Concrete Materials and Concrete Construction

Repair of Reinforced
Concrete Structures
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Concrete Materials
Materials and
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Concrete Construction
Construction
Commonly Encountered
Problems
1. Spalling, cracking, water leakage, surface
erosion, staining.
2. Water and corrosion related deterioration
a improper design and detailing
b. cracks
c. carbonation
d. poor original quality concrete, porous
concrete
e. lack of maintenance or improper
maintenance
f. presence of chlorides
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Commonly Encountered
Problems
3. Volume changes - creep and shrinkage
4. Structural failure
5. Fire
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Condition Assessment
1. Information Gathering
2. Field Survey
3. Field Tests
4. Laboratory Tests
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Repair Methods & Materia

1. Repair Materials
a. portland cement
b.polymer modified concrete
c. resin mixtures
d.substitute materials
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Nomenclature
polymer concrete (PC): formed by
polymerizing a mixture of a monomer and
aggregate (no other bonding material)
latex-modified concrete (LMC): also known as
polymer portland cement concrete.
Conventional concrete made by replacing
part of mixing water with a latex.
polymer-impregnated concrete (PIC):
produced by impregnating or infiltrating a
hardened concrete with a monomer and
subsequently polymerizing the monomer in
situ.
Significance
Both PC and LMC have been in commercial
use since the 1950s;
PIC was developed and has been in use since
the 1970s.
Depending on the materials employed, PC can
develop compressive strengths of the order
of 140 MPa (20,000 psi) within hours or even
minutes and is therefore suitable for
emergency concreting jobs in mines,
tunnels, and highways.
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Significance -- LMC
LMC possess excellent bonding ability to old
concrete, and high durability to aggressive
solutions; it has therefore been used mainly
for overlays in industrial floors, and for
rehabilitation of deteriorated bridge decks.
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Significance -- PIC
In the case of PIC, by effectively sealing the
microcracks and capillary pores, it is
possible to produce a virtually impermeable
product which gives an ultimate strength of
the same order as that of PC.
PIC has been used for the production of highstrength precast products and for improving
the durability of bridge deck surfaces.
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Polymer Concrete
Polymer concrete (PC) is a mixture of
aggregates with a polymer as the sole
binder. To minimize the amount of the
expensive binder, it is very important to
achieve the maximum possible dry-packed
density of the aggregate.
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Polymer
Commercial products are available with a variety of
formulations, some capable of hardening to 105 MPa
(15,000 psi) within a few minutes without thermal
treatment.
Epoxy resins are higher in cost but offer advantages
such as adhesion to wet surfaces.
Styrene monomer, and methyl methacrylate (MMA) with
benzoyl peroxide catalyst and an amine promoter
are often used.
Products with increased strength have been obtained
by adding to the PC monomer system a silane
coupling agent, which increases the interfacial bond
between the polymer and aggregate.
Properties
The properties of PC are largely dependent on
the amount and properties of polymer in the
concrete.
PC made with MMA is a brittle material that
shows a nearly linear stress-strain
relationship with high ultimate strength, but
the addition of butyl acrylate produces a
more ductile material
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Stress-Strain Diagram
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Properties
Due to good chemical resistance and high initial
strength and modulus of elasticity, industrial use of
PC has been mainly in overlays and repair jobs.
Thermal and creep characteristics of the material are
usually not favorable for structural applications of
PC.
Polyester concretes are viscoelastic and will fail under
a sustained compressive loading at stress levels
greater than 50 percent of the ultimate strength.
Sustained loadings at a stress level of 25 percent did
not reduce ultimate strength capacity for a loading
period of 1000 hr.
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Latex-Modified Concrete
The materials and the production technology
for concrete in LMC are the same as those
used in normal portland cement concrete
except that latex, which is a colloidal
suspension of polymer in water, is used as
an admixture.
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Latex-Modified Concrete
Earlier latexes were based on polyvinyl acetate
or polyvinylidene chloride, but these are
seldom used now because of the risk of
corrosion of steel in concrete in the latter
case, and low wet strengths in the former.
Elastomeric or rubberlike polymers based on
styrenebutadiene and polyacrylate
copolymers are more commonly used now.
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Construction
Latex
A latex generally contains about 50 % by
weight of spherical and very small (0.01 to 1
m in diameter) polymer particles held in
suspension in water by surface-active
agents.
The presence of surface-active agents in the
latex tends to incorporate large amounts of
entrained air in concrete; therefore, air
detraining agents are usually added to
commercial latexes.
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Latex
10 to 25 percent polymer (solid basis) by weight of
cement is used in typical LMC formulations,
the addition of latex provides a large quantity of the
needed mixing water in concrete.
The application of LMC is limited to overlays where
durability to severe environmental conditions is of
primary concern.
LMC is made with as low an addition of extra mixing
water as possible; the spherical polymer molecules
and the entrained air associated with the latex
usually provide excellent workability.
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Concrete Mix
Typically, water-cement ratios are in the range
0.40 to 0.45, and cement contents are on the
order of 650 to 700 lb/yd3 (390 to 420 kg/m3).
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Construction
Curing
The hardening of a latex takes place by drying
or loss of water.
Dry curing is mandatory for LMC; the material
cured in air is believed to form a continuous
and coherent polymer film which coats the
cement hydration products, aggregate
particles, and even the capillary pores.
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Properties
The most impressive characteristics of LMC are its
ability to bond strongly with old concrete, and to
resist the entry of water and aggressive solutions.
It is believed that the polymer film lining the capillary
pores and microcracks does an excellent job in
impeding the fluid flow in LMC.
These characteristics have made the LMC a popular
material for rehabilitation of deteriorated floors,
pavements, and bridge decks.
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Polymer-Impregnated
Concrete
The concept underlying PIC is that if voids are
responsible for low strength as well as poor
durability of concrete in severe
environments, then eliminating them by
filling with a polymer should improve the
characteristics of the material.
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Polymer-Impregnated
Concrete
It is difficult for a liquid to penetrate it if the
viscosity of the liquid is high and the voids in
concrete are not empty (they contain water
and air). Therefore, for producing PIC, it is
essential not only to select a low-viscosity
liquid for penetration but also to dry and
evacuate the concrete before subjecting it to
the penetration process.
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Polymer-Impregnated
Concrete
Monomers such as methyl methacrylate (MMA)
and styrene are commonly used for
penetration because of relatively low
viscosity, high boiling point (less loss due to
volatilization), and low cost.
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Polymer-Impregnated
Concrete
After penetration, the monomer has to be polymerized in situ. This
can be accomplished in one of three ways.
A combination of promoter chemical and catalysts can be used for
room-temperature polymerization; but it is not favored because
the process is slow and less controllable.
Gamma radiation can also induce polymerization at room
temperature, but the health hazard associated with it
discourages the wide acceptance of this process in filed
practice.
The third method, which is generally employed, consists of using
a monomer-catalyst mixture for penetration, and subsequently
polymerizing the monomer by heating the concrete to 70 C with
steam, hot water, or infrared heaters.
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Sequence of operation
Casting conventional concrete elements: Since
the quality of concrete before penetration is
not important from the standpoint of
properties of the end product, no special
care is needed in the selection of materials
and proportioning of concrete mixtures.
Section thickness is generally limited to a
maximum of about 150 mm, since it is
difficult to fully penetrate thick sections.
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Curing the elements
Following the removal of elements from forms,
at ambient temperatures conventional moist
curing for 28 days or even 7 days is
adequate because the ultimate properties of
PIC do not depend on the penetration
concrete quality.
For fast production schedules, thermal curing
techniques may be adopted.
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Drying and evacuation:
The time and temperature needed for removal of free
water from the capillary pores of moist-cured
products depend on the thickness of the elements.
At the drying temperatures ordinarily used (i.e., 105 C),
it may require 3 to 7 days before free water has been
completely removed from a 150- by 300-mm concrete
cylinder.
Temperatures on the order of 150 C can accelerate the
drying process so that it is complete in 1 to 2 days.
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Soaking the dried concrete in a monomer
The in situ penetration of concrete in the field
may be achieved by surface ponding, but
precast elements are directly immersed in
the monomer-catalyst mixture.
Commercial monomers contain inhibitors that
prevent premature polymerization during
storage; the catalyst serves to overcome the
effect of the inhibitor.
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Sealing the monomer
To prevent loss of monomer by evaporation
during handling and polymerization, the
impregnated elements must be effectively
sealed in steel containers or several layers
of aluminum foil;
in the rehabilitation of bridge decks this has
been achieved by covering the surface with
sand.
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Polymerizing the monomer
Thermal-catalytical polymerization is the preferred
technique.
The time for complete polymerization of the monomer
in the sealed elements exposed to steam, hot water
or air, or infrared heat at 70 to C may vary from a few
to several hours.
In the case of a MMA-benzoyl peroxide mixture, no
differences in strength were found between
specimens polymerized at C with hot air for 16 hr or
with hot water for 4 hr.
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Recommendations for
Improved Durability
1. Increase concrete cover
2. Better quality assurance during construction
(including curing)
3. Better concrete quality (low w/c ratio)
4. Epoxy coated bar (controversial)
5. Sealing and painting
6. Maintenance
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Repair Materials and

Methods
Goals:
Strength of repair work should be, at least,
as much as the old concrete.
Bond between old and new concrete should
be very good.
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Parameters Affecting the

Repair
1) Permeability
The subbase can be wet leading to a
significant amount of moisture below the
repair. The moisture will evaporate and it will
develop vapor pressure; therefore overlays
should be able to breath.
If the permeability is too low the repair will
delaminate. Portland cement concrete is
able to breath. Epoxies and polyesters are
not able to breadth causing delamination.
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Repair
2) Drying Shrinkage
If the same mix is used the concrete will shrink
and crack, losing the bond. This causes the
development of microcracks at the interfacial
bond producing delamination.
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Repair
3) Coefficient of Thermal Expansion ()
quartz sand has a high a value.
differences in a between old and new
concrete will cause differential strains.
use a as close as possible to the old
concrete.
4) Elastic Modulus
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General Considerations fo
Repair
1) How thick is the repair section?
Thin layer --> may not need form --> shotcrete
Extensive deterioration --> have to remove
old concrete, e.g., corroded bars.
2) Substrate
moist/dry?
3) Temperature
very low --> cement will hydrate slowly
very high --> cement will hydrate fast
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Repair
4) Ventilation
In closed rooms do not use urethane and MMA
(toxic)
5) Vertical x Horizontal Surface
6) Traffic Conditions
Critical traffic conditions
epoxies set in 5 min.; in 1/2 h it develops fc =
10,000 psi
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Repair
7) Appearance
8) Durability of the repair
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Construction Techniques
a) Cast in place formwork
section thickness: 6-8 in
remove old concrete --> clean --> use water
jets
(sand blast is not as used because of
pollution)
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Construction Techniques
b) Shotcrete
for thin repair
c) Tremie
underwater repair --> large operations
d) Pumping
slurry cement paste
e) dry packing
mix sand and cement --> compact --> wet --> hydration
little drying shrinkage ( due to particle contact)
f) crack injection
MMA --> good sealer --> thin fluids
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Shotcrete Rehabilitation
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DRY-MIX SHOTCRETE
PROCESS
Cementitious binder and aggregates
thoroughly mixed (central mixing, transit
mixer, volumetric proportioning mixer or dry
bagged premix)
Water Added if necessary to bring shotcrete to
Earth Dry consistency 3 to 6% moisture
content.
Mix added to shotcrete delivery equipment or
gun.
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DRY-MIX SHOTCRETE
PROCESS
Compressed air conveys the shotcrete from
the gun down the hose.
Water introduced under pressure through a
water ring at the nozzle.
Shotcrete jetted from a nozzle at high speed
onto a surface with the force of the
impacting jet compacting the material.
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Wet-Mix Shotcrete Proces

All ingredients including mixing water
thoroughly mixed.
The mortar or concrete is added to the
chamber of the delivery equipment.
The mix is either pumped or pneumatically
conveyed down the hose by compressed air.
High-pressure air is added at the nozzle to jet
the shotcrete at high velocity onto the
impacting surface.
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Comparison of Wet and

Dry Mix Shotcretes
Wet Mix Shotcrete
Advantages
Less Rebound
Less Dust
Less Nozzleman Skill Required
Air Entrainment Possible
Large Volume Rates of Placement Possible
Lower Cost Ready Mix Supply Often Possible
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Wet Mix Shotcrete

Disadvantages
Generally Lower Compressive Strengths
(unless silica fume and superplasticizers
used)
Cannot Adjust Moisture Content at Nozzle
when Shooting Wet Areas
Restricted to Layers 2 to 3 inches thick in a
single pass
Not suitable for small volume, intermittent
work
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Dry Mix Shotcrete

Advantages
Generally Higher Compressive Strengths
Nozzleman Can Adjust Water For Better
Adherence in Wet Substrate Conditions
Available in Premixed Dry Bags Form for StopStart Type Work
Air Entrainment Possible
Greater Thickness of Application Possible on
Vertical and Overhead Surfaces
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Dry Mix Shotcrete

Disadvantages
Higher Rebound
More Dust
Larger Air Compressor Required
High Level of Nozzleman Skill Required
Potential for Laminations, sand lenses, dry
pockets, etc.
Difficult to entrain air
Lower volume rates of placement
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Construction

Concrete Materials and Concrete Construction

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Repair of Reinforced

Repair Methods & Materia

Repair Materials and

Parameters Affecting the

Parameters Affecting the

Parameters Affecting the

8) Durability of the repair

Wet-Mix Shotcrete Proces

Comparison of Wet and

Wet Mix Shotcrete

Dry Mix Shotcrete

Dry Mix Shotcrete

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