Repair Materials

ASHWIN JOSHI
 Introduction: Repair Materials
2

 Deterioration of concrete is natural phenomenon

 Physical, chemical or mechanical processes brings
gradual degradation
 Premature deterioration of concrete is still
unacceptably high even if specifications are properly
implemented
 Corrosion of reinforcement is one of the most
dreaded causes of failures
 Repair and Rehabilitation therefore become
established facets of construction today
 Developments in Repair & Rehabilitation
3

 Repair Program is an EXPERT JOB

 From beginning it should be carried out in
PLANNED MANNER
 At present NO widely accepted GUIDELINES for
design, SPECEFICATIONS;
 Unfortunately, in India a large number of structures
are heading for repairs
 Lack of Co-ordination between Diagnosis and Repair
 Repair Persons / contractors are not
KNOWLEDGEABLE of different chemicals available
 Material Selection
4

 Complex process involving understanding of

requirement of repair by
 Engineer
 Owner
 Service and Exposure conditions
 Installation Techniques
 Final Selection of materials is based on
 Cost

 Performance

 Risk Assessment
 Challenges Faced
5

 Dimensional Behavior relative to Substrate

 Relative Dimensional changes causes INTERNAL
STRESSESS within repair material
 High internal stresses may result in Tension Cracks,
loss of load carrying capacity & De-lamination
 Materials for Structural Applications: obstacle to
achieve 100% efficiency
 1. Initial Loading on Repair material & Removal of load form
structure during repair
 2. Dimensional Behavior of repair material on substrate: Based
on load subjected to Temp. and Moisture Changes
 Parameters for Selection Criteria
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 1. Type of Concrete to be repaired and its AGE

 2. Magnitude and Thickness of Repairs
 3. Site Conditions
 4. Temperature &
 5. Environmental Influence
 Selection Criteria
7

 Almost every repair job has UNIQUE conditions and

special requirements
 Composition & Properties of repair materials have a
profound effect on the performance and durability of
repair
 Repair materials perform adequately only if they are
prepared, applied & Cured as per the specified
procedures, which may use appropriate tools &
Considerable Skills
 Repair Materials, being generally proprietary in
nature, are very costly
 Factors considered in Selecting Repair Material
8

o Function of Repair Material

 Physical & Mechanical Properties

1. Dimensional Stability
2. Coefficient of thermal expansion
3. Strength in compression, tension & flexure
4. Stiffness, elastic modulus & Poisson's Ratio
 Factors considered in Selecting Repair Material
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 Durability Related Properties

1. Permeability to liquids, Vapors and Gases
2. Diffusion Resistance
3. Water Absorption and Porosity
4. Weathering Resistance
5. Resistance to Chemicals
 Chemical Compatibility with other repair Materials
 Identification of anticipated service conditions
 Conditions prevailing at the time of repair
 Methodology for Selection of Repair Materials
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 Definition of Service Conditions:

 Identification of major & minor chemicals, traces, spillages,
cleaning chemicals, slurries & abrasives
 Determination of appropriate application condition:
 Viscosity, Flow characteristics, pot life, curing requirements
film/layer thickness and size of repair
 Tools and Equipments required:
 Pumps, sprayers, injecting / grouting machine, dryer, mixer,
batching plant, heater etc.,
 Methodology for Selection of Repair Materials
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 Repair and Maintenance:

 Anticipated Durability of repair, maintenance requirements,
replacement / renewal / strengthening requirements
 Material testing and assessment for quality
assurance and quality control
 Selection of applicator / contractor
 Material and job specification
 Classification of Repair Materials
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 Patch Repair Materials

 Cementitious Mortar / Concrete

 Polymer modified cementitious mortar / concrete

 Polymer Mortar / concrete

 Quick Setting Compound

 High Alumina Cement Based
 Calcium Sulphate Based
 Magnesium Sulphate Based
 Sulphur Based
 Classification of Repair Materials
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 Injection Grouts
 Cementitious Grouts (With or Without Fibers)

 Gas forming grouts

 Sulpho-aluminate grouts

 Polymer grouts

 Bonding Acids
 Polymer emulsion type

 Polymer resin type

 Classification of Repair Materials
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 Resurfacing Materials
 Protective Coatings and membranes
 Impregnates and hydrophobic Sealers
 Toppings / Screeds
 Overlays
 Gunite / Shotcrete

 Other Repair Materials

 Corrosion inhibitors
 Rebar protective coatings
 Cathodic protection
 Re-alkalization
 Efflorescence in Masonry
15

 Efflorescence:
 a change on the surface to a powdery substance upon exposure
to air, as a crystalline substance through loss of water (OR)
 to become incrusted or covered with crystals of salt or the like
through evaporation or chemical change.

 Efflorescence is normally the white, powdery scum

that can appear on masonry walls after
construction but can also be brown green or
yellow, depending on the type of salts.
Efflorescence
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 Distress in Masonry: Efflorescence
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 Not easy to eradicate efflorescence (cancer in bldg.)

 DPC (damp proof course) is required
 Effects: damp wall; disintegration of masonry; decay
/ dry rot of woodwork; crumbling of plaster etc.,
 Tamarind water is used in washing and removing
traces of efflorescence since its organic acid and is
mild
 Necessary Conditions for Efflorescence
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 First: There must be water-soluble salts present

somewhere in the wall.
 Second: There must be sufficient moisture in the wall
to render the salts into a soluble solution
 Third: There must be a path for the soluble salts to
migrate through to the surface where the moisture
can evaporate, thus depositing the salts which then
crystallize and cause efflorescence
 Necessary Conditions for Efflorescence
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 All three conditions must exist for phenomenon to

take place
 If any one of these conditions is not present, then
efflorescence cannot occur….!
 Though the efflorescence problem is complex, it is
not difficult to prevent
 Though one cannot eliminate the phenomenon, it is
quite simple to reduce all three and make it nearly
impossible for efflorescence to occur.
 Source of Efflorescent Salts
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 Alkalies of Sodium Sulfates (Na3S04) and Potassium

Sulfates (K2S04).
 Alkali sulfates appear because they exist somewhere
within the masonry wall
 The Brick
 Mortar
 Grout and / or
 Combination of all the three
 Alkalies combine with sulfates from the masonry to
form sulfate salts.
 Process of Phenomenon
21

 Alkali sulfates in the wall are dissolved by water into

a solution which then moves through the natural
pores in the masonry
 The solution migrates to surface of the wall
 Water Evaporates
 Salts gets deposited

 Main source of alkalies for the salts is the

Portland cements used in the mortar and grout
 Remedy / Causes
22

 Using alkali Portland cement will often eliminate the

efflorescent problem.
 Another culprit is, of course, the CLAY BRICK itself
but they are not great contributors
 Sand: May contain soluble salts; Contaminated sand
may contain sulphates
 Washing sand cleanly before using it in mortar or
grout may eliminate this problem
 Water: Clean, Portable & salt free water must be
used for construction
 Summarizing Conditions:
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 1. Reduce all soluble alkali sulfates

 2. Use good details to prevent water from entering
the masonry
 3. Use good construction practices to eliminate
migratory paths for moisture