REPAIR OF CONCRETE STRUCTURES

CASE STUDIES
DR SYED EHTESHAM HUSSAIN
CONCRETE TECHNOLOGY CONSULTANTS (CONTEC) KHOBAR

CONCRETE DURABILITY PROBLEMS

IN THE GULF REGION
1. SEVERE EXPOSURE CONDITIONS
- High concentrations of chloride & sulfate ions in soil - High salinity in seawater - High temperature & temperature fluctuations - High humidity

CONTEC - EVALUATION, STRUCTURAL ASSESSMENT, REHAB DESIGN, FAILURE ANALYSIS, NDT

CONCRETE DURABILITY PROBLEMS

IN THE GULF REGION
2. POOR QUALITY MATERIALS
- Absorptive & dusty aggregates - Contamination in sand and coarse aggregates - Poorly graded sand - High salinity in water

CONCRETE DURABILITY PROBLEMS IN THE GULF REGION

3. USE OF OLD (INAPPROPRIATE) SPECS.

- Type V cement or OPC (No mineral admixtures)
- High water-cement ratio - Inadequate curing/curing period - Low cover to reinforcement - Poor workmanship - Fast construction & lack of proper quality control

PRESENT IMPROVED SPECIFICATIONS

- Type I cement (C3A > 8%)

- Mineral admixtures (silica fume, fly ash and slag)

- Low w/c ratio (< 0.40) - High cover (75 mm)

- Additional protection
- QC techniques for durability RESULTED IN IMPROVED SERVICE LIFE

EFFECT OF EXPOSURE CONDITIONS

AND CONCRETE QUALITY ON LIFE

CONCRETE QUALITY

ADDITIONAL PROTECTION

PRESENT

70s-80s NORMAL

10

20

30

40

50

LIFE (YEARS)

COMMON REINFORCEMENT CORROSION PROBLEMS

1. Marine structures

2.
3. 4. 5. 6.

Strcs. in contact with soil & groundwater

Strcs. exposed to excessive condensation Bridge decks Strcs. exposed to deposition of sand/dust Deterioration due to design defects

MARINE STRUCTURES

STRCS. IN CONTACT WITH SOIL & GROUNDWATER

STRCS. EXPOSED TO EXCESSIVE CONDENSATION

BRIDGE DECKS

STRCS. EXPOSED TO DEPOSITION OF SAND/DUST

DETERIORATION DUE TO DESIGN DEFECTS

PIPE OPENING IN WALL

CABLE DUCT

COMMON REPAIR TECHNIQUES

1. DO NOTHING 2. COATINGS 3. PATCH REPAIR 4. REPLACEMENT OF CHLORIDE CONTAMINATED CONCRETE

COMMON REPAIR TECHNIQUES

5. RE-SKINNING reconstruction of cover concrete 6. RE-CONSTRUCTION

7. CATHODIC PROTECTION
8. STRENGTHENING

DO NOTHING
STRUCTURE LEFT UNREPAIRED

LOW LEVEL OF DETERIORATION

LEVEL OF DETERIORATION IS STRUCTURALLY ACCEPTABLE REMAINING SERVICE LIFE IS LIMITED STRUCTURE CAN OPERATE UNDER REDUCED LOADS

COATINGS
BARRIER TO INGRESS OF CHLORIDES

PROLONG SERVICE LIFE

NO DETERIORATION

CHLORIDE CONMTAMINATION LEVELS ARE LOW

COATINGS
COMMONLY USED COATINGS

ACRYLIC BASED CEMENTITIOUS COATINGS

EPOXIES PULYURETHANE PENETRANTS (SILANES & SILOXANES)

PATCH REPAIR
UNSOUND CONCRETE REPLACED WITH REPAIR CONCRETE REPAIRED AND ADJACENT AREAS GENERALLY COATED CHLORIDE CONTAMINATED CONCRETE IS NOT REMOVED

INCIPIENT ANODE CORROSION

PATCH REPAIR
GALVANIC ANODES IN UN-REPAIRED AREAS LOW INITIAL COST NEEDS TO BE REPEATED AT REGULAR INTERVALS LIFE CYCLE COST MAY BE HIGH

RE-SKINNING
ENTIRE COVER IS REPLACED WITH REPAIR CONCRETE COATED TO PROLONG LIFE CHLORIDE TESTING REQUIRED NO INCIPIENT ANODE CORROSION HIGH INITIAL COST LONG-TERM SOLUTION

REPLACEMENT
STRUCTURE OR ITS PART RECONSTRUCTED USING DURABLE CONCRETE EXTENSIVE DETERIORATION THIN SECTIONS SLABS AND COLUMNS HIGH INITIAL COST

LONG-TERM SOLUTION

CATHODIC PROTECTION
PATCH REPAIR OF UNSOUND CONCRETE

DIRECT CURRENT PASSED BETWEEN INSTALLED ANODE AND REBARS

CHLORIDES MOVE AWAY FROM THE REBARS ALKALINITY INCREASES AROUND REBARS

CATHODIC PROTECTION
CHLORIDE REMOVAL IS NOT REQUIRED

LONG-TERM SOLUTION LIFE OVER 40 YEARS

NEEDS REGULAR MONITORING

SELECTION OF REPAIR STRATEGY

FACTORS
CAUSES OF DETERIORATION LEVEL OF DETERIORATION SEVERITY OF EXPOSURE CONDITIONS

LEVEL OF CHLORIDE CONTAMINATION

REQUIRED SERVICE LIFE FUTURE MAINTENANCE REQUIREMENTS INITIAL AND LIFE CYCLE COST

SELECTION OF REPAIR TECHNIQUES

PRACTICAL EXAMPLES

CASE 1 - LOW DEGREE OF DETERIORATION & LONG SERVICE LIFE

CASE 1
NO OR LOW DEGREE DETERIORATION MARINE EXPOSURE HIGH RISK OF CHLORIDE CONTAMINATION LOW CHLORIDE CONTAMINATION IN CONCRETE

REQUIRED SERVICE LIFE - LONG

APPROPRIATE REPAIR

COATING

CASE 2 LOCAL DETERIORATION

CASE 2
ISOLATED DETERIORATION LOCAL CAUSES (CONSTRUCTION DEFECTS, LEAKAGE etc.) MILD EXPOSURE CONDITIONS LOW RISK OF CHLORIDE CONTAMINATION

LOW CHLORIDE CONTAMINATION IN CONCRETE

APPROPRIATE REPAIR

PATCH REPAIR

CASE 3 EXTENSIVE DETERIORATION & LONG SERVICE LIFE

CASE 3
EXTENSIVE DETERIORATION SEVERE EXPOSURE CONDITIONS HIGH RISK OF CHLORIDE CONTAMINATION HIGH CHLORIDE CONTAMINATION IN CONCRETE

REQUIRED SERVICE LIFE - LONG

APPROPRIATE REPAIR

RE-SKINNING PLUS COATING

CASE 4 SEVERE EXPOSURE & LONG LIFE

CASE 4
LOW TO MODERATE DETERIORATION SEVERE EXPOSURE CONDITIONS HIGH RISK OF CHLORIDE CONTAMINATION HIGH CHLORIDE CONTAMINATION IN CONCRETE

REQUIRED SERVICE LIFE - LONG

APPROPRIATE REPAIR

CATHODIC PROTECTION

CASE 5 EXTENSIVE DETERIORATION & SHORT SERVICE LIFE

CASE 5
LOW TO MODERATE DETERIORATION SEVERE EXPOSURE CONDITIONS HIGH RISK OF CHLORIDE CONTAMINATION HIGH CHLORIDE CONTAMINATION IN CONCRETE

REQUIRED SERVICE LIFE - SHORT

APPROPRIATE REPAIR

PATCH REPAIR

CASE 6 SMALL SECTIONS

CASE 6
EXTENSIVE DETERIORATION THIN SECTIONS SLABS, COLUMNS

SEVERE EXPOSURE CONDITIONS HIGH RISK OF CHLORIDE CONTAMINATION

HIGH CHLORIDE CONTAMINATION IN CONCRETE

APPROPRIATE REPAIR

REPLACEMENT

CONCLUDING REMARKS

1. PREMATURE CONCRETE DETERIORATION OBSERVED DUE TO

- AGGRESSIVE EXPOSURE CONDITIONS

- POOR QUALITY MATERIALS

- USE OF INAPPROPRIATE SPECIFICATIONS

2. IMPROVEMENT IN SPECIFICATIONS IN RECENT YEARS HAS IMPROVED THE SERVICE

LIFE OF STRUCTURES

3. STRUCTURES SUSCEPTIBLE TO REINFORCEMENT CORROSION INCLUDE

- Marine Strcs
- Strcs. In Contact With Soil/GW - Strcs. Exposed To Condensation - Strcs. With Accumulation of Dust - Other Structures Exposed to Aggressive Conditions

4. FACTORS TO BE CONSIDERED TO SELECT A REPAIR STRATEGY

Causes and Extent of Deterioration Severity of Exposure Conditions Level of Chloride Contamination

Required Service Life

Future Maintenance Requirements Initial and Life Cycle Cost

5. PATCH REPAIR
Provides Short Term Solution at Low Initial Cost Needs Repair at Regular Intervals Life Cycle Cost may be High

6. RE-SKINNING Provides Long Term Solution

High Initial Cost

Suitable Where Deterioration is Extensive

7. CATHODIC PROTECTION
Provides Long Term Solution

High Initial Cost

Suitable Where Deterioration is Low, Chloride Contamination is High and Exposure Conditions are Severe