP System: Consists of plates and rods
P d FRP S C i f l d d
of carbon or Glass fibers which are machine
impregnated and cured in the factory and supplied
impregnated and cured in the factory and supplied
in a wide range of cross sectional sizes.
11/28/2
018 49
DISTRUCTIVE AND NON‐
DISTRUCTIVE TESTING
DISTRUCTIVE TESTING
SEEING IS BELIEVING!!!
MBRACE ADDS MUSCLES TO STRUCTURES!!!
11/28/2
018 50
FRP Design Guidance
• FIB/FIP bulletin 14
• ACI 440.2
• Concrete Society, UK Tech. Report 55
Concrete Society UK Tech Report 55
S
Strengthening Techniques
h i T h i
Columns ‐ Axial Beams – Flexure & Shear
g g q
Shear Strengthening
g g
sf
df sf
β
wf wf wf
A f f f (sin β + cosβ )d f
Vf =
sf
where Af = 2tfwf
11/28/2018 12:02 AM sf = wf + d/4
SARRU CONSULTANTS 56
Beam – Flexure & Shear Strengthening
Beam – Flexure & Shear Strengthening
Fib A h
Fiber Anchors
Axial Strengthening & Confinement
Quality Control Systems
Bond Tests
Quality Control Systems
Bond Tests
Strengthening of Columns Extra moment and Axial load
capacity Mumbai
i M b i
(Adding additional Floor)
Slab Strengthening
Slab Strengthening
11/28/2
018 62
MAJOR PROJECTS DONE
MAJOR PROJECTS DONE
ENCHEY MONASTRY: 120 Year Old Structure
MAJOR PROJECTS DONE
11/28/2
018 64
MAJOR PROJECTS DONE
11/28/2
018 65
APPLICATIONS.
CHALTAN BRIDGE SURAT
CHALTAN BRIDGE, SURAT
Flexural Strengthening of I‐Girders of
l lS h i f Gi d f
Chaltan Bridge with MBrace Carbon
Fiber Sheets in Gujarat
BEFORE
Bonded MBrace Carbon Fiber
AFTER
BRIDGE STRENGTHENING
BRIDGE STRENGTHENING
Longitudinal Crack
Crack Injection with Epoxy Resin
MBar Insertions into Precut grooves
Sealing of Grooves
Flexural Strengthening
Strengthening of Cement Silo
Bangalore
l
Strengthening of Cement Silo with
MBrace G Sheet EU 900
Thank You!

Repair Philosophy .

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Repair Philosophy .

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CONCRETE REPAIR,PROTECTION

AND STRENGTHENING SYSTEMS

COMMON CAUSES OF CORROSION

Carbonation Chloride Attack

Fe2+ + 2Cl‐ FeCl2

FeCl2 + H2O Fe(OH)2 + 2 H+ + 2Cl‐

Hydrophobic impregnators is treatment of the concrete to produce a water repellent surface.

Silane based water repellent

Columns ‐ Axial Beams – Flexure & Shear

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