CONCRETE REPAIR,PROTECTION

AND STRENGTHENING SYSTEMS

Dr.S.Annamalai
Senior Principal  Structural Consultant
p
Visiting professor Anna uty, Sathyabama uty

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1
 THE CULPRIT OF CORROSION!!!!

COMMON CAUSES OF CORROSION

Carbonation Chloride Attack

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 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.
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 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
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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.
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 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.

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 REPAIR PROCESS
REPAIR PROCESS

ÆCRACK INJECTION
ÆCORROSION PROTECTION
Morta
r
ÆCONCRETE REFURBISHMENT
o

ÆSURFACE PROTECTION
Different Coefficients of Thermal Expansion causes
differential movemnent

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 CONCRETE INJECTION
CONCRETE INJECTION

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 CRACK REPAIRS ‐ STEPS
CRACK REPAIRS 

„ Install ports

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Method for Low Depth Crack
Method for Low Depth Crack

„ Low pressure syringe
L i

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Method for Fine Cracks
Method for Fine Cracks

„ SURFACE MOUNTED

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Method for Fine Cracks
Method for Fine Cracks

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Method for Fine Cracks
Method for Fine Cracks

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Method for Fine Cracks
Method for Fine Cracks

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Method for Fine Cracks
Method for Fine Cracks

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Method for Wide Cracks
Method for Wide Cracks

„ Drilled hole packer injection

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Crack injection ‐ Equipments
Crack injection ‐

Low Pressure Grouting using Pump
G i i

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 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
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 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

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 Patch Repairs to the Vertical members
Patch Repairs to the Vertical members

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 Patch Repairs to the Horizontal Members
Patch Repairs to the Horizontal Members

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Form and Pour Dual Shrinkage
Compensated Micro‐Concrete

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 Spray applied repairs for large surface area
p y pp p g

Spray Mortar

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 Spray applied repairs for large surface area

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Surface Preparation

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Surface Preparation

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Surface Preparation

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 Surface Preparation

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Surface
Su ace Preparation
epa at o

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 Surface Preparation

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 CONCRETE PROTECTION SYSTEMS
CONCRETE PROTECTION SYSTEMS

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 PROTECTION SYSTEM CLASSIFICATITON
PROTECTION SYSTEM CLASSIFICATITON

COATINGS

HYDROPHOBIC 
IMPREGNATIONS

SEALERS
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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

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 ADVANCE SURFACE PROTECTION SYSTEMS:
HYDROPHOBIC IMPREGNATORS

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

Recommended Methods

Silane based water repellent

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Reference

Silane treated
Not Treated
Not Treated

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 Boundaries coated with Hydrophobic 
Boundaries coated with Hydrophobic
Impregnators: Sydney Opera House

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 Reference: Hakura Island, Maldives 
f k l d ldi

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 STRENGTHENING OF CONCRETE 

STRUCTURES WITH MBRACE FRP SYSTEMS

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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

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TRADITIONAL METHODS CONRETE JACKETING
TRADITIONAL METHODS: CONRETE JACKETING

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 TRADITIONAL METHODS: STEEL PLATE 
BONDING

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 TRADITIONAL METHODS: JACKETING WITH 
TRADITIONAL METHODS: JACKETING WITH
SPRAYED CONCRETE

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 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

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 FIBER REINFORCEMENT TYPES
FIBER REINFORCEMENT TYPES

Glass Fiber
Glass Fiber Carbon Fiber
Carbon Fiber Aramid 
Aramid
Sheet Sheet Fiber Sheet

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Plate type reinforcement 44
 STATE OF THE ART TECHNIQUE
STATE OF THE ART TECHNIQUE.

Fibre Reinforced Polymer Composite

+ =

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 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
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System Built‐up:
System Built up: Carbon Laminate
Carbon Laminate

Peeling of the Ply

MBrace Laminate

MBrace Laminate Adhesive

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 System Built up: Bar System
System Built‐up: Bar System

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 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.

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 DISTRUCTIVE AND NON‐
DISTRUCTIVE TESTING
DISTRUCTIVE TESTING

SEEING IS BELIEVING!!!

MBRACE ADDS MUSCLES TO STRUCTURES!!! 

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 FRP Design Guidance
• FIB/FIP bulletin 14
• ACI 440.2
• Concrete Society, UK Tech. Report 55
Concrete Society UK Tech Report 55

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S
Strengthening Techniques
h i T h i

Columns ‐ Axial Beams – Flexure & Shear

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 Strengthening Techniques 
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

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 Strengthening Techniques 

Axial Strengthening & Confinement

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Quality Control Systems

Bond Tests

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Quality Control Systems

Bond Tests

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 Strengthening of Columns Extra moment and Axial load 
capacity Mumbai 
i M b i
(Adding additional Floor)

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 Slab Strengthening
Slab Strengthening

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 MAJOR PROJECTS DONE
MAJOR PROJECTS DONE 

ENCHEY MONASTRY: 120 Year Old Structure

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 MAJOR PROJECTS DONE

ENCHEY MONASTRY: 120 Year Old Structure

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 MAJOR PROJECTS DONE 

ENCHEY MONASTRY: 120 Year Old Structure

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 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

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 BRIDGE STRENGTHENING
BRIDGE STRENGTHENING

Longitudinal Crack
Crack Injection with Epoxy Resin

MBar Insertions into Precut grooves
Sealing of Grooves

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Strengthening Techniques 

Flexural Strengthening

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 Strengthening of Cement Silo
Bangalore
l
Strengthening of Cement Silo with 
MBrace G Sheet EU 900

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 Thank You!

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