Ce 2071 - Repair and Rehablitation of Structures (For Viii - Semester)

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CE 2071– REPAIR AND REHABLITATION OF STRUCTURES
(FOR VIII – SEMESTER)
UNIT – I
MAINTENANCE AND REPAIR STRATEGIES
Compiled by,
R.SURYA M.E;
ASSISTANT PROFESSOR
DEPARTMENT OF CIVIL ENGINEERING
SRI VIDYA COLLEGE OF ENGINEERING & TECHNOLOGY
VIRUDHUNAGAR
www.Vidyarthiplus.com
UNIT – I
MAINTENANCE AND REPAIR STRATEGIES
Maintenance, repair and rehabilitation, Facts of Maintenance, importance of

maintenance, various aspects of Inspection, Assessment procedure for evaluating a
damaged structure, causes of deterioration.
MAINTENANCE.
Maintenance is preventive in nature. Activities include inspection and works,
necessary to fulfill the intended function or to sustain original standard of service.
TYPES OF MAINTENANCE
i. Daily Routine maintenance.
ii. Weekly Routine maintenance.
iii. Monthly Routine maintenance.
iv. Yearly Routine maintenance.
CLASSIFICATION OF MAINTENANCE:
1. PLANNED MAINTENANCE
It improves uptime and quality of output and reduces repair maintenance costs
through the continuous quality improvement of equipment operation.
Planned Maintenance provides guidelines for a total system of activities in which all
employees work to improve the quality of product output, increase production
uptime, reduce costs of operations and reduce the amount and complexity of
machinery required.
It includes scheduled and unscheduled maintenance programs with strategies for
responding to machinery and equipment failures.
Planned maintenance includes two main activities:
A) PREVENTIVE MAINTENANCE
It is a schedule of planned maintenance actions aimed at the prevention of
breakdowns and failures.
The primary goal of preventive maintenance is to prevent the failure of equipment
before it actually occurs.
It is designed to preserve and enhance equipment reliability by replacing worn
components before they actually fail.
Preventive maintenance activities include equipment checks, partial or complete
overhauls at specified periods, oil changes, lubrication and so on. In addition,
workers can record equipment deterioration so they know to replace or repair worn
parts before they cause system failure.
Recent technological advances in tools for inspection and diagnosis have enabled
even more accurate and effective equipment maintenance.
The ideal preventive maintenance program would prevent all equipment failure
before it occurs.
B) CORRECTIVE MAINTENANCE:
Corrective maintenance consists of the action(s) taken to restore a failed system to
operational status.
This usually involves replacing or repairing the component that is responsible for
the failure of the overall system.
Corrective maintenance is performed at unpredictable intervals because a
component's failure time is not known a priori.
The objective of corrective maintenance is to restore the system to satisfactory
operation within the shortest possible time.
Corrective maintenance is typically carried out in three steps:

1. Diagnosis of the problem. The maintenance technician must take time to locate the
failed parts or otherwise satisfactorily assess the cause of the system failure.
2. Repair and/or replacement of faulty component(s). Once the cause of system failure
has been determined, action must be taken to address the cause, usually by
replacing or repairing the components that caused the system to fail.
3. Verification of the repair action. Once the components in question have been
repaired or replaced, the maintenance technician must verify that the system is
again successfully operating.
2. ROUTINE MAINTENANCE:
Routine maintenance is such activities as cleaning, dusting, lubricating, checkup of
important parts such as battery.
These activities are to be performed on a daily or weekly basis. Some of these form
part of scheduled maintenance.
Routine maintenance, normally does not involve any replacement of parts
3. SCHEDULED MAINTENANCE:
Scheduled maintenance is a maintenance activity undertaken on equipments as per
a plan of action, which gives the sequence in which various jobs would be attended.
The schedule gives the calendar day and time at which a particular job is
undertaken.
A maintenance schedule is prepared for a week. As the job content of maintenance
activity is variable, the schedule for the next day is usually firmed up at the end of
each day.
The scheduled maintenance activities may be preventive or break down in nature.
The maintenance schedule is prepared based on certain rules such as:
1. First come first served
2. Emergency priority job first
3. Shortest competition time job first.
4. Longest competition time job first
5. Random
4. PREDICTIVE MAINTENANCE:
Predictive maintenance allows plant management to control the machinery
and maintenance programs rather than vice versa.
In a plant using predictive maintenance, the overall machinery condition at
any time is known, and much more accurate planning is possible.
Predictive maintenance utilizes many different disciplines, by far the most
important of which is periodic vibration analysis.
It has been shown many times over that of all the non-destructive testing
that can be done on a machine; the vibration signature provides the most
information about its inner workings.
The resulting benefits of preventive maintenance are many. Some of them are listed
below:
Safety. Machinery that is not well maintained can become a safety hazard.
Preventive maintenance increases the margin of safety by keeping
equipment in top running condition.
Lower cost. A modern and cost-effective approach to preventive
maintenance shows that there is no maintenance cost optimum. However,
maintenance costs will decrease as the costs for production losses decreases.
No preventive maintenance action is performed unless it is less costly than
the resulting failure.
Reduction in failures and breakdowns. Preventive maintenance aims to
reduce or eliminate unplanned downtime, thereby increasing machine
efficiency. Downtime is also reduced when the preventive maintenance
process gives maintenance personnel sufficient warning so repairs can be
scheduled during normal outages.
Extension of equipment life. Equipment that is cared for will last longer
than equipment that is abused and neglected.
Improved trade-in/resale value of equipment. If the equipment is to be
sold or traded in, a preventive maintenance program will help keep the
machine in the best possible condition, thereby maximizing its used value.
Increased equipment reliability. By performing preventive maintenance
on equipment, a firm begins to build reliability into the equipment by
removing routine and avoidable breakdowns.
Increased plant productivity. Productivity is enhanced by the decrease in
unexpected machine breakdown. Also, forecast shutdown time can allow the
firm to utilize alternate routings and scheduling alternatives that will
minimize the negative effect of downtime.
Fewer surprises. Preventive maintenance enables users to avoid the
unexpected. Preventive maintenance does not guarantee elimination of all
unexpected downtime, but empirically it has proven to eliminate most
downtime caused by mechanical failure.
Reduced cycle time. If process equipment is incapable of running the
product, then the time it takes to move the product through the factory will
suffer. Taninecz found, from an Industry Week survey, that there is a strong
correlation between preventive maintenance and cycle-time reductions as
well as near-perfect on-time delivery rates. Also, approximately 35 percent of
the surveyed plants who widely adopted preventive maintenance achieved
on-time delivery rates of 98 percent, compared to only 19.5 percent for non-
adopters.
Increased service level for the customer and reduction in the number of
defective parts. These have a positive direct effect on stockouts, backlog,
and delivery time to the customer.
Reduced overall maintenance. By not allowing machinery to fall into a
state of disrepair, overall maintenance requirements are greatly decreased
FACETS OF MAINTENANCE:
The avoidance of accidents, which may harm people.
The continued operation of facility.
The protection of the capital investment in the asset.
IMPORTANCE OF MAINTENANCE.
It improves the life of structure.
Improved life period gives better return on investment.
Better appearance and aesthetically appearing.
Leads to quicker detection of defects and hence remedial measures.
Prevents major deterioration that leads to collapse.
Ensure safety occupants.
REPAIR.
Repair is the technical aspects of rehabilitation. It refers to the modification
of a structure, partly or wholly, which is damaged in appearance or serviceability.
REPAIR ASPECT OF MAINTENANCE.
Even though designers allow a large margin of safety in their designs, once
deterioration reaches a critical limit, immediate repair is needed to restore the level
of
performance to its intended level of service. In fact if the rehabilitation work is not
carried out in time, the structure may not be repairable to the required level of
service.
The execution of such a repair is an exacting, technical matter involving 5 basic
steps.
i. finding the deterioration
ii. determining the cause
iii. evaluating the strength of existing building or structure
iv. evaluating the need of repair
v. Selecting & implementing a repair procedure.
I)FINDING THE DETERIORATION

Before the repair can be effected, there must be a realization that something is
wrong, and the realization must come before it is too late to; make a repair, ie before
the
structure has collapsed
For eg:- timbers and timber piling can be damaged by insects or marine
organisms, virtually to the point of collapse, without exhibiting any external
evidence
which would be apparent except to a trained observed. Even a common defect like
corrosion of steel can be difficult to detect because if occurs, principally, in the most
inaccessible parts of the structure. The reason is simple. The accessible parts are
painted, but the inaccessible parts often are neglected.
The point to be made is that is that the engineer charged or interested in
maintenance must be trained, technically, in where to look, how to look & what to
look
for, before he can even be expected & realize that there is trouble knowing all these
requires a knowledge of various kinds & causes of deterioration & before checking
the
engineer must know all these.
II) DETERMINE THE CAUSE
To select the repair step, the cause has to be identified. In case of concrete the
specific cause might not be known due to several agents acting. What can be done is
to
Eliminate possibilities and design repair procedures for any of the remaining few. In
such cases the cost will go higher. But it should also be noted that the failure to
understand the cause of a defect fan lead to the selection of a repair procedure
which
would be harmful, rather than helpful.
For eg:- (racks in walls due the foundation settlements run diagonally)
(Cracks due to corrosion of reinforcement run straight & parallel at uniform
intervals &
show evidences of rust, staining)
A few tips are as follows
a. Inspect & observe the structure
b. Observe in bad & good weather
c. Compare with other constructions on the area or elsewhere & be patient
d. Study the problem & allow enough time to do the job
III) EVALUATE THE STRENGTH OF THE EXISTING STRUCTURE

This should be done to know whether it is safe to continue using the structure or
limit it to a less severe extend of usage if the structure has not completely
deteriorated
the adequacy of determination of strength becomes important for that the following
methods can be used
A) FIXED PERCENTAGE METHOD
It is to assume that all members which have lost less than some
predetermined % of their strength are still adequate and that all members
which have lost more than the strength are inadequate. It is usually from 15%
onwards higher values are applicable for piling % stiffness bearing plates etc
B) ANALYSIS OF THE ACTUAL STRESS CONDITION:
This method is to make detailed stress analysis of the structure, as it
stands including allowances for loss of section where it has occurred. This is
more difficult & expensive. Here also the first stop is to make preliminary
analysis by fixed percentage method and if it appears that major repairs will
be required, the strength is reevaluated based on detailed stress analysis,
considering all contributions to such strength.
C) LOAD TEST
Third step is load test. Load tests may be required by the local building
Offered, but they should only be performed where computation indicated that
there is reasonable margin of safety against collapse, lest the test bring the
Structure sown. Load test show strengths much greater than computed
Strengths when performed on actual structures. When performed on actual
Structures. In repair work every little bit of strength is important.
Accordingly the use of load test is recommended but with a full & clear
Understanding of their limitations and range of applicability.
IV) EVALUATE THE NEED OF REPAIR
When the cause of the deterioration has been determined and the strength of the
Existing structure has been checked, a decision must be made whether
a. To permit deterioration to continue
b. To make measures to preserve the structure in its present condition
c. Without strengthening
d. To strengthen the construction
e. If deterioration is exceptionally sever, to reconstruct or possibly abandon it.
These decisions are based on
safety
economy &
appearance subject to various principles different decision may
beappropriate for different elements of same structure
Case – a] Analysis show that structure still has adequate strength
If the appearance of the existing condition is objectionable – repair
Now
If appearance is not a problem then
Put the condition under observation to check if it is dormant or Progressive.
If dormant – no repair
If progressive – check the feasibility & relative economics of Permitting
deterioration to continue and performing a repair at some later Date & of making
the repair right away
Case – b] Analysis shows that the strength of the structure currently is or sowty will
be
in adequate
Either repair it or
Rebuild it or
Abandon it, partly or completely or
consider a change of use
V) SELECT & IMPLEMENT A REPAIR PROCEDURE:
Consider total cost
Do repair job in time
If defects are few & isolated repair on an individual basis.
Otherwise do in generalized manner
Ensure the repair prevents further development of defects
In case of lost strength, repairs should restore the strength
If appearance is a problem, the number of applicable types of repairs become
limited & the repairs must be covered
Repair works should not interface with facilities of the structure
Take care in addition of section to a member and in reattributing live loads and
other live load moments.
After selecting a suitable method of repairs, and after considering all the
ramifications of its application, the last step is to prepare plans & specification and
proceed with the work.
REHABILITATION.
Rehabilitation is the process of restoring the structure to service level, once it
had and now lost, strengthening consists in endowing the structure with a service
level, higher than that initially planned by modifying the structure not necessarily
damaged structure.
FACTORS TO BE CONSIDERED BY THE DESIGNER AT THE CONSTRUCTION SITE.
Minimum and maximum temperatures
Temperature cycles
Exposure to ultra violet radiation
Amount of moisture
Wet/dry cycles
Presence of aggressive chemicals
STAGES OF INSPECTION AND MAINTENANCE

Inspection
Analysis
Action Possibilities.
DETERIORATION
a symptom of reduced quality or strength(or)
process of changing to an inferior state(or)
The process of becoming progressively worse.
CAUSES OF DETERIORATION
1. Deterioration due to corrosion
2. Environmental effects
3. Poor quality material used
4. Quality of supervision
5. Design and construction flaws
1.DETERIORATION OCCURS DUE TO CORROSION
A.SPALLING OF CONCRETE COVER
Spalling concrete is concrete that has broken up, flaked, or become
pitted. This is usually the result of a combination of poor
installation and environmental factors that stress the concrete,
causing it to become damaged. On a low level, it can be purely
cosmetic in nature, but it can also result in structural damage, such
as damage to reinforcing bars positioned inside the concrete. For
this reason, it is important to address spalling when it first starts
to appear.
The signs of spalling are easy to spot. The surface will become
rough and flaky, and may pit. In some cases, chunks of concrete
break loose from the installation. The concrete can also start to
crack, especially if large chunks break off. It can be repaired by
totally removing the damaged section of concrete and filling it in
with cement.
The best time to address spalling is when concrete is first poured,
by taking steps to prevent it from occurring in the first place. The
concrete should be mixed with the right amount of water, and
ideally the mix kept as dry as possible because a high water
content can weaken the material.
It also needs time to cure properly and should be handled carefully
during curing. Sealing the concrete can also protect it from the
elements. There are a number of sealants available for concrete
and they can also work with a decorative finish.
B.CRACKS PARALLEL TO THE REINFORCEMENT.
CONCRETE CRACKING DUE TO CORROSION OF REINFORCEMENT
 The corrosion of steel reinforced concrete member by the formation of electro-

chemical cell results in cracking (characteristically parallel to the
reinforcement), spalling or in delamination of concrete.
 This corrosion may occur due to chloride attack and carbonation.
MECHANISM OF CRACKING
 The corrosion of steel results cracking and further deeper propagation of

cracking in two successive steps.
Firstly
The production of corrosion occupies a volume several times larger than the
original steel so that their formation results in cracking. This makes it easier for
aggressive agents to ingress towards the steel, with a consequent increase in
the rate of corrosion.
Secondly
The progress of corrosion at the anode reduce the cross-sectional area of steel,
thus reducing its load carrying capacity resulting increase in deflection
encouraging cracks to be pronounced.
Location of appearance
These are normally seen in columns and beams where environment is in favor of
corrosion.
Cause of cracking
Normally poor quality concrete is subjected to such types of cracking. Inadequate

clear cover also makes easy intrusion of aggressive materials like chloride or results
carbonation.
Remedy
Good quality concrete adding suitable admixture depending on the environment
surroundings of desired concrete member. Providing adequate clear cover also
discourage cracking of this type.
C.SWELLING OF CONCRETE
 Swelling, turgescence or tumefaction is a transient abnormal
enlargement of a body part or area not caused by cells. It is caused by
accumulation of tissues. It can occur throughout the body
(generalized), or a specific part or organ can be affected (localized).
 Swelling is considered one of the five characteristics of inflammation;
along with pain, heat, redness, and loss of function.
D.DISLOCATION INTERNAL CRACKING & REDUCTION IN AREA OF STEEL

REINFORCEMENT
2.ENVIRONMENTAL EFFECTS:
Micro-cracks present in the concrete are the sources of ingress of moistures
atmospheric carbon di-oxide into the concrete which attack reinforcement and with
various ingredients of concrete. In aggressive environme4nt concrete structure will be
severely reduces.
Construction
Advice and guidance for preventing pollution, managing waste and resources sustainably on
construction, demolition and excavation sites.
Good site layout, resource management, and taking sensible steps to minimise pollution can
greatly reduce the environmental impact of your site.
Pollution prevention
Every year we respond to 350 pollution incidents caused by construction. Individual

builders, small/medium enterprises and larger companies are all responsible for the impact
they have on the environment. Pollution during construction can be prevented by careful
planning and management of on-site activities.
Follow our guidance to help keep the environment clean and safe.
Construction, demolition and excavation waste
Around 20 million tonnes of construction, demolition and excavation (CD&E) waste was
sent to landfill in 2010. At the end of 2011 CD&E waste was the largest contributing waste
type in illegal waste sites.
Your Duty of Care is a legal requirement that applies to the use, treatment, disposal and
transportation of waste. Failure to comply with the law risks penalties in court and can lead
to serious impacts on the environment.
Good site management and well managed waste handling makes good business sense,
reduces costs and enhances community relations.
Sustainable construction
Sustainable construction is about the better management of resources, reusing waste

materials where possible, and reducing your carbon footprint. It includes how
developments impact on and provide for the surrounding infrastructure and natural
environment as well as the fabric of buildings.
Good practice can help you achieve sustainability and reduce costs.
Planning
Local authorities consult the Environment Agency about planning applications.
We use evidence to assess the potential environmental risks associated with a particular
development. Whilst we provide evidence and comment on planning applications, we do
not have the power to grant or refuse permission for a development. This role rests with the
Local Planning Authority.
Often there is not enough information included in planning applications for us to determine
what impact the development will have on the environment. You can help speed up your
planning application by filling in a pre-application form.
Effect of selecting poor quality material for construction
Quality of materials, to be used in construction, should be ensured by means

various tests as specified in the IS codes. Alkali-aggregate reaction and sulphate attack
results in early deterioration. Clayey materials in the fine aggregates weaken the mortar
aggregate bond and reduce the strength. Salinity causes corrosion of reinforcing bars as
well as deterioration of concrete.
DETERIORATION
a symptom of reduced quality or strength(or)
process of changing to an inferior state(or)
The process of becoming progressively worse.
QUALITY OF SUPERVISION
Construction work should be carried out as per the laid down specification.
Adherence to specified water-cement ratio controls strength, permeability
durability of
concrete. Insufficient vibration may result in porous and honey combined concrete,
whereas excess vibration may cause segregation.
DESIGN LEVEL FACTORS:
Concrete structures are an assembly of operating systems that experience
temperature, air pressure and vapour pressure, gradients.
Seasonal and diurnal fluctuations on outdoor conditions provide variability and
direction of the gradients.These operating conditions can accelerate premature
failure of the components in a repair. The relative severity of these factors will vary
depending on the use and location of the structure; and the types of repair material
used and so on. Predicting these fluctuations and accommodating them at a design
stage is important.
Allow for change in use in design:During the service life of a structure, its
environment and occupancy may change. As a result, the structure will have to
withstand stresses different from those for which it was originally intended.
For e.g.:- Addition of roof garden to parking lot requires additional protection
against ponding of water on the roof of parking lot.

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MAINTENANCE AND REPAIR STRATEGIES

Maintenance, repair and rehabilitation, Facts of Maintenance, importance of

Corrective maintenance is typically carried out in three steps:

I)FINDING THE DETERIORATION

III) EVALUATE THE STRENGTH OF THE EXISTING STRUCTURE

STAGES OF INSPECTION AND MAINTENANCE

B.CRACKS PARALLEL TO THE REINFORCEMENT.

CONCRETE CRACKING DUE TO CORROSION OF REINFORCEMENT

 The corrosion of steel reinforced concrete member by the formation of electro-

 The corrosion of steel results cracking and further deeper propagation of

Normally poor quality concrete is subjected to such types of cracking. Inadequate

D.DISLOCATION INTERNAL CRACKING & REDUCTION IN AREA OF STEEL

Every year we respond to 350 pollution incidents caused by construction. Individual

Construction, demolition and excavation waste

Sustainable construction is about the better management of resources, reusing waste

Local authorities consult the Environment Agency about planning applications.

Effect of selecting poor quality material for construction

Quality of materials, to be used in construction, should be ensured by means

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