REHABILITATION OF BRIDGES AND

CASE STUDIES
Webinar for KHRI

Er. VIVEK NAIK

Past President – Indian Concrete Institute
MD – Apple Chemie India Pvt. Ltd.
 Innovations

Successfully commercializing a product, process or service as per

demand of the market or targeted consumers.
Jugaad is not wrong- It is innovative!

Frugal innovation, or as we call it Jugaad is not

something lower in quality. It is a cheaper
solution to a standard problem without
compromising on performance and utility. It is
the answer to a problem where standard
solutions are not affordable, feasible or
applicable.

Unknowingly, we use these in everyday life. But

Jugaad is used everyday in construction and
repair industry. It is the uncommon way to solve
common problems!
 3R
REPAIR
• Making up old/new building component to give balance serviceable
life. It will not increase the load carrying capacity of the building after
Repair.

REHABILITATION
• Structural Repair to building component – this comes under failure of
performance of the part of building, leading to unsafe or impossible
use of building for the performance for which it is designed.
It includes strength of the structure

RETROFITTING
• Repair, Rehabilitation and further modification of structure to make it
suitable for modern look, change of aesthetics, functions, strength
criteria & other technical requirements etc.
Life Sciences of Concrete Repairs
At the Dentist

•Repairing a tooth is often

similar to repairing damaged
concrete
Key Stages at the Dentist

Examine
teeth

Further
Future investigation
maintenance
e.g. search
e.g. regular for voids,
cleaning
X-Ray?

Select the
repair Options
e.g. gold e.g. extract,
amalgam, fill?
composite?

*
5 Key Stages in Concrete Repair

Future •Assessment of
maintenance the structure

Select repair
Diagnose cause
process
of deterioration
Step
3

Options and
objectives of repair
*
5 Key Stages in Concrete Repair

Future •Assessment of
maintenance the structure

Select repair
Diagnose cause
process
of deterioration
Step
3

Options and
objectives of repair
*
The Condition Survey

 Identify the cause

 Determine the effect

 What is the

consequence?

*
Content of Condition Survey

• Review past, current & future

1 use
• Visual aspects

2
• Non-destructive tests
• Probing or destructive testing
• Laboratory analysis

* Synopsis By Er. Vivek Naik

Methods of Diagnosis - NDT

* Synopsis By Er. Vivek Naik

5 Key Stages in Concrete Repair

Future •Assessment of
maintenance the structure

Select repair
Diagnose cause
process
of deterioration
Step
3

Options and
objectives of repair
*
Exposures on Reinforced Concrete
Cl-
Freeze /
Thaw

CO2

H2O NOx

SOx

*
 The Carbonation of Concrete

Ca (OH )2 + Co2 + H20 CaCO3 + 2H20

Calcium + Carbon + Water Calcium + 2 x Water
Hydroxide dioxide carbonate

1st Phase : Diffusion inwards of Relative air rate of

carbon dioxide Humidity : carbonation :

2nd Phase: Reaction between carbon

Less than 30% low
dioxide and water molecules
40 to 75% high
3rd Phase : Reaction between resultant
carbonic acids & the alkaline
m. Than 75% low
components of concrete.

CaCo3 is white/brittle and slightly soluble in water 16

FACTORS INFLUENCING THE DEPTH OF CARBONATION

• GRADE OF CONCRETE
• WHETHER CONCRETE IS PROTECTED OR
NOT
• PERMEABILITY OF CONCRETE
• TIME
• DEPTH OF COVER
• THE ENVIRONMENTAL INFLUENCES
FACTORS INFLUENCING THE DEPTH OF CARBONATION
Concrete Defects and Damage
 Mechanical damage
 Mechanical Impact
 Overloading
 Movements (Settlement)
 Explosion
 Vibration
 Chemical damage
 Alkali Silica Reaction
 Sulphates, Salts
 Acids, Soft water
 Biological (Acids)
 Physical damage
 Freeze-Thaw Action
 Thermal Movements
 Erosion/Abrasion
 Shrinkage

*
Reinforcement Corrosion
Chemical attack
Carbonation
Acids
Corrosive contaminants
Chlorides

Stray electrical current

*
5 Key Stages in Concrete Repair

Future •Assessment of
maintenance the structure

Select repair
Diagnose cause
process
of deterioration
Step
3

Options and
objectives of repair
*
Options for the Owners

 Do nothing
 Downgrade structure
 Reduce further damage
 Repair and restore
 Part reconstruction
 Demolition

*
13
Considerations for Owners

 Costs
 Design life
 Performance requirements
 Temporary works
 Construction
 Future maintenance

*
Objectives for Concrete Repair

1. Replace defective concrete

2. Restore structural integrity
3. Restore durability
4. Restore aesthetic
appearance
5. Restore geometric
appearance

*
5 Key Stages in Concrete Repair

Future •Assessment of
maintenance the structure

Select repair
Diagnose cause
process
of deterioration
Step
3

Options and
objectives of repair
*
Selection of Method of Repair

Non structural
repairs

Structural
repairs
*
 Selection of Method of Repair
STEPS IN BOTH THE CASES OVERLAP TO SOME EXTENT

STEPS FOR STRUCTURAL REPAIRS :

• Injecting the structural crack with suitable material
• Strengthening the structure (Guniting/Polymer mortars)
• Cosmetic repairs , if required
• Surface coatings

STEPS FOR NON STRUCTURAL REPAIRS:

• Sealing of the cracks for stopping water leakages etc.
• Cosmetic repairs

IN CASE OF CHLORIDE CONTAMINATED CONCRETE, STEPS ARE:

•Providing a completely passive.barrier around reinforcement by removal
of all concrete around bars (theoretical and not very practical)
Resorting to Cathodic Protection

*
Method of Repair

Selection of Method of Repair and Material

Specifications of Repair products

*
Selection of Method of Repair

 Polymer Repairs
 Epoxy Repairs
 FRP
 Carbon Wrap/ Aramid Wrap
 Post Tensioning
 Plate Bonding
 Composite Repairs

*
Specifications of Repair products / Materials

 Cement / Cement Grouting + Polymer

 Micro fine Cement + Micro Silica
 Site Repair Composites
 Ready to use Repair Composites
 Epoxies
 Low Viscosity Grouts

*
Structural Repairs – Core Strengthening

*
Structural Repairs – Core Strengthening

*
Structural Repairs – Core Strengthening

*
Substrate Preparation

 Remove Defective Concrete

 Water Jetting
 Chiselling

*
Substrate Preparation

Defected area Proposed repair

area

Proposed repair
Defected area area

 Mark perimeter of repair area.Layout should be simple geometric

shapes.

*
Substrate Preparation
<45 degree

90 degree
45 degree

Clearly Defined Edges at Angle > 45 Degree

*
Substrate Preparation
 Remove concrete behind bars

 Avoid under and over cutting sides

 Roughen surface (2mm min)

*
Substrate Preparation
 Clean bars

 Use abrasive blast cleaning technique or

High pressure water jet (1100 bar)

“Correct preparation is key to a

successful concrete repair”

*
Application Method

Hand Application

*
 Application Method
Shot Crete/Shot Gunite

*
Application Method
Application of mortar with pressure equipment and nozzle.

*
Application Method
Form & Pour:

*
Application Method
Form & Pour:

Pouring grout through openings

*
Application Method
Form & Pour (Machine)

*
Concrete Protection

Refurbishment is
incomplete without the
protection of concrete.

*
 Levels of Concrete Protection

System 1: System 2: System 3:

Durable concrete protection Durable concrete and High performance protection
reinforcement protection for extreme conditions

1 2 3
2

1 1

1Deep penetrating 1 Migratory corrosion inhibitor 1 Migratory corrosion inhibitor

hydrophobic impregnation 2 Deep penetrating 2 Deep penetrating
hydrophobic impregnation hydrophobic impregnation
3 Protective coating

For exposed concrete structures For severely exposed or weak For severely exposed or weak
showing no visible concrete defects concrete with a high risk of concrete with a high risk of cracking
(crack width < 0.3 mm) steelcorrosion

*
Complete Process

Removal of damaged concrete Rust removal of Corrosion protection Bonding bridge

rebars layer

Rendering mortar Concrete Concrete

Application of repair mortar
protection protection
(1st layer) (2st layer)

*
5 Key Stages in Concrete Repair

Future •Assessment of
maintenance the structure

Select repair
Diagnose cause
process
of deterioration
Step
3

Options and
objectives of repair
*
Protection Coatings

*
Future Maintenance

 Detailed records
 Monitoring
 Inspection instructions
 Responsibilities
 Local requirements

*
 Case Study – I

Kaigaon – Toka Bridge on Nagpur

Mumbai Highway
 Strengthening of Old Bridges

•Innovations
•Polymer Repair System
•Injection & strengthening system
•Carbonation protection system
REMEDIAL MEASURES

Replacement of existing
Neoprene bearings
•Repairs to articulations
joints

•Expansion joint
replacement

•Repairs to weak concrete

•Epoxy injection in cracks

Repair &
Rehabilitation
Kaigaon Toka Bridge on Godavari River
Flash
 Case Study – II

Newaj Bridge on Indore Dewas

Highway
 •Bridge Details

Spans -8 numbers
Length of each span -24.6 m
construction – 1975 (?)
Total length of Bridge – 210 m
Modification – 1980 (??)
WhatsApp Video 2019-11-25 at 3.08.33 PM.mp4
Bhima River Bridge
Bhima River Bridge
Bhima River Bridge
Bhima River Bridge
Bhima River Bridge
Bhima River Bridge
Bhima River Bridge
Bhima River Bridge
Bhima River Bridge
 Case Study – III

Wanchoo Point Bridge, Indore

Indore Wanchoo Point
Indore Wanchoo Point
Indore Wanchoo Point
Indore Wanchoo Point
Indore Wanchoo Point
Thank you