J.

Endawati

CONCRETE REPAIR AND

PROTECTION

Intended Learning Outcomes

Bagaimana
memperbaiki beton?
Apakah metode
perbaikan beton yang
umum dilakukan?
Bagaimana
menentukan metode
perbaikan yang akan
dipergunakan?

Concrete Repair

Proses ini lebih sophisticated dibandingkan membuat

struktur baru dan memerlukan keterlibatan
specialized Engineer untuk menentukan prosedur
perbaikan yang sesuai.

Concrete Repair

Untuk dapat melakukan perbaikan yang tepat,

mekanisme kerusakan perlu diselidiki serta
dimengerti.
Engineer kemudian merencanakan strategi
perbaikan yang tepat.

Tujuan Perbaikan Beton

A)

B)

Memperbaiki komponen beton yang rusak

sehingga mempunyai kemampuan seperti awal
rencana
Penyesuaian komponen beton yang sudah lama
dengan kondisi peruntukan/layan yang baru =
perubahan disain

Mulai
Penyelidikanawal
Analisis

evaluasi

Retrofitting

Tidak

CukupAmanatautidak
perludiretrofit

Mulai

Perencanaan
Retrofit

Kembangkankembali
Penyelidikanawal
StudiKelayakanKonstruksi

PersyaratanPemilik,
Pemberitugas

MenentukanPemilihan
MetodeKonstruksi

Eksperimen
Penyelidikan
Tidak
DetailKonstruksi

Diagram Alir
Perencanaan Retrofitting

PerhitunganPerencanaan
Analisis,evaluasi
Tidak

TujuanTercapai
Ya
Gambar,spesifikasi
PelaksanaanPerbaikan
Selesai

Ya

UjiLaboratrium,
PenyelidikanLapangan

Anatomi
Perbaikan
Beton

Strategi Perbaikan

Pemilihan material
Pemilihan metode
perbaikan
Support Design
Safety Precaution
Costs / biaya
Logistik

Proses
Tulangan
Pemotongan
Pembersihan
Perbaikan
Proteksi
Persiapan Permukaan
Beton
Bonding
Apply new material

Ketentuan Performansi Hasil

Perbaikan Beton

Perlindungan terhadap tulangan

Estetika
Integritas dan kompatibilitas
Beban yang dapat didukung
Kedap air

Kriteria Pemilihan Sistem Perbaikan

Stabilitas elemen
Biaya
Gangguan terhadap pengguna
Kondisi beton existing
Kondisi sekitar
Kesesuaian antara material yang diperbaiki dengan
substrate

Tahapan Perbaikan Beton

Persiapan permukaan beton

2)
Aplikasi sistem perbaikan yang sesuai
3) After-Treatment
1)

Persiapan Sebelum Pekerjaan

Perbaikan
Persiapan permukaan beton
Cleaning of reinforcement
Coating reinforcement
Bond Coat

Persiapan Permukaan Beton

Tujuan :
Menyediakan permukaan beton yang kuat, bebas
dari bahan-bahan yang membahayakan

Persiapan Permukaan Beton

Permukaan beton yang akan diperbaiki harus

bebas dari beton yang terlepas, lemah, retak atau
yang rusak. Permukaan baja dengan deposit karat
harus dibersihkan. Permukaan karat dalam batas
normal tidak memerlukan pembersihan lebih
dahulu.

Persiapan Permukaan Beton

Techniques for surface treatment of concrete:

- Mechanical
- Thermal
- Other methods (chemical, ...)

Persiapan Permukaan Beton

Cara Mekanis
- Chipping: Jackhammer, hammer and chisel
- Hammering: Needle gun, hammering machine
- Milling: Miller
- Grinding: Grinder
- Brushing: Wire brushing, brushing machine
- Shotblasting: Shotblasting machine
- Free blasting: Gritblasting, sandblasting
- Vacu-blasting: Gritblasting with suction unit attached

Persiapan Permukaan Beton

Mechanical Techniques for surface treatment of
concrete:
- Water-abrasive blasting: Water-grit/sand
blasting
- Pressure water blasting: < 40 MPa
- High pressure water blasting: 40 120 MPa
- Ultra high pressure water blast.: 150 300 MPa
- Water-vacu blasting: Water blasting with suction
unit attached usually for ultra high pressure
units

Persiapan Permukaan Beton

Grinding

Persiapan Permukaan Beton

Shotblasting

Persiapan Permukaan Beton

Ultra high pressure

water blasting

Persiapan Permukaan Beton

Cara Thermal :
- Flame Treatment: Hand torch, Machine
driven torch
- Cold blasting: Dry ice blasting, Liquid CO2blasting

Preparation of Concrete Surface

Marking out, Hack back to 10-20mm behind re-bars, ensure
concrete cover
Saw cut the edge, Brush/grind the re-bar
Prime coat for re-bar, bond coat for substrate
Batching of repair mortar and apply.
Dowel bars:
Holes drilled with rotary-percussive drills to provide keys
Air blown by pneumatic device
Required length of insertion
Give it a 1/2 turn and then turn back to original position
Give 2 hrs initial set off time

Repair Systems/Treatment

Sistem perbaikan yang dipilih tergantung pada

penutup beton yang dapat dicapai dan ketentuan
perbaikan beton yang akan diperbaiki.

Concrete Repair Methods

Buildings Department (1998) lists the following
common repair techniques for concrete:
Patch Repair
Recasting/Partial Recasting
Sprayed Concrete
Micro-concrete
Pre-packed concrete
Non-shrinkage grout
Sealing system
Protective Coating

Traditional Repair Methods

Patch Repair
Cementitious mortars
Resin-based mortars
Recasting/Partial Recasting
Sprayed Concrete
Dry process spray
Wet process spray

1. Patch Repair

Sesuai untuk perbaikan beton dengan volume kecil.

Bagian yang rusak harus dihilangkan dan
diperbaiki dengan mortar untuk perbaikan yang
sesuai
Pada umumnya, terdapat dua macam repair mortar
yang dapat dipakai untuk memperbaiki beton :
Cementitious mortars
Resin-based mortars

1. Patch Repair

1. Patch Repair (Contd)

Mailvaganam and Taylor (1994) prefers resin based mortars. It is

one-tenth of concrete.
The coefficient of thermal expansion is five times more than that of
concrete.
It has the strongest compressive strength than the other type of
cementitious based mortars.
Recently, polymer is added into the mortar in order to increase their
strength.
However, there are some limitations in polymer repair materials e.g. it
may cause delamination or blistering when applied on the damped
areas; and It is not recommended to be applied in areas where fire
resistance is required. It has poor fire resisting property and it has thermal
incompatibility with substrate concrete

Properties of typical concrete repair

materials
(Mays, G. and Wilkinson, W., 1987)

Types of Mortar

Types of Mortar (Contd)

Types of Mortar (Contd)

Types of Mortar (Contd)

Tests on Repair Mortar:

Compressive strength (28 days) 30-60 MPa

Tensile strength (7 days) 2 MPa
Mod of Elasticity (28 days) 15-25 kN/mm2
Bond Strength (7days) 2.0 MPa
Shrinkage Cracking (7 days) Coutinho ring test
Permeability
Workability
Chemical Analysis
Open-up inspection: 1 / 25sm patch repair
Pull-off test (bond coat adhesion strength): 1/ 50sm patch repair
Pass if 1/2 fracture in substrate or pull-off stress > 1/4 of the 7-day
bond str
Core a 75mm dia. Full thick of the repair with 7days age.

Bond Strength of Patch Repair

tested by pull-off test

Pull-off test on the

adhesion strength of the
bond between the repair
mortar and the substrate
concrete, aided by any bond
coat
identify re-bar position
Repair area shall have a
minimum age of 7 days
Re-bar sensor to identify the
location of reinforcement bars

Core

A 75mm dia. Core containing the full thickness of the

repair was produced

Detail of the core

Dummy
A suitable metal plate
was glued to the cored
hole and let it dry for
one hour;
this attachment was
pulled with increasing
tensile force using a
calibrated device until
failure occurs.

Result 1

Criteria:
fracture shall be at least half
in the substrate concrete, unless
the pull-off stress is not less
than 1/4 (i.e. 0.5 MPa) of the
minimum 7 days
bond strength of the repair
mortar (2.0 MPa).

Result 1
Fracture at bond surface,
bond strength = 27psi (0.9
MPa) - PASS

Result 2
Half of the fracture
at substrate, bond
strength = 18psi (0.6
MPa) - PASS

Results 3 & 4

Result 3: less than half of

the fracture at substrate,
bond strength = 12psi
(0.4MPa) FAIL

Result 4: fracture at
surface material, bond
strength = 9psi (0.3 MPa)
- FAIL

2. Recasting
In this method, the damaged part of the structural element will be demolished, replace corroded
reinforcement and recast it with same or even better grade concrete in order to restore its
structural strength.
Considerations for practical uses
Pay attention to the discontinuity which causes any instability to the linked structural elements due
to demolition.
Dowel bars and/or replacement steel bars should be placed on the cleaned reinforcement bars.
For recasting of slabs, evacuation may be required for flats above or below the element.
The joint between old and new concrete should be paid with special attention. Poor joints will
result easy seepage of water and causes of
corrosion.
Shear key is required for large areas of recasting.
Pre-soaking of substrate is necessary
Avoid air trapping by thorough compaction of repair mortar.

Recasting by form and pump

Application ranges
When defective depth is
ranges from 75mm to
100mm.
Also for vertical members
e.g. wall and column.
When structural restoration
is required.

Full Depth Recast

3. Sprayed Concrete
Sprayed concrete is a
technique which is
widely
used in high-volume
concrete repair work.
The concrete mix will be
sprayed with or without
admixture or polymers
to the defected areas
under high air pressure.
This process can be
done by means of
nozzle gun.

Dry Spray Concrete

There are two different methods of spraying:

Dry process spraying
Wet process spraying

Dry process spraying is the process which the mixture of damp sand and cement is passed through the
delivery hose to the nozzle and the water is mixed at that time.
This process is often used for repair work.
It is because of its fast application process and restoration of structural strength at an early stage.
The performance characteristics of dry sprayed concrete are they have good density and high strength.
It has very good bond to a suitable substrate.
These advantages make it more variable than conventional concrete and wet process sprayed concrete.
(SCA, 1999)

Wet Spray Concrete

Wet process spraying means all the ingredients
including water are mixed together before
transporting to the site for repairing works.
It is not normally applied for building repairs since
the size of equipment is much larger than that of dry
process spraying.

Cracks prevention

Concrete surface must be

reinforced with small-mesh
small diameter
reinforcement before
carrying out sprayed
concrete. This can prevent
developments of cracks
when the concrete shrinks.

Spray Concrete
Considerations for practical uses
The process should be in a continuous process.
Concrete mixed should be complied with acceptable standard and quality.
The operation should be carried by experienced nozzleman.
Acceptance test should be carried out to test the skill of the nozzleman.
The process should be held at right angle to and at one meter from the surface of
the repair areas.
Min. spray concrete thickness should be considered before spraying process.
Reference should be made to Code of Practice for Structural Use of Concrete.
Good surface preparation should be done.
Sufficient safety precautions must be taken.

Application ranges
Large areas of repairs with thickness > 50mm
In vacant flats and/or public areas, this can minimize the nuisance to peoples.
Partial strength is to be restored.

Spray Concrete

Other Repair Methods

Micro-concrete
Pre-packed concrete
Non-Shrinkage Grout
Joint Sealing System

1. Micro-concrete
By applying this method, the contaminated or damaged concrete are removed and
replaced by fluid micro-concrete.
It is used to re-form desired concrete profiles.
Usually, prescribed mixes are available in the market with shrinkage compensators to
control shrinkage in plastic and hardened states.

Considerations for practical uses

It needs special design by the supplier and specialist advice is required.
Formwork with leakproof is required.
Pre-soaking of the formwork and substrate is required.
Aggregates used should not be greater than 10mm.
In order to improve workability, aggregates should be rounded in size.
Good curing of the repair is essential.
Application ranges
For use in area with limited working space or congested reinforcement
For use in thin sections where the use of normal concrete is impractical

1. Micro-concrete

1. Micro-concrete

1. Micro-concrete

1. Micro-concrete

After Treatment

All cement based repair systems require after

treatment by means of keeping the surface moist for
a certain time after application.
If after treatment is not carried out properly this
can jeopardise the success of the repair.

Crack repairs

Structural crack repair

Sealing crack repair
Re-bonding of
delaminated concrete

Crack repairs (structural)

Structural crack repair
Injection with Epoxy
Systems (EP) or
Injection with
Microcement (CEM)

Crack repairs (sealing)

Sealing crack repair
Injection with
Polyurethane Systems
(PUR) or
Injection with Acrylic
Systems (AY)

Crack repairs (sealing)

Crack repairs (re-bonding)

Re-bonding of
delaminated concrete
Stitch pinning with
Epoxy Systems (EP)

Structural Strengthening
A) Repair
Insufficient reinforcement
Corrosion of reinforcement
Structural/fire damage
B) Adjustment to changing service conditions
Excessive deflections
Change in use
Seismic upgrade
Design mistakes

Structural Strengthening

Structural Strengthening

Composite strengthening systems

Carbon fiber reinforced polymers (CFRP)
Plates
Fabrics
Glass fiber reinforced polymers (GFRP)
Fabrics
Pre-stressed systems

Structural Strengthening

Provides secondary reinforcement

Ensures failure mode remains ductile
Enhance ductility, axial, flexural and shear
strength
Limit crack width

Structural Strengthening

Structural Strengthening

Sika CarboDur System

Structural Strengthening

Structural Strengthening

Pre-stressed systems

Cathodic Protection

Special method to repair concrete structures

with chlorid contamination

Cathodic Protection

Cathodic Protection

Cathodic Protection

Maxit CarboCath
System