REPAIR OF CONCRETE

SUPERSTRUCTURE AND
SUBSTRUCTURE
 COURSE OUTLINE
1. EPOXY INJECTION
2. CAULKING
3. PATCHING
4. RECASTING CONCRETE/GROUT
5. CARBON FIBER SHEET BONDING TO DECKSLAB
6. STEEL PLATE BONDING
7. PARTIAL DECKSLAB REPLACEMENT
8. WATERPROOFING ON DECKSLAB
9. FAST SETTING MORTAR CONTINUED DECKSLAB
10.PROTECTIVE MORTAR
11.PROTECTIVE COATING
12.CARBON FIBER SHEET/PLATE BONDING TO CONCRETE
GIRDER
13.JACKETING WITH CONCRETE
 EPOXY INJECTION
 Epoxy injection is used to restore
structural soundness of structures
exhibiting inactive cracks. Cracks
with more than 0.3 mm up to 3.0
mm widths can be bonded and
sealed by injecting low viscosity
epoxy.
 Work Sequence
1. Cleaning of Cracks.
2. Fitting of Injector
3. Sealing of Cracks at the Surface
4. Fitting of Injector
5. Injection of Epoxy
6. Curing of Injected Material
Required Materials and
Tools/Equipment
Required Materials
1. Epoxy Resin for Injection
2. Epoxy Resin Adhesive
3. Sealant (Epoxy Putty)
4. Set of Injection Tool
Required Equipment/Tools
1. Epoxy Injection Pump or Gun
2. Power Disc Grinder/Cutter
3. Portable Generator
4. Brush etc.
 CAULKING
 Crack widths could be more than
3.0 mm with depth of less than 300
mm. In this case, the top surface
edges should be chipped or sawn
to form a V-type or U-type groove,
in order to provide a caulking for
inlet of gravity flow of resin into the
crack by injection pump.
 Work Sequence
1. Cleaning of the cracks.
2. Preparation of Caulking
3. Drilling Holes and Fixing the
Injection Pipes
4. Injecting Epoxy Grout
5. Curing of Injected Material
Required Materials and
Tools/Equipment
Required Materials Required Equipment/Tools
1. Epoxy Grout 1. Epoxy Injection Pump
2. Sealant 2. Power Disc Grinder
3. Portable Generator
4. Brush
5. Set of Injection Tools
 PATCHING
Patch repair is performed to restore small areas
where sound concrete is damaged by spalling,
REBAR
scaling and impact.
Patch repair is classified into two types
considering defective area and surface:
 Type-A is applicable to surfaces without REPAIR MORTAR
exposed rebar, having defective widths of up
to 300mm and depths of up to 50mm.
 Type B is used for surfaces with exposed rebar,
with defective widths between 300mm and REBAR RUST INHIBITIVE PRIMER
600mm, and up to 100mm depths.
 Portland cement mortar is used for Type-A and
Polymer cement mortar is used for Type-B.
REPAIR MORTAR
 Work Sequence
1. Removal of Defective Concrete
2. Cleaning of Concrete and Rebar
3. Application of Epoxy Bonding Resin
4. Placing Cement Mortar
5. Curing
 Required Materials and
Tools/Equipment
Required Materials Required Equipment/Tools
Portland Cement Mortar 1. Chisel
1. Portland Cement
2. Portable Generator
2. Sand
3. Wire Brush
3. Water
4. Concrete Nail 4. Small Hammer
5. Bonding Agent to Concrete (Epoxy 5. Mortar Mix Bucket
Bonding)
6. Safety goggles
Polymer Cement Mortar (PCM)
1. PCM Powder 7. Trowel
2. PCM Emulsion 8. Dust mask
3. Concrete Nail
4. Bonding Agent to Concrete (Epoxy
Bonding)
 RECASTING CONCRETE/GROUT
Recasting Method, which involves
casting of the damaged area, by
placing concrete or grouting mortar
on the formwork, is usually most
suitable for severely damaged
concrete, or for largely damaged
areas with densely spaced rebars.
If concrete placing by vibration is
often a problem, grout and free
flowing self-compacting concrete
should be developed to minimize the
vibration required.
Application Criteria
 Work Sequence
1. Removal of Concrete
2. Preparation of Old Concrete and
Rebar
3. Cutting of Deteriorated Rebar
and Adding New Rebar
4. Setting Formworks
5. Mixing of Mortar
6. Mortar Grouting
7. Curing and Removal of
Formworks
 Required Materials and
Tools/Equipment
Required Materials Required Equipment/Tools
 For Concrete
1. Sawing Equipment
1. Portland Cement
2. Silica fume 2. High Pressure Water Blasting
3. Aggregate/Sand
3. Handy Concrete Breaker or
4. Rebar (Reinforcing bar, Grade 60)
jackhammer
5. Bonding Coat to Concrete (Epoxy Resin Adhesive)
6. Anti-corrosion Primer to Rebar (Zinc Rich Primer) 4. Handy power Chisel
7. Cotton mat (Curing)
5. Concrete Mixer 30 liters
 For Mortar
1. Premixed type fast setting mortar 6. Mortar Mixer with Pump (For
2. Clean Water Mortar)
3. Reinforcing steel bar
4. Bonding Coat to Concrete (Epoxy Resin Adhesive)
7. Vibrator
5. Anti-corrosion Primer to Rebar (Zinc Rich Primer) 8. Troweling tools
 CARBON FIBER SHEET BONDING TO
DECK SLAB
Carbon fiber sheet for reinforced concrete
repairs and strengthening systems consists of
a combination of carbon fiber reinforcing
material and adhesive resin such as epoxies
and other materials. This composite product is
intended to enhance the capacity of the
concrete deck slab and extend its service life.
The works shall consist of furnishing and
installing two types of Carbon Fiber Sheets as
shown in Figure 4-6 for concrete
strengthening systems in accordance with the
plans and specifications. The systems shall be
designed to strengthen and stiffen concrete
bridge deck slab and tested by the Engineer
to verify performance
APPLICATION CRITERIA
 Work Sequence
1. Preparation of Concrete
2. Application of Primer
3. Adjustment of Unevenness with
Putty
4. Application of Epoxy Resin for
Undercoat
5. Installation of Longitudinal Layer
CFS
6. Installation of Transversal Layer
CFS
7. Squeezing out of Entrapped Air
8. Surface Protection
 Required Materials and
Tools/Equipment
Required Materials Required Equipment/Tools
Carbon Fiber Products
1. Abrasive Sandblaster
1. CFS (Strap Type)
2. Air Compressor
Epoxy Materials
3. Disc Grinder
1. Epoxy primer
4. Portable Generator
2. Epoxy putty
5. Paint Roller/Brush
3. Epoxy resin adhesive
 STEEL PLATE BONDING
The effect of bonding a plate to the tension
face of a reinforced concrete section is to
increase the depth from the compression
face to the neutral axis and the area of
effective reinforcement, thus, increasing the
moment of resistance of the section.
The steel plate bonding has two types,
namely, wide plate and narrow plate as
shown in Figure 4-8. wide plates are used for
strengthening the slab in both main
reinforcing bar and distribution bar directions.
Narrow plates are used for strengthening the
slab in one direction only.
APPLICATION CRITERIA
Type of steel plate bonding to be applied
shall be according to the direction of the
damaged rebar of the deck slab. The
bonding of steel plates to concrete members
has been undertaken considering two
methods as follows:
INJECTION METHOD – this method involves
single plates of required thickness, with gaps
sealed at the edges between the steel and
the concrete. Resin is the pumped ensuring
that no voids occur between the plate and
the concrete.
 APPLICATION CRITERIA

PRESSURE ATTACHING METHOD – similar to

injection method, this requires single plates of
required thickness with gaps sealed at the
edges between the steel and the concrete.
However, epoxy resin in this method is
injected to ensure that no voids occur
between the plate and the concrete.
 Work Sequence
INJECTION METHOD
1. Surface preparation
2. Setting of steel plate on the slab
3. Sealing of steel plate
4. Injection of epoxy resin
5. Curing and painting
 Work Sequence
PRESSURE ATTACHING METHOD
1. Surface preparation
2. Application of epoxy resin
3. Pressure attachment of steel
plate
4. Curing and painting
 Required Materials and
Tools/Equipment

Required Materials Required Equipment/Tools

Injection Method
Injection Method
1. Steel plate
1. Disc grinder
2. Primer (epoxy base)
2. Welder
3. Epoxy resin adhesive for injection
3. Electric drill
4. Epoxy sealant
4. Epoxy injection pump with accessories
5. Anchor bolts 5. Wire brush
Pressure Attaching Method Pressure Attaching Method
1. Steel plate 1. Disc grinder
2. Primer (epoxy base) 2. Welder
3. Epoxy resin adhesive 3. Electric drill
4. Epoxy sealant 4. Epoxy injection pump with accessories

5. Anchor bolts 5. Wire brush

6. Wood and angle for fitting

 PARTIAL DECK SLAB REPLACEMENT
Partial replacement of slab is carried
out to replace portion of the
concrete that has been severely
damaged. If damaged portion is not
removed, further deterioration is
expected, which could impair the
strength, stability and serviceability of
the structure. The cause of such
damage could be corrosion of
reinforcement, fracturing, spalling,
delamination, honeycomb or water
leakage.
 Work Sequence
1. Support of Existing Structure
2. Removal of Deck Slab Concrete
3. Preparation of Old Concrete and
Rebar
4. Setting of Formworks
5. Cutting of Existing Rebar and
Addition of New Rebar
6. Placing of Concrete
7. Curing and Removal of Formworks
 Required Materials and
Tools/Equipment
Required Materials Required Equipment/Tools

1. Portland Cement 1. Sawing Equipment

2. Silica Fume
3. Rebar (Reinforcing bar, use Grade
40 for 16mm diameter)
4. Epoxy Resin (Bonding Coat to
Concrete)
5. Zinc Rich Primer (Bonding Coat to
Rebar)
2. High Pressure Water Blasting
3. Handy Concrete Breaker or
Jackhammer
4. Handy Power Chisel
5. Concrete Mixer 30 liters
6. Vibrator
7. Troweling tools
 WATERPROOFING ON DECK SLAB
Concrete is naturally alkaline and
therefore protects the steel. However,
the effect of its contact with water
and corrosive materials reduces the
alkaline environment and allows an
electrolytic process to start, thus
corroding the rebar. The result of the
corrosion and rusting is to expand the
rebar which then damages and
eventually destroys the surrounding
concrete of the deck. The primary
protection against this destructive
damage is through installation of
waterproofing membrane on the
deck slab.
Application Criteria
 Work Sequence for Rubberize
Membrane Type
1. Preparation of Deck Surface
2. 1stLayer (Primer)
3. 2ndLayer (Base Coat)
4. 3rdLayer (Intercoat)
5. 4thLayer (Top Coat)
6. 5thLayer (Tack Coat)
7. Asphalt Pavement
 Work Sequence for Asphalt Compound
Membrane Type
1. Preparation of Surface
2. Primer Coating
3. Melting Asphalt Compound
4. Application of Asphalt Compound
5. Application of Silica Sand for
Protection
6. Curing/Asphalt Pavement
 Required Materials and
Tools/Equipment
Required Materials Required Equipment/Tools
Rubberized Membrane RubberizedMembrane
1. Primer 1. Paint Roller
2. Rubberized Membrane (2nd
layer ~ 4th layer)
3. - Tack Coat (Finish Coat)

Asphalt Compound Membrane Asphalt Compound Membrane

1. Primer 1. Kettle with Heater
2. Asphalt Compound 2. Roller Brush or Hair brush
Membrane
3. Rubber Brush
3. Silica sand No.4
 FAST SETTING MORTAR CONTINUED
DECK SLAB

Most of RCDG bridges are simple

span bridges. Furthermore, there are
many multiple span RCDG bridges
designed as simple spans with gaps
between the spans. In order to
strengthen the stability of the bridge
structure, continued deck slab
method is adopted to reduce the
bridge maintenance work and to
maintain good performance.
 Work Sequence
1. Removal of Deck Slab Concrete
2. Setting of Formworks
3. Addition of Longitudinal/Transverse
Rebar
4. Clean up inside form
5. Apply Epoxy Resin to Existing
Concrete Surface for Proper
Bonding to Fast-setting Mortar
6. Keep the form in wet condition
7. Mix with water
8. Pour from lower side to upper
position
9. Finishing of Surface, Curing
 Required Materials and
Tools/Equipment
Required Materials Required Equipment/Tools

1. Premixed type fast setting mortar 1. Sawing Equipment

2. Clean water 2. High Pressure Water Blaster

3. Epoxy Resin (Bonding Coat to 3. Handy Concrete Breaker or

Jackhammer
Concrete)
4. Handy Power Chisel
4. Special anti-corrosion paint/Zinc-
rich Primer (Bonding Coat to 5. Electric Mixer with steel blade
Rebar) 6. Water container
7. Generator
8. Hydraulic Pump system
9. Brush
 PROTECTIVE MORTAR
 Protective mortar is made from
polymer cement with lithium
nitrate which is effective against
chloride ions.
 After or during application of
appropriate repair method,
protective mortar shall be applied
to concrete member.
 Work Sequence

1. Surface Preparation
2. Keep dry condition and avoid
sunshine
3. Weigh PCM with Lithium Nitrite
4. Weigh the emulsion
5. Mix Powder and Emulsion
6. Application of PCM with Lithium
Nitrite
7. Curing of PCM with Lithium Nitrite
 PROTECTIVE COATING
if the bridge is located more than
1km from the coastal area, concrete
member will be deteriorated due to
carbonation. It is recommended that
protective coating should be applied
as preventive maintenance.
Protective coating is made from acryl
urethane based coating which is
effective against carbon dioxide,
weather/UV rays, chemical and oil
damage.
After repairing damage, protective
coating shall be applied on the
concrete member
 Work Sequence

1. Surface Preparation
2. Mixing acryl urethane protective
coating materials
3. Application of protective coating
 CARBON FIBER SHEET/PLATE BONDING
TO CONCRETE GIRDER

Carbon fiber sheet/plate for

reinforced repair and strengthening
systems are combination of carbon
fiber sheet/plate material and resins
such as epoxies and other adhesive
materials, acting as a composite
material to enhance the capacity
and extend the life of concrete
structures
Application Criteria
 Work Sequence for CFS
1. Preparation of Concrete
2. Application of Primer
3. Adjustment of Unevenness with
Putty
4. Applicationof Epoxy Resin for
Undercoat
5. Installation of CFS(1stlayer)
6. SqueezingOut of Entrapped Air
7. Over Coating Resin Application
8. Installation of CFS(2ndlayer)
9. Surface Protection
Work Sequence for CFP
1. Preparation of Concrete
2. Application of Primer
3. Adjustment of Unevenness with
Putty
4. Application of Epoxy Resin on CFP
5. Installation of CFP
6. Squeezing Out of Entrapped Air
7. Pressure Attachment of CFP
 Required Materials and
Tools/Equipment
Required Materials Required Equipment/Tools

 Carbon Fiber Products 1. Abrasive Sandblaster

1. Carbon fiber sheet 2. Air Compressor

2. Carbon fiber sheet Strip 3. Disc Grinder

3. Carbon fiber Plate 4. Portable Generator

 Epoxy Materials 5. Paint Roller/Brush

1. Epoxy primer
2. Epoxy putty
3. Epoxy resin
JACKETING WITH CONCRETE
Concrete jacket is applied to protect
the deteriorated concrete due to
corrosion of rebars, damage due to
rapid water flow or broken due to
continuous impact from materials
flowing in the channel such as drift
woods.
 Work Sequence

1. Removal of Deteriorated
Concrete
2. Addition of Rebar
3. Setting-up of Formworks
4. Placing of Concrete
5. Curing of Concrete
 Required Materials and
Tools/Equipment

Required Materials Required Equipment/Tools

1. Concrete with Fine Aggregate 1. Drilling Machine to Concrete

1. Cement 2. - Concrete Vibrator
2. 10mm Crushed Aggregate 36.0
kg
3. Sand (assumed with 2% water
content) 18.5 kg
4. Water (maximum) 5.4 liters
5. Super plasticizer (nominal) 25ml
2. Formwork
1. Steel Formwork (Circular)
2. - Plywood formwork