25 Years of Structural Repair

Paul Lambert

Centre for Infrastructure Maintenance Materials & Corrosion Engineering

Materials & Engineering Research Institute Mott MacDonald
Sheffield Hallam University Altrincham
Problems with Reinforced Concrete
Carbonation
Chloride Induced Corrosion
Carbonation Plus Chlorides
Conventional Patch Repair

UNPITTED PITTED

CATHODE ANODE
Conventional Patch Repair

UNPITTED PITTED

INCIPIENT
CATHODE ANODE
REPAIR
ANODE
Incipient Anodes
Problems with Reinforced Concrete
• The need to reconstruct Europe after WWII
brought reinforced concrete to the forefront.

• Inexperience in design, construction and quality

control resulted in poor long-term durability.

• The 1960's was also a time of massive

development in highway infrastructure in the UK.
 Problems with Reinforced Concrete
• The UK Highways Agency
has around 16,000 reinforced
concrete structures.
• Around 85% were designed &
constructed between 1960
and 1970.
• In the UK, most roads are
regularly salted in the winter
(plus never more than 100
miles from the sea).
• Within 20 years many were in
need of significant repair.
Park Hill Flats, Sheffield
Park Hill Flats, Sheffield
 Park Hill Flats, Sheffield
• Park Hill was previously the site of
back-to-back housing, known as
"Little Chicago" in the 1930's.

• After Sheffield was virtually flattened

during the blitz, the back-to-backs
were replaced with modern,
concrete 'cities in the skies‘

• In the 1990's Park Hill flats were

listed as historically important and
are now Europe's largest Listed
Building!
 Getting Organised
• Sprayed Concrete Association (SCA) -
1976.
• Concrete Repair Association (CRA) -
1989.
• Society for the Cathodic Protection of
Reinforced Concrete (SCPRC) - 1993.
– Later changed its name to the Corrosion
Prevention Association (CPA).
New Techniques
New Techniques
CP & Electrochemical Repair
e e e

OH-
Cl- Cl- Cl-

OH-
+ve
½O2 + H2O + 2e- (metal)  2OH- (aq.)
OH-
Fe (metal)
WATER  FeWATER
2+ + 2e-
WATER

OH-
New Markets
 New Needs
Country New Build Repair & Year
Refurbishment
% %
Japan 85 15 1995

USA 71 29 1993

France 70 30 1993

Germany 69 31 1995

50 50 1995
UK
47 53 2000
 The State of the Nation (ICE)
Assessment of Condition of UK Infrastructure
Category Condition Sustainability
Change
Grade Grade
Overall
C-  C

Energy D+  D

Waste Management C-  D+

Water & Wastewater B  C+

Flood Risk Management C  B

Rail C  D+

National Roads C+  D

Local Transport C  C-

Seaports B-  C+

Airports C+  D+

A = Good, B = Fair, C = Average, D = Poor, E = Bad

 American Infrastructure Report Card
by American Society of Civil Engineers
Category Condition
Grade
Roads D

Bridges C

Transit D+

Rail C-

Aviation D+

Power Grid D

Drinking Water D-

Waste Water D-

Dams D

A = Exceptional, B = Good, C = Mediocre, D = Poor, E = Failing

Ynys-y-Gwas Bridge, 1985
 New Standards
BS EN ISO 12696
Cathodic Protection of
Steel in Concrete
UK HA Design Manual
Cathodic Protection for Use
in Reinforced Concrete
Highway Structures
BS EN 15257
Competence Levels and
Certification of Cathodic
Protection Personnel
BS EN 1504
Concrete Repair
• Part 1: Definitions
• Parts 2 – 7: Products
• Part 8: Quality Control of
the Products
• Part 9: Principles for Repair
• Part 10: Site Application &
Quality Control of the
Works
 BS EN 1504
• From 31st December 2008 Euro Norm EN1504 came into
full force (in the UK, BS EN 1504).
• Full title is ' Products and Systems for the Protection and
Repair of Concrete Structures – Definitions,
Requirements, Quality Control, Evaluation of
Conformity'.
• After 20+ years of development, it is intended to address
many of the aspects that relate to the design and
execution of repairs and maintenance to concrete
structures.
 Main functions of BS EN1504
• Specify minimum performance levels of repair materials
for particular applications (CE mark).
• Identify procedures for sampling, testing and confirming
that materials are in accordance with the manufacturer's
specification.
• Identify performance tests to assist the engineer or
specifier in the selection of the most appropriate
products.
• Provide standardised approaches for the design and
execution of repairs.
 The Ten Parts of BS EN 1504
• Part 1: General Scope & Definition.
• Part 2: Surface Protection Systems.
• Part 3: Structural & Non-Structural Repair.
• Part 4: Structural Bonding.
• Part 5: Concrete Injection.
• Part 6: Grouting to Anchor Reinforcement
or Fill External Voids.
• Part 7: Reinforcement Corrosion Prevention.
• Part 8: Quality Control & Evaluation of Conformity.
• Part 9: General Principles for the Use of Products
and Systems.
• Part 10: Site Application of Products and Systems
and Quality Control of the Works.
 Structure of BS EN1504
BS EN 1504 – 1: Definitions Test Methods

BS EN 1504 – 2 to 7:
BS EN 1504 –
9: Products

•anchoring products
Principles

•injection materials
•surface protection

•bonding materials
•repair materials > 50 Standards

•steel protection
(e.g. BS EN 13396
BS EN 1504 –
– Chloride Ingress)
10:
Application &
QC of Repairs

BS EN 1504 – 8: Quality Control of Products

 Part 9: General Principles
• Principle 1 – Protection Against Ingress.

CONCRETE
• Principle 2 – Moisture Control.
• Principle 3 – Concrete Restoration.
• Principle 4 – Structural Strengthening.
• Principle 5 – Physical Resistance.
• Principle 6 – Resistance to Chemicals.
• Principle 7 – Preserving or Restoring Passivity.
• Principle 8 – Increasing Resistivity.

STEEL
• Principle 9 – Cathodic Control.
• Principle 10 – Cathodic Protection.
• Principle 11 – Control of Anodic Areas.
Common Causes of Defects (Part
9, Clause 4.3)
 Management Options (Part 9,
Clause 5.2)
• Do nothing for a certain
time
• Re-analyse structural
capacity, possibly
downgrading the function
• Prevent or reduce further
deterioration
• Improve, strengthen or
refurbish all or part
• Reconstruct all or part
• Demolish all or part
paul.lambert@mottmac.com

p.lambert @shu.ac.uk