57 Common Defects 7.1, COMMON DEFECTS AND REMEDIES ‘As defects in precast concrete elements would inevitably result in direct and indirect cost in terms of rectification and construction time, it is worthwhile to ensure that they are prod sd and handled in a way reduce such incidences. The following table illustrates some of these common defects, their causes and preventive measures. Table 7.1 List of common defects and recommended measures 1, Dimensional Deviation Variation in the dimension of procast elements would affect the joint alignment between these elements when erectod Precast slab element may warp due to insufficient concrete strength at lifting or improper storage condition a) Mould forms may not be sufficiently rigid to maintain specified tolerances during concrete placement. b} Precast elements may not have gained sufficient concrete strength when demoulded, ©) Top surface finish of precast elements may not be properly leveled and troweled during production which result in different sectional thickness. d) Precast elements (especially slender wall or slab panels) may be subjected to undue stress and deformation when they are not properly supported during storage. a} Regular check on the dimen- sions and rigidity of mould forms before casting opera- tions. As a general guide, the recommended plate thickness for steel mould are 4.5mm ~ Up to 50 castings 6 mm - Up to 100 castings 8mm — Up to 200 castings Mould forms conditions will deteriorate with time and usage. They should be repaired, stiffened or replaced when needed 5 Cube tests should be con- ducted to ascertain the concrete strength of elements before demoulding, Spreading and leveling of conerete placement using appropriate tools such as | Precast elements should be properly stored and stacked at designated points using suitable support spacers and frame rack system, dPRECAST CONCRETE ELEMENTS | COMMON DEFECTS 1. Dimensional Deviation (cont'd) 2. Cracks ‘+ For minor deviation, corrective measures such as surface grinding, trimmingihacking and skim coat application can be appropriately used to remedy the situation, Note Precast elements that are not within acceptable tolerance limits and have significant effects on the structural integrity or architectural performance should not be used, coe ee a} Precast elements may not have attained sufficient s domoulding. b} Cracks may have occurred during initial lifting due to friction between the elements and the casting mould forms Recommendations a} {Proper curing method, curing time and temperature should be adopted. lii’Cube test should be con- ducted to ascertain the concrete strength of elements before demoulding b) Appropriate form release agents should be used and uniformly applied onto the mould surface to minimise friction ) The thickness of the precast elements may be too thin (70mm or less} and flimsy for safe demoulding and handling di Cracks may have occurred during erection due to lack of planning and provisions given to the precast panel geometry, crane rigging configuration and location of apenings. Sectional thickness of precast, ‘element should be increased te accommodate demoulding ‘and handling stresses. d (Proper handling techniques should be adopted. {Sutfcient iting points should be used to minimise over- stressing on certain areas. (i)Adgitional reinforcing bars should be placed around the ‘openings and odd comers. livTemporary stiffeners for ‘openings should be provided during erection sePRECAST CONCRETE ELEMENTS | COMMON DEFECTS 59 2. Cracks (cont'd) 3. Chip-off and Damages * Allcracks should be examined by a qualtied engineer to determine if they present a structural problem. ‘+ Depending on the locations and seriousness of the cracks, different repairs method can be used to make good the affected precast elements. ‘Hairline cracks {not more than 0.3mm) can be repaired by cutting a V groove of specified minimum depth along the cracklines, followed by patching. * For surface cracks (more than 0.3mm or through cracks, epoxy injection ‘method should be used to ensure that the cracks are completely bound and filed with epoxy. Note Refer to Annex A of CP 81:1999 - for more detailed information on the prevention and repairs for various types of cracks. eee Recommendations a} Chipoff at paneledges are usually caused by the hard bearing at supports or excessive force exerted on the elements when handling 4} Precautions should be taken to avoid damaging the elements in the course of placement on vehicle, travel to site and during the unloading operation Bearing pads should be used to cushion the contact areas from damage. b} Improper storage method. b)[iThe storage area should be rolatively flat and dry. livPrecast elements should be properly stored and stacked at designated points using suitable support spacers and frame rack systom.