ACi COMMITTEE REPORT

Titie no. 94M31 -

-
ACI 555R-O1

Removal and Reuse of Hardened Concrete

Reported by ACI Committee 555

Joseph F. Lamond'
Chair

Roy L.Campbell, SI. Almengo Girddi Nichloas J. T.Jenkins

Timthy R. Campbell William Haic& Raymond Miller
loseph A. Carares Herben C. Hak, Ir. PhilipT. Seahraok

This mpo msem infomunion on r@mowl and nwe o/ hnrdencd con- Chapter 2-Klnds of concrete and d -
crere. Cuidnnce/o, <I,T3sessmenIqfconcrere sm<cfunsfor complcir orpor- removal, p. 301
tiai dnnolition is pmvided The applicditit3 odvanrogcs. limitatim~.anrl 2.1-Introduction
snfery consideratians o/ vorious Iypes o f c o ~ r @nmovnl
u merhodr. includ- 2.2-Assessment of concrete structures for complete or
mg hzmi tmis, M - o p e m t e d power twls, vchicie-munred eguipmenr.
etpiosivr blasthg, drills and saws. nonupkwivr demiirion agemu,
partia! demolition
nvchanicnl splincrs. hearing Md t k m i mls, nnd hydmdemoiirion 2.3-Types and degrees of removal
(warrr-jet blasíingJ, ar@pmided 7% avnüobie surface removal sysum, 2.4-Types of concrete and effects on removal and reuse
theirpmboblc applicatiom, rmd Uivonroges ond duadvontages o/ ~ O n o u s 2.5-Monitoring and safety considerations
r y p c ~afswface nnioval systmtr ondiscwsed. Considemtimsforevoiuar-
ing andpmessing wasv Eoncntcforpmduction o/ nggngorrr sui&le for
mudes in crmcmtc n?nslrKCtW" onpnscntcd
Chapter 3-Removai methods, p. 305
3.1-lntroduction
Keywonb aggregates; concrete renwvai: caidioOn survcy; dcmolition; 3.2-Hand tools
diamond saw; dmp hammer; explasivt b W g : hantenal concrete; h y h - 3.3-Hand-operated p w e r tools
dunoliaoo, impact brealer; jet-flame c m r ; mechanical spitter; Mxture 3.4-Vehicle-mounted equipment
propation; nonexplosive demolitim agent; recycld aggregates: recycied 3.5-Explosive blasting
comzecc;rotatmg cuner he&, spring-ectionbreakm; t h e d lance: water- 3.f-Drills and saws
jet blasting; wrecking bdl.
3.7-Nonexplosive demolition agents
3.8-Mechanical splitters
CONTENTS
Chapter l-introduction, p. 301 3.9-Demolition of concrete structures by heat
l.I--<icope 3. l&Hydrodemolition (water-jet hlasting)
1.24bjective
Chapter 4-Surface removal, p. 310
4.1-lntroduction
ACI Comminee Reports, Guides, Standard Practices,
4.2-Purpose of surface removal
and Commentaries are intended for guidance in planning.
4.3-Systems available for surface removal
designing, executing, and inspecting construction. This
4.4-Definition of final surface
document is intended for the use of individuals who are
4.5-Requirements for surface preparation
competent to evaluate the significance and limitations of
4.6-Concrete pavement surface removal
its content and recommendations and who will accept re-
4.7-influence of surface conditions on bond properties
sponsibility for the application of the material it contains.
The American Concrete Institute disclaims any and al1re-
sponsibility for the stated principles. The Institute shall Chapter CProduction of concrete from recycled
concrete, p. 317
not be hable for any loss or damage arking therehm. 5.1-Introduction
Reference to this document shall not be made in con-
tract documents. If items found in this document are de-
sired by ibe ArcbitecüEngineerto be a pari of the contract
doniments, they shall be restated in mandatory language
for incorporation by the ArchitexUEngineer.
 ACI C O M M E REPüRT
5.2-Aggregate prcduction process
5.3-Aggregate quality
5.4-Effects of recycied aggregates on concrete m e s
5.5-Mixture proportioning
5.6-Concrete production
Chapter GReierences, p. 323
6.1-Referenced standards and reports
6 . 2 4 i t e d references
CHAPTER 1-INTRODUCTION
1.1-scopa
This repon provides available information on concrete re-
movai methods with detailed discussions on surface remov-
al. Reuse of removed concrete as concrete aggregate is also
addressed. The type and kind of concrete and its location
within a structure directly affect the removal methods to be
used. Selection of proper tools and equipment are cntical for
a cost-effective and safe concrete removal project.
1.2-Objective
Dnven by cost, need, and limited resources, the technolo-
gy for concrete removal and reuse is rapidiy aavancing. Par-
tial removal of cnticai structural components for repair
rather than replacement, geographicai constraints, access to
structures planned for removal, environmental regulations,
and worker and structure safety wiil continue to effect an
evolution of developing methcds and equipment.
With safety as a foremost consideration, thorougb plan-
ning is essential when engaged in a removal project. The
scope and type of concrete to be removed should be evaluat-
ed and examined in detail to determine the most advanta-
geous system(s). This report provides information on
selecting the most appropnate systems.
Concrete reuse is primariiy reiated to a project’s location.
For exampie. limited availabiiity of matenais in a particular
region may result in a cost-effective use of equipment and
manpower to remove nearby concrete structures with the
intent of reusing the removed materiais as a roadway base
or as coarse aggregate for concrete. This report is confmed
to the evaluation and processing of hardened concrete used
as concrete coarse aggregates.
Work continues in a number of countries to improve
equipment and methods, including the use of robotics. h-
ceedings from the RLEM Symposium heid in October 1993
in Odense. Denmark, and other W E M publications provide
additional information. These pubiications include: Demoii-
tion and Reuse of Concrete and Masonry (Kasai 1988).
Demolition and Reuse of Concrete and Masonry (Lauritzen
1993). “Disaster Planning, Structural Assessment, Demoli-
tion and Recycling” (De Pauw and iauntzen i993), “Recy-
cling of Demoiished Concrete and Masonry” (Hansen 1992).
and “Specification for Concrete With Recycled Aggregates”
(RILEM Technicai Committee 121 1993). The Strategic
Highway Researcb Program (SHRP) in the United States
studied problems that have an influence on the removal of
concrete for hridges (Vorster et al. 1992).
CHAPTER 2-KINDC OF CONCRETE AND
DEGREE OF REMOVAL
2.1-lntroductlon
This chapter addresses complete and partid removal from
different types of structures and assessment of structure con-
sidenng safety, stability. cost, consmctibility, and environ-
mental impact. The complete or partial removal of
presaessed, reinforced, and unreinforced concrete structures
should be assessed by a competent team experienced in al1
phases of the concrete removal operation.
One should identify sound concrete and examine what
effect the removal may have on remaining concrete and
reinforcement when partial removal is undertaken. Most
importantly, concrete removal or demoiition sbouid be
performed under appropnate supervision, regardless of
the project size.
2.2-Assessment of concrete structures for
complete or partial demolltlon
2.2.1 General considerations-Guidance on performing a
condition survey of concrete structnres is covered extensive-
ly in ACI 201.1R. Listed below are other general items to
consider before either partial or complete concrete removal.
If the decision to remove concrete is based on ewnomic or
reasons other than concrete detenoration, a detailed condi-
tion survey rnight not be necessay.
22.1.1 Safery-A predemolition survey shonld be per-
formed to determine if the pianned work could cause any
structure to coiiapse. Before to starting work, a survey of the
joh site should be made to determine the hazards and the
safeguards necesssry to ensure that work is performed safely.
Continually check for hazards due to weakening of the
structure.
2.212 Environmentnl impact-A work plan requiring the
removal of a smifture, either +y 01totally, shwld address
the impact on the sumunding environment. impacts on the
environment i n c l u k neighbonng tenants and smundmg
smctures: noise pollution; dust pohtion; water m f f s due to
work, s t o m , or bth;and oher enwOnmentai factors such as
asbestos and hazardous chemicals. An inventory of potential
environmental impacts shonld be deveioped and used as a
checklist during concrete removai operations.
2.2.13 Plansprovided ordrawnf o r a s s e s s m @ n t d -
tation-During the condition survey of ttie coocrete stnicture,
prepare drawings or sketches that reflect existing conditions.
These drawings or sketches become part of the condition sur-
vey report to provide preremoval documentation.
22.1.4 Compiete set of structural and architecturai
drawings-ln performing a condition survey of concrete
structures, the use of as-built strucmal and architeciural
drawings is shungly mnnnended fw work plan d e v d v e n t .
The drawings can be reviewed and evaluated for assessing
existing conditions, areaci of disúess or potential hazards, devel-
opment of work pians, and concrete removal operations. With
accurate and thomgh drawings, a work pian can be devdoped
safely and effectively, wbile minimizing environmental
impacts and costly errors. If original drawings are noi avail-
able or if modifications appear to have been made, spot de-
saudhro m p w m nray ncMt to be itone to asccrtaia
reinforcement location,size, and caidition.
221.5 Budgetary and iogistic constraints-Budgetary
and iogi6tic constraintr shwld te identi€ied and incorporated
into me wodr plan.
2.22 Evaiw'on of concrete
22.2.1 Fkki&w~entarioi, [visual ewninationbRefer
U, ACI 201.1R to develop a checklist for field documentation
of~stnicaue.ACI201.1Rprovidesinformationonexami-
nation of uniformiiy and raiing of distress manifestations.
%.23.2 Detailed eumtination
(i) Femgrup+lüe usefulaess of any pemgraphic
examinatim procedumon the objectives of the invesagation,
poposad or underivay, CM be determined by a discussion
witb m nrpaienced petmgrapber. ASTM C 457 can be used
to develop data that wiil explain why freezing-and-thawing-
related dmage has occurred. ASTM C 856 gives the follow-
forpetrograplúc
ing p u r p o ~ ~ exdmtion ofconctrte:
Determine, in detaü. the condihn of concrete in a
Smicain;
Deiermine infcnor quality, distress. 01 deterioration of
. mwte in a stnicture;
Determiae wbether dkaii-siiica or alkali-carbonate
nactioa, or cement-agpgate rosction, or reactions
b e w
te mcontaminan& and the mmix have iakm place,
and theh effects upon ihe concreie;
Petamtne whetñer mC wricrete lias been subjerted to
eaid atfLned by suif&e atiack. other cbemcal attack.
eariy firetzing, M to aber harmfui effects of freezing
. and mawiag; and
Dethmuie Whether concrete subjected to tire is essen-
t i d y undamaged 61modetmly or seriously damaged.
(iiJ Nondestructive testing (NDTFTbere ate numer-
ws &nd&ractive test methcds fBr estimating súength of
eimcmc. ~tfew of wbich am listed (LS follows:
a) SiaPaa har<hiess methods,
b) Pnretrsrioii resistanw techniques;
c)Pr>fIantes*r;and
d) Ultfawmic @se velociry method.
TbGre are aso other nondestructive test methods for
detenniaiPg pmpertíes other than strength a few are
listed as follows:
a) Magneae m*ho<ti-reinforcement cover and location:
b) Ei&d meibods-minforccment m s i o n , thick-
ncss of conmempavements, moisture content. and moisture
pekatim;
c) Radioltetive meibds-density, voids, composition, and
8cBre8rtioa: and
d) Uitra6onie pulse Vgiocis- and pulse echo iechniques-
to dcctwine aaflrs naü voids in mass concrete.
r adtüiionai lestmciimds and their appticaticm and Limita-
h premature collapse or failure of any portion of the shucture.
tions,nfertoACI228.1R&ACISP-82 (Maihoh9 1984).
2223 Cause ofdisrrpss-In deveioping removal pme-
&mes, COnaMer die cause of disass on thc removal process
%ait *y &ffectthe stnicture's integrity.
W Reuse of concrete Nbbk-Refer to Chapter 5.
ad3s T m m p m and drposit of waste material-Very
We of &e appximately 135 miliion ton8 (123 mllion
tomes) of removed concrete rubble in European communi-
ties, United States, and Japan is reused. Due to the declining
availabitity of disposal sites, recycling alternatives should be
evaluated as quality aggregate sources.
2.2.3 Reporr
2.2.3.1 Summary of scope of work-Define purpose and
limitations of preiiminary investigation and findings, con-
crete removal work plan, safety, schedule requirements,
environmental aspects, or recycling plan.
2.2.3.2 Findings-Describe the structure, its present
condition, nature of loading and detrimental elements. origi-
nal wndition of the structure, materials used in construction.
and practices used in constructing the structure. Photographs
should be used to illustrate the conditions.
2.2.3.3 Rccommendarions-Include complete or partial
dernolition. salvage, removal methods, safety and environ-
mental considerations, and further investigation or testing as
required.
2.2.3.4 Tord esrimured cosr-Provide cost estimates for
various removal methods. panial or complete concrete re-
moval, reuse, transponation and waste disposal. and addi-
tional inspection and testing. Other associated C O S ~ Sshould
be identified and estimated where practical, including pro-
tection of adjacent construction.
2.2.35 Phuros and drawings-Use of drawings illustrat-
ing as-built. cwent conditions and areas of concern (for ex-
ample, concrete quality, distress, loading, and utilities) is
required to demonstrate the need for concrete removal, the
logic for the method, and amount of removal recommended.
photographs can illustrate distress manifestations and provide
documentation of existing conditions. Where possible. in-
clude some means for identifying scaie, such as inciuding a
ruler or other recognized object like a pencil or coin.
2.2.3.6 Supporting data in comprehcnsive form-To
support findings and recommendations. the data developed
through visuai examination, conng, nondeshuctive testing,
pemgraphy. phoiographs. drawings, and sketches should be
arranged in a comprehensive format that can readily be fol-
lowed. For example, plans could be labeled with symbols
identifying where samples or photos were taken, with each
sample or photo containing a bnef but concise descnption. It
is essential that the extent of damage be established. regard-
less of the cause. Whether concrete quality of the remaining
structure is sufiicient to support a sound repair should be de-
termined.
2.2.4 Engineering survey-Before starting any demolition
operations, an engineenng survey of the structure conducted
by a competent individual is required. The purpose of the
survey is to determine the condition of the structure so that
precautionary measures can be taken, if necessary. to prevent
2.2.5 Health and safefy safeguards-A number of steps
should he taken to safeguard the health and safety of workers
at the job site. These preparatory operations involve the
overall planning of the demolition job, including the meth-
ods used to demolish the structure, the necessary equipment.
and the measures to perform the work safely. Planning for
demolition is as imponant as actuaily doing the work.
 ACI COMMREE REWRT
2.3-Types and degrees of removal
23.1 Purpose of removal
23.1.1 Murerial condifions-Concrete removal from a
structure may he required due to structure distress where the
integnty of the concrete has detenorated, or where upgrad-
ing or modification of a structure where sound concrete
needs to he removed for an addition. In some instances
where concrete removal is necessary due to distress, sound
concrete may need to be removed for anchoring purposes.
2.3.1.2 Complete demulition (one-piece, multiple-piece,
rubble. crushed)-Several methods and various types of
equipment can he used in concrete removal. Depending on
the size, complexity, availahle equipment, and safety aspecb,
concrete elements can be removed as single or muitiple pieces
for disposal. or crushed and reduced to ruhble for general
disposal or recycling.
2.3.1.3 Purria1 removul-In partial demolition of con-
crete structures, saivaging or utilizing thr remaining, intact
structure should be properly evaiuated.
Replacc what is removed-a ponion of a structure
should be removed and replaced in kind with pmper
adjustments to the added element to prevent any previ-
ous distress.
Do not replace what is removed-a section of a con-
crete element is removed and is not cntical to the over-
al1 integrity of the remaining structure. An example
would be removal of architectural or redundant ele-
ments that are not essential to the structural integrity.
Create opening or void-partial demolition may be
requued to pmvide temporary or permanent access for
equipment. ñxtures, framing, or other purposes. The
structure is thoroughly evaiuated to determine whether
partial demolition can be perfonned with or without
temporary or permanent extemal supporls.
With diminishing numbers of disposal sites, waste man-
agement has hecome widespread. In the development of a
work plan for concrete removal, the recycling of the concrete
waste-for example, reinforcing steel, aggregates, and con-
crete-will need to be evalualed for practicality and eco-
nomics. Creative reuse of concrete can be challenging and
rewarding. Refer to Chapter 5 of this report for reuse of hard-
ened concrete in the production of ready-mix concrete.
2.3.2 Degrees of removal
Complete demolition
Partiai demolition may he performed to correct an align-
ment defect or other deficiency in new consüuction or
remove detenorated concrete in an existing structure.
i. Layer (overlay. cover. f i n i s h t a partial demolition
layer usually involves removal to a certain depth great-
er than 1/2 in. (13 mm)
( 1 ) Physically defined limit (different mixtures, hani-
er, ma!erial integnty)
(2) Arbitrary limit (specitic depth)
ii. Surface-a surface demolition usually is a surface
removal of less than 112 in. (13 mm)
( 1 ) Binder and fines only
(2) Al1 constituents
* Piece of section
i. Entire element
ii. Portion of element
(1) Physically defined limit (joint, different mixhires,
banier, material integrity)
(2) Arbitrary h i t (specified size)
(3) Reinforcement
2.4-T@~s of concrete and dfects on removal
and reuse
24.1 Cenerul-Concrete süuctures can be classifíed gen-
erally into four groups: mass concrete siruchires; under-
gmund structures; reinforced concrete struchlIzis; and
presuessedpst-tensioned shuchues. With the nwnerous
demolition techniques available, such as crushing, chopping,
splitting, blasting. cutting/drilling, laser, electric heating,
and micmwaving, selecting the appropnate method is impor-
tant. When selecting a removai method the foüowing consid-
-
erations should be evaluaied:
*
Safety;
Finance:
Timelimits;
Quaiity of concrete and geometry of the demolished
object;
Quantities, location, and a breaking boundary;
* Aggregate hardness;
Concrete compressive strength;
- Envimment;
Specificrisks;
Utility locations; and
Adjoining construction.
2.4.2 Mass concreie stmtures-Mass concrete stntctures
include hydraulic structum, dams,large mat foundadons,
bridge piers, ihick walls, and reacm foundations. TyPieai
concrete removal methcds rrsed are explosive blasting. dia-
mond wire sawing, presplitting using nonexplosive dsmti-
tion agents and mechanical splitiers, vehicle-muunted
impact hammering and rotaq head cutlhg. stitch cutting,
and ddling. Methcds less used but avaüable include icmo<e-
controlled themal lance cutting, abrasive water-jet blasting,
elecmcal heating of steel reinforcement, and mimwave
heating of cover concrete.
2.43 Underground structures-Removal of un d-
s more difñculf requiring the need for honZmial
s ü u c ~ r e is
support and individuals expenenced in both planning and
supervising the removal. Underground shuctures may be
removed using hydraulic hreakers. large lmnmers, bkasting.
crushing augers. diamond wire saws, and chemical splitting.
2.4.4 Reinforced concrete strucmres-Most of the meth-
ods discussed in Chapter 3 are applicable to reinforced con-
crete structures depending on the iype, si=. use,and degree
of removal.
2.4.5 Prestressed/post-teni~ed s t r u c t u r e s - ~ ~
post-tensioned concrete structural elements may be remavsd
using thennai lance, hydraulic breaker, drop hall, aod jack-
hammer. Particular care should be taken in dennolition as th
stored energy in the tendons can, ifreleased suddenly,
structural coüapse or whiplash of tensiom on anchorage
components (Occupational Safeiy and Healtb Administra-
 REMOVAL *ND REUSE @ HARWNED CONCRETE
tion 1991bJ.Nev~allcwwuhastobcnearancho~esdur-
ing m y fom dnmaval other than mIrolied detensioning.
Tpic OSHA ‘scchnical M d (Occupational Safety and
Heaith Adminktration 1991b) identiñes four main catego-
ries of prestressed members. Tne category, or categones,
should be identified before aitempiing any demolition, bear-
ing in mind that any presuessed süucme may contain ele-
ments of more than oae category.
w - M e m b e r s presuessed before the applica-
tion of tbe superimposed loads and having a i l tendons
- fuiiy bonded to the concrete or p u t e d within ducts.
--As Category 1. but with the tendons left
ungmuted. This type of consüuction can someúmes be
ncognized from the access poinis that may have been
provided for inspection of the cables and anchors.
Unbnded tendons have been used in the consüucuon
of beams, siabs, and other members.These tendons are
pmtected by grease and may be surrounded by plastic
sheathing instead of the usual metal duct.
f&gay2-Members that are prestressed progressively
as the building consmction pmceeds and the dead load
increases, usuip bonded teodons,as category 1.
Categoiy 3, but using unbonded ten-
&ns as Category 2.
Examples of construction using members of Categories 3
and 4 may be found for exampie, in the podium of a tal1
building or wme types of bndges. Tbey require that particu-
lar c8n be taken in demolition (Occupational Safety and
Heaith Administration 1991b).
2461 Pretensioned meder-SimpIe pmensioned
buMs aadslabs ofspanr up toabout 23 ft (7 m) have been dc-
moiiskd in a similar to otduraiy reiníorced comete.
pnteasioaadbeamsandslabsmaybe~ftsdandlowerrdiothe
gmund as M e l e units after í h removal of MYcomposite
coomie covering from tops and ends of the units. if units are
toolorgetoberemovcdinonesectionapplanthatmayinvolve
teqeeuy wippst shouid be developed by a profesional en-
gimm experiencad in presuessed concrete removal.
MS3 Sepurately siressed precast units-If possible,
units of this type should be l o w d to the ground before
brealong up, if possible. Requirements dictated by an expe-
riead engima shouM be adhered io closeiy. especially
whcntbcrtsnaagrwttdte~.
2.453 Mondirlric SmcChcres-A professional engineer
experiend in presaossed concrete construction should be
consuited báae aay aüempt is made to expose the tendons
or anchoragcs cf súuctures whem two or more members
have bcen messed to@her. Temporary supports are usually
requindso the iendons and the anchorage can be cautiously
eñposed in these circumstaaces, it is essentiai that indis-
. .
CnrmDate attempts to expose and destress the tendons and
anchoragcs are not made.
2.45.4 Progressively presnessed srrucrures-The
8dVice of a professional engineer is required for removal
of prognssively prestressed süuctures. ”he engineer’s
Iccdmmended remval methnds should be saictly adheed
to. The stored energy in this type of süuciure is large.
2.5-Monitorlng and safety considerations
25.1 Methods ?o monitor the demolition-Because each
method of removal is ddferent, a separate analysis should be
pmpared for each method. Outlined as follows is a general
@dehe to assist in developing a safcty program. Eacb job
wiU need to be evaluated individually and coordinated with
affecied governmental agencies. The following provisions
m not all-inclusive.
2.5.1.1 Planning for construction-Each operation and
stage of a project should be planned in advance, beginning
before the preparation of bids and then throughout the
p j e c t . Superintendents and foremen should participate in
this planning process. Thorough planning will provide a
weii-organized job, eliminating the potential for some acci-
dents. Tne following items should be. considered during
plannhg.
Location of utilities and services:
a. Review locations of al1 utilities. Whenever opera-
tions are required to be within the minimum distances
of power lines estahlisbed in the OSHA regulation (Oc-
cupational Safety and Health Administration 1991a).
arrangements should be made to have the line moved
or de-energized. erect haniers. or set up special work-
ing procedures. Except on private easements, the ap-
propriate regional notification center should be
coniacted to determine the location of subsurface utili-
ty installations in the area before excavation; and
h. Locate equipment, tool sheds, and office in a safe
and convenient place.
Employee access problems should be resolved by the
individual in charge at rhe project:
a. Adequate work areas;
b. Adequate walkways and runways;
c. Adequate ladders, stairway. or elevators;
d. Work areas and passageways clear of rubbish, de-
bris, a i ~nails;
I
e. Protection of flm and roof openings; and
- f. Adequate iilumination.
Schedule work for safety:
a. Have safety equipment (hard hats, goggles, ear
plugs, mnch jacks, safety belts, and respiratory pro-
tection) on site when needed:
b. Plan work so that there are not too many trades in a
small area at the same time; and
c. Schedule work crews so the flow of equipment and
manpower does not create a safety hazard.
work procedure:
a. Material handling-
1) Plan for methods of elevating, lowering. and han-
dling materials (adequate space, proper auxiliary
equipment, such as cranes, hoists, elevators, and
üucks); and
2) Plan for methcds of loading and unloadmg (ade-
quate space, proper auxiliaiy equipment, such as
loaders, cranes. ngging, and forklifts).
h. Plan for the use of tools and equipment-
1) Repair, maintenance. and care;
2) Inspection; and
 3) Adequate supplies of the nght tmls for each pmof
the job.
2.5.1.2 Generuí sufety precautions-The follOWhlg are
general safetv precautions:
Every rlaionable effon should be taken to ensure the
safety of workers in al1 situatim, w h e t k or not pm-
vided for in a company’s niles and safety program;
No worker should be required or knowiBgly pennittcd
to work in an unsafe place, uniess for ihe purpose of
making it safe, and then only after proper precautiom
have been taken to protect the worker doing such W a k
Before the start of work, the supervisor or safety
officer, or both, should survey site conditions for rkks
or hazards and determine safeguards necessaiy to
accomplish the work in a safe manner;
A training program should be designed and impie-
mented dunng the project that wiU insiruct workers in
general safe work practices as well as methods to avoid
the unique hazards of the workers’ specific job assign-
ments;
Periodic inspections should be conducted during the
project to identify unsafe conditions and work prac-
tices. Those unsafe conditions and work practices
should be corrected immediately; and
Al1 required safety and health notices should be posted
at the joh site, as required, 01 be othenvise available ai
the site.
25.13 Sqfery progrum objecrives-The following are
safety program objectives:
* To provide a safety and health program consistent With
gocd consttuction demoütion practices;
To prevent aecidents, injuries, and illnesses;
To create an attitude of safety consciousness among
- general management, field supervision, and al1 crafís;
To assign specific responsibilities for effective imple-
mentation and continuation of the safety program; and
* To provide continued development of safety and health
education, training and testing.
2.5.1.4 Sufety program implementation-The follow¡ng
can h e - .
b imnlement _-
. m~ram:
a safew
Planning for safety in the concrete removal operation
through job hazard andysis. Draw upon available or
hired experience and expertise to anticipate and elimi-
nate accident-prone conditions;
Providing mechanical and physical safeguards to the
maximum extent posible;
Conducting a program of routine safety and health
inspections to identi& and correct unsafe worlring con-
ditions or practices, control health hazards, and comply
fully with the safety and health standards for every job;
Training al1 individuals in proper safety and health
practices;
h v i d i n g necessary pemnal pmtective quipment and
insbuctions for its proper use and care;
Providing a means for employees to inform their
supervison of hazards at the work site;
investigating, promptiy and thoroughly, every accident
to determine the cause and correct the problem to pre-
vent its recurrente; and
Roviding k t - a i d msterials and trained k t - a i d per-
sonnel on job sites.
23.15 safety program requiremenf-The following
.
are reuuirements for a safew_m -
. m:
Deveiop and impiement a d e t y progmm with mies
and assigned responsibitities;
Make these niles and poücies known to al1 employees
and subcontractors;
Appoint a safety coordinator;
Establish a safety irailiing prngnim to engun h t
employees are trained in basic hazards of the job &te
and specific hazards unique to each empbym’s job
assignment;
h v i d e superintendenta with appmPnate safe.ty r u k s
and regulations from government agencies;
Discipline employees who willfully disregard this
program; and
Reward employees for good safety performance.
CHAPTER M E M O V A L METHODS
3.1-intmduction
Dunng the 1950s and 1960s. the contractor g e n e d y w8s
limited to hand-held breakers and jackhammers oprrated by
compressed air, core drüis, walk-behind diamond saws,
wrecking balls, small hydraulic hammers, and conmctor-
built dmp hanuners for h a k i n g up concrete. A few Specid-
ty demolition contractors removed whole s m f u T e s .
Today, this has all changed. Esuipment and methods de-
veloped in one countxy are soon marketcd worldwide andad-
vertised in the various irade magazines. Trade associations
provide a gwd source of f m s performing a particular type
of work, and contractors keep extensive lists of subcontrac-
tors that do work in particular cities. Equipment dealers,
demolition contractors, concrete sawhg and drüiing con-
tractors, and a wide range of construction magazioes are
helpful to stay abreast of equipment that is available for con-
crete removal. Due to the high cost, operator training, and
skilled supervision required, many items of equipment and
methods wiii be provided by specialty contractors (Peurifoy
and iedbetier 1985)
This chapter provides general descnption and summaty
infmation 011 concmc removal sysiems and mehds. The
advantages and limitations of various concrete m o v a l
methods can be found in ACI 546R.
3.2-Hand tools
A number of hand tools used in stwe and niasonry Work
for many years are g w d for removing concrete in s d l
amounts. Pry bars, bush hammers, sledgebammers, drals,
points and various chisels are just a few of these t&. lb-
shaping and hardening of the bits is needed.
3.3-tiandaperated power tools
33.1 Hand-held pneumatic twls-Hand-held pntumSoc
tools are avdable Ui a wide range of sizes (pavemmt break-
ers and jackhammers being the most crommon.) These lypes
of tmls have been in use for aimost 100 years and are Of Ng-

Fig. 3.1-Dmp blade (highway pavement demolition).
ged consüuction. Compressed air is usually available on
most consüuction sites. Lighter chipping hammers are also
available. It is necessary to ensure an adequate supply of air
pressure and volume as well as provisions for moisture col-
lection and lubncation (Manning 1991).
33.2 Hand-held hydraulic twlsHydraulic power is pro-
vided by small, lightweight power packs that can also oper-
ate a number of other tools. The Hydraulic Tool
Manufacturer's Association (HTMA) classifies hydraulic
tools as Qpe 1. E, or III with minimumflow rates of 5.8, and
12 gpm (19.30, and 45 lpm), respectively. A wide range of
tools is available. including smali impact hammers, drills,
saws, and grinders for use in concrete removal.
33.3 Hand-held electricd fa&-Hand-held elecnical
tools are the smaliest type of hand-held power tools avail-
ahle, have lowerenergy output. and are usually limited to use
in confined areas.
33d Gasoline-powered tools-Gasoline-powered tools
are ideai for smaii drüiing and breakingjobs in hard-to-reach
locations. These tools are available in two models. one for
drillingand percussion, the other with percussion oniy. Both
twls weigh less ihan 60 Ib (27 kg) with a number of dril1
steels and other tool bits available.
3.35 Drop hammers/b[ades-Dmp hammershlades are
used to demoiish concrete highway pavements, parking lots,
and other slabs on grade (Fig. 3.1). Weight and drop height
are balanced to thickness and strength of concrete and degree
of hnakage requued. Several firms manufacture s d thret-
wheeled hydraulic powered, seif-contained drop hammer
concrete breakers ihat are operated by one person. They are
available in several sks. These units are faster than hand-
operated pavement bnakers and are available with several
enghe options andan assortment of twl bits. They are faster
than a jackhammer or 90lh (41 kg) pavement breaker. They
produce ves, little dust. They oniy require one operator and
the units are self-propelled and easily portable. The units are
ideal for removing small areas of slab on grade up to 12 in.
(300mm) ihick. Depending on the model, units are available
with a breaking force up to 38M) ft-lb (5150 N-m).
Fig. 3.2-Vehicle-mounfed impact breaker (bridge deck
demalition).
3.4-V&lckbmoUnted equlplnent
Demolition attaehments of a wide range of sizes and types
are available to mount on small backhws, skid loaders, and
equipment requiriag caniers of over 2M).OOO Ib (9O.OOO kg)
in weight. A wrecking ball requires a m e boom. Other
demolition attaehments need to have a carrier equippd as a
backhoe or excavator.
The vehiclcs can be rubber tired or mwler mounted. The
unit shouid have suffcient hydraulic capacity to o p a t e hoth
the boom and ihe atiachment. Small units have been raised
with iarge cranes to upper ievels of buildings. Where used on
elevated slabs, care n e d s to be taken not to overload the siah
orto remove süuchual supports holdmg up the slab support-
ing ihe equipment during demolition.
3.4.1 Hydraulidpneumaric impacr breakersniammers-
Hydrauiidpneumatic impact breakershammers Pig. 3.2)
are cOmmOn pieces of equipment available fmm many man-
ufacturers. Several manufaclurers market several different
sizes with impact energy classes from 125 fi-lb (169 J) to
over 20,000 fi-lb (27,000 J).
"he hammer selected W u i d be matched to the carriez it
wüi be mounted on, and the frequency or impact rate, hy-
draulic pressure, wdring weight, and d e s i details need to
be considcred when selecting a hammer. Some specifica-
tiom h i t the impact energy w b n only partial removal of
an existing structure is requircd. Advantages of the impact
hammersarethewide nuigeofsizes acd the &y avaihbility.
These units have esseatially r e p W the wrecking baü.
Pneumtic breakers are avaüable in fewer sizes and by
fewer manuíacturers. "he h a k e r s , powered by compressed
air, can be used whm the carrier does not have sufficient
hydrauiic capability. Both pneumatic and hydraulic
breakers can be used for undenvater work.
3.4.2 Spring-acíion hnnvners-Spring-action hammers
(sometimes referred to as mechanical sledgebammers) are
boom-mouoadmols that are appiicable for breakllig concrete
pavemenis, decks,w a ü ~and , oihe~thin membe.ss."he ann of
tbe hamma is hydrauticauy powered ami the impact head is
spring-powered. niC SpMg is compressed by the downward
mowment of the ann of the backboe 01excavator, and its en-
agy is released just prior to impact. There are üuck units
 ACI COMMlTl.EE REPORl
Fig. 3.4-Twin-drum mfary cufter head.
available that make it easier to move between projects. The
operation of the hammerand advancement of the üuckduring
removal are contmlled from a cab at the rear of üuck. Spring-
action hammers (Fig. 3.3) are available in severai sizes with
blow energies np to 300,000ft.-lb. (400 kJ) (Manning 1991).
This equipment is much faster than the impact hammers
where the thickness of the concrete pavement permits its use.
When the equipment is üuck-mounted on rubber tires, it can
be easily moved from job site to job site.
3.4.3 Wrecking ball and crane-The wrecking hail is at-
tached to a crane and is either dropped or swung into the con-
crete. The weight of the bali can vary depending on the crane
capacity. This method requires a highiy sküled operator for
safe operation. The recommendations for wrecking bali ver-
sus crane capacity. safety factors, breaking strength of sup
porting iive load, and other safety considerations w1 be
found in the Nationai Cooperative Highway Research Ro-
gram Synthesis of Highway Practice 169 (Manning 1991).
3.4.4 Rorufing currer heuds-Rotatuig cutter head attach-
ments provide continuous cutting by the rotation of the cutter
drum(s) with sizes that fit v d o u s hydraulic excavators and
skid ioaders. Two styles of cutter heads are avaiiable for ex-
cavators: (1 ) transverse. twin drums (Fig. 3.4); and (2) in-he,
Fin. 3.5Single-dmm m t a v cuner head (planer).
single drum.The drum for the in-he cutter head rotates
around the axis of the boom and works similar to a large driii.
The drums are available with flat or rotating conical bits.
Skid loaders are used to remove mcrete hom top faces of
decks, slabs, and lock w&, whereas excavators are typicaüy
used to remove concrete fmm vertical andoverhead faces. Slsd
loaders use a single uansverse drum aaachmnt (Fig. 3.5).
3.4.5 Concrere cnrshers-Coucrete crushers, in a number
of sizes and cutting jaw configurations, are ideal for remov-
ing curbs, parapets, slabs, and beam and wall sections, and
for crushing large pieces of concrete removed by other meth-
ods. Models are available with one hydraulic cylinder, others
with two cylinders, and a wide range of sizes, from smaü
units with only a few tons. to large ones with 2500 toas
(22,000 kN) of crushing pwer.
3.4.6 Ripper-The npper is a large blade aitached to a
backhoe used to break up slabs-on-grade and to separate the
reinforcing steel from the concrete. Ripper blades have also
been mounted on large crawler tractors to remove reinforc-
ing steel after the concrete is broken up by other methcds.
The ripper is ideal for removing large areas of slab-on-grade
and concrete pavement.
3.4.7 Resorranffrequency breaker-Tbe resonant frquen-
cy breaker frachires or breaks concrete highway pavement
using a self-propelled, four-wbeel rubber-tired power unit
that uses resonant beam technology to apply energy througb
a bigh-frequency resonant impact breaker to the concrete
pavement (Fig. 3.6). The unit has been used successfully on
interstate highway work with nomial breaking rates averag-
ing 10,000 yd*/day (8400 m*/day).
3.CE~cplosiveblasting
Explosive hlasting has been successfully used forremoval
of large volumes of distressed and deteriorated concrete by
the Corps of Engineers on a number of locks and dams
(Fig. 3.7). Blasting has been used for compiete buüdmg
demolition and for undewater demolition (iba¡ 1988).
Concrete is a difficult material to blast becauseof &e va&
ation in strength and amount of reioforcing s t d preseat
(Hemphill 1981). Safety regulations, envKonmental consid-

Fig. 3.6Resonant frequency breaker (highway pavemenr
demolition).
erations, and the need tn monitor for ground vibrations limit
appiicable locations for rhis meihod. Controlled blasting
techniques have been developed to minimize damage. The
1988 RlLEM Symposinm included 13 papen on blasting
and related meibods (Kasai 1988).
An explosive blasting tecbnique referred to as min-blast-
ing (Lauritzen and Petmen 1991) has been used for partial
demolition of concrete sauctural members. The technique
requires a licensed worker and conuolled blasting tech-
niques to maintain safety and minimize damage to the con-
crete ihat remains and the smunding envuonment.
Blasting mats are used to minimize flyrock, and textile fiber
rnats are used to lower dust and noise levels.
3.8-Diills and saws
Drius and saws using hard cuiting diamond tools provide
smooth hoíes or surf&es. These twls have minimal vibra-
tion and, when water-cooled, muiimize dust. Hard aggre-
gates or high concenílations of reinforcing steel can greatly
reduce the cutiing speed and iife of dril1 bit or saw.
3.6.1 Core drills-consmction grade core drills generally
are available in s b h m lrss thao 1in. (25 mm) up to 24in.
(600mmj diameter.Tbe drüls can be powered by elecuicity,
compressed air, or hydrauiic power packs. Heavier units are
usuaily powered with gasoline or diasel engines or com-
pressed air and are truck- or skid-mounted. Compressed ak
or nitrogen have also been used to cool ihe bit where tbe use
of water is a problem.
3.63 Diamond saws-”be m s t common type of saw
Made for cutting concrete is the wet-cutting diamond blade.
hycutíing d i m n d biades and abrasve blades ate also a v d -
able. Thae are a number of blade manufachirers with some
rsodufios several diffmnt quality levels. nie composition of
ihe bond, iype. size, and conceniration of diamouds varies.
For cuiting slabs and pavements, there are hand-held. walk-
behind, and nding saws. Track-mounted saws are available
for cuts in waüs and the underside of slabs.
Fig. 3.7-fiplosive blu.sring (removal qf lock chamberface).
3.6.2.1 Hand-held diurnond suws-Hand-held diamond
saws generally are available with 10, 12, or 14 in. (250,300.
or 350 mm) diameter blades and powered by electricity. gas-
oline engines, compressed air, or hydrauiic power packs.
These are lightweight units designed for intermittent sawing.
Special hand-held saws are now available ihat use a chain
saw cutting bar that can minimize overcutting at comers
whiie providing cuts up to 15 in. (380 mmj deep. Another
manufacturer has hand-held hydraulic saws that use nng-
shaped blades that can make a 10 in. (250 mm) deep cut with
a 14 in. (350 mmj diameter blade.
3.6.2.2 Walk-behind diamond saws-Waik-bebind dia-
mond saws are the most commonly used power saws. Tbere
are two types: a light duty saw for smail jobs, and heavier
models with up to 65 hp (48 kWj engines. For use in con-
fined areas, some models have blades that can be mounted on
either the nght or lefi side.
3.6.2.3 Rideuble puvemenr saws-Rideable pavement
saws provide high productivity with blades up to 30 in.
(760 mmj in diameter.
3.6.2.4 Wall suws-Wall saws (Fig. 3.8) make accurate
cuts in walls by nding on a track bolted to the concrete.
Means are also provided to maintain pressure of the blade on
the surface being cut. Blades sizes used are in the same range
as floor saws. The saws are powered by a remote source us-
ing either compressed air, hydraulics. oran elecuical system
(Lazenby and Pbillips 1978).
3.63.5 Diamond wire suws-A diamond wire saw is a
continuous loop of multisüand wire cable suung with steel
beads bonded with diamond abrasive that is pulled through tbe
concrete (McGovem 1992). The beads are separated with
springs or spacers. Direction of the cable is changed with idler
puileys (Fig. 3.9). The power unit drives and provides tension-
ing of the cable. Use of tbis method has increased as more spe-
cialty coniractors doing this work have become available. This
method is ideal for mass concrete and other sections tcm thick
for diamond-tipped circular saws and where noise or vihration
may be a problem (as in hospitals).
Pilot holes are dnlled ibrough the concrete with the wire
cable passed through and coupled to form the continuous
loop. Dnve units can be either hydraulically or electrically
powered. When the limit of movement of tbe dnve unit is

Fig. 3.8-Wall saw (tapering of comer at nwmlith joint)
Fig. 3,GDiamond wire cuning (idie wheel redirecting
wire).
Fig. 3.IOStitch-dnlled cut (dam overflow sectian).
reached, the unit can be moved or the wire cable shortened.
Water is used for the cooling and removal of cuttings. Sev-
eral articles have been published on diamond wire saws
(Franklin and Dusseault 1991; Hulick and Beclmiaa 1989;
and Manning 1991). The size of the concrete blockremoved
is only limited by the clearances required and the capaciíy of
available Iifting equipment.
&
Fig. 3.Il-Result.sfrOm use of nonexplosive agent ( b c k wall).
3.6.2.6 Stitch drillingStitch drilling is a technique used
to produce cuts in concrete by overlapping drilled boles
(Fig. 3.10). Stitch drilling may be used wbere depth of cut
required is greater than can be cut with a diamond saw
(Lazenby and Phillips 1978). The depth of cut is iimited
by the drilling equipment's accuracy in maintaining overlap
between adjacent holes.
3.7-Nonexplosive demolltion agents
Nonexplosive demolition agents (NFDA) were developed
in Japan and fust marketed about 1979. A pmprietaxy mixture
consisting primarily of calcium oxide and calcium silicate is
mixed with water, poured into predrilied holes, and after a pe-
ricd of time, the mixture expands and ex- an expansion
force sufficient to crack the concrete (Suprenant 1991). The
results of the use of NEDA are shown in Fig. 3.11.
Careful planning of the demolition work, including hole
size, spacing and pattern, amount of water used, temperature.
mixing of materials, loading of holes, curing, and safety pro-
visions need to be addressed. The drilled holes are usually
1 - 112 to 2 in. (38 to 50 mm) in diameter with a spacing of
16 to 24 in. (400to 600 mm) for plain concrete,and 8 to 16 in.
(200 to 400 mm) for reinforced concrete. While excellent
results have been obtained, the agent must be used in sound
concrete to achieve the desired crack pmpagation. Other
equipment is required for complete removal of the concrete
material. Safety considerations include caution during mixing
and placing and danger from posible blowout of agent from
the hole. Danger of blowout increases wiih larger-diamewr
holes.
Once placed in the holes, the mixture must be protected
from running water. Plastic sleeves have been used where
water is in the hole. The material must be allowed to c m
similar to concrete otherwise tbe breaking force may not
develop for 24 or more hours. The material continues to
be improved and a number of types are now availabte for
different temperature conditions and reaction times.
Eight papers discuss NEDA were preknted at tbe 2nd
RILEM Conference (Kasai 1988). Most of these dealt with
spliming mechanism of the concrete under expansive pnessure,
others with chemical composition, properties,and applidons.
Fig. 3.IZ-Plug andfeather mechanical splitte,:
3.8-Mechanical spiltters
Mechanical or hydranlic splitters are placed in predrilled
holes, with the splitting action developed by a steel plug or
wedge positioned between two hardened steel shims or
feathers (Fig. 3.12). Placed in the retracted position, hydrau-
lic pressure applied to the piston plug advances it, and the
feathem are forced against ihe sides of the hole, producing
the splining d o n with a f o m of up to 700,000 Ib (3 100 kN).
depending on the size of the unit. One manufacturerhas several
models with mnunended predrilled hole diameters from 1 -
3/16 to 1-3/4 in. (31 to 45 mm) with spacing of holes from
12 to 36 in. (300 to 900 mm) (Manning 1991: Kasai 1988).
One splitter manufactured in Gemany that can be reinserted
into holes (Fig. 3.13) was used to remove concrete from
chamber faces at Dashields Lock (Meley 1989).This unit re-
quires 3-1l2-h. diameter (90mm) holes.
This method is adaptahle to a wide range of job conditions.
An open face or space is needed on at least one side to allow
for mvement of the bmken concrete. Two free surfaces
would be more eficient. When the splitter is used to cut an
opening in a wall or slab, a starter hole provided by a core dnll
or other means is needed. The holes drilled for the splitters
must be straight and of a specified diameter (Suprenant 1991).
J.%Demolltion of concrete structures by heat
Several papers on jet-time cutter method, thermal cutting,
and experimentation by applying electrical current through
reinfming steel, laser beam, and use of minowave energy
were presented ai FULEM 1988 Symposium (Kasai 1988).
3.9.1 Jet-jiame cutter method-The jet-flame cutter meth-
od consists of a cuning unit for generating a superionic
flame, a coniroller to control rate and pressure of oxygen, ker-
osene, and cwling waters to the cutter. A dnve unit holds and
m v e s the unit. This method has also been used undenvater.
3.92 Thermal lance-Thermal lances have been used for
a number of y m to cut mass concrete. The lance consists of
a pipe filled with imn wire through which oxygen is passed.
Once ignited, the pipe, wire, and oxygen are consumed, pro-
ducing a high t e m p h u e . Various matenals have been used
in the pipe to produce a wide range of temperatures. Due to
safety considerations. this method has had limited use in
general Concrete constiuction but has found use in beavy in-
dustrial facilities and nuclear facilities (Manning 1991; La-
zenby and Phillips 1978; Kasai 1988).
3.9.3 Electrical heating uf reinforcing steel-The method
of electrical heating of reinforcing steel is used to debond the
Fig. 3.13- Piston-jack mechanical spline,:
concrete from around the reinforcemeot. Cracks develop in
the concrete cover that facilitate its removal. The method
uses aitemating current.
3.1ü-Hydrodemolitlon (water-jet biastlng)
Hydrodemolition (also called water-jet hlasting) is typi-
cally used where the preservation of the reinforcing steel is
desired for reuse in the replacement concrete sucb as in the
rehabilitation of hndge and parking garage decks (see also
seaion 4.3.3) (Fig. 3.14). Hand-held water-jet guns have
been used to cut concrete. This method is vibration free and
avoids danger associated with tire with the tiame cutting
methods. Reinforcing han are not cut or damaged (Manning
1991; Kasai 1988).
Water-jetsystems have been used with abrasives to cut re-
hforcing steel in Japan. Three demolition projects are pre-
sented in Kasai’s (1988) report where abrasive water-jet
cutting was used.
CHAPTER 4-SURFACE REMOVAL
4.l-lntrodU~UOn
Snrface removal of concrete i s common for new and old
construction. Typically, it is required to correct an alignment
defect or prepare the surface for a subsequent treatment.
Work may be on a small and crude scale with hand tools, or
a large scale with motor driven equipment and automatic
sensors.
The technology of removal has advanced substantially in
recent decades. The advancements have been driven by a de-
sire to reduce unit labor costs, to improve both worker com-
fort and safety. and to reduce environmental contamination.
This chapter presents a descnption of the available sys-
tems, their probable application. and advantages and disad-
vantages of various types of removal. Some of the systems
are propnetary or developmental. Therefore. only limited
data are available.

Fig. 3.14-Reinforcing sieel exposed hy hydmdemolition
mefhud.
Concrete surface removal can apply to horizontal, vertical,
and overhead surfaces. Some systems, however. wüI only be
suitable for one mode, typically horizontal.
Systems available for surface removal can be generally
separated into:
* Mechanical removal (routing or grooving);
* Impact of hard particles (abrading); and
* Hydraulic removal (hydrodemoliuon).
In addition, there are chemical removal systems, commndy
acid etching, that can be used for concrete removal. Their
use, however, has been discouraged in recent years due to
safety and environmental considerations.
Selection of a system will vary with accessibility, size of
the work. locally availabie equipment and expertise and,
most importantly, the end use of the surface. In many cases,
more than one system can be considered.
The proprietary nature of systems combined with the
range of final surface profiles that will result often necessi-
tates consultation with removai contractors during system
selection.
4.2-Purpose of surface removal
Common reasons for surface removal of concrete include:
To correct unsound, stained, or damaged concrete such
as weak and dusiing surfaces;
To correct alignments tbat may have been caused by
construction ermrs such as bulges and high spots on
slabs, or fins from formwork leakage; these are typi-
cally planeness corrections;
To prepare the surface for subsequent layers such as
overlays. toppings. tiie, and coatings; and
* To improve skid resistance.
4.3-Systems avaiiable for surface removal
There are a wide range of systems avaiiable even within a
particuln generic type of removal equipment. Recently,
there has been a movement to larger and self-propeiied units
as the construction industry becomes more involved in con-
crete rehabilitation. This section describes the general natuce
of the equipment with suggestions on advantages and disad-
vantages as well as possible uses. Additional infomation on
AISO Available
In Narrow Chisels
Fig. 4.1-Chisels
removing concrete from bridgcs can be found in Manning
(1991) andvorsteret al. (1992).
4.3.1 Mechanical removal
4.3.1.1 Generai-Mechanicai removal is a general tem
involving a wide range of removai eqnipment and tech-
niques. Historically, most removal was done by mechanical
means, and today the largest volume of removal is still using
the mechanical removal system. Hand operafions have been
slowly replaced by mechanized systems.
One concem about mechanical systems is that, when used
for surface preparation, toois can leave a ‘%ruised”surface
that in turn can reduce the bond strength to subsequent over-
lays (see Section 4.7). The “bniising” concem is panicularly
relevant with chipping tools.
43.12 Chipping-Chipping tools, including hammer-
dnven and hand-held percussion breakers, are the most
widely used removal tmls. They are available h a wide
range of sizes, tip types (hardened steels and carbine) and
styies (chisel or moil point) (Fig. 4.1).
Hand-held pneumatic breakers are widely used and weii-
established tools for removing cmtaminated and detenorated
concrete. Their iightweight and excellent maneuverability
make them ideally suited to remove damaged coocrete from
smali, isolated areas and from vertical and overhead surfacs.
They can be used on cracked, spalled, 01 delaminated con-
crete, and on cbionde-confaminaied concrete when the de#
of removal is known from the evaluation of the stnicture.
The procedure is tedious and the quality of the würk is
strongly dependent on the care and aniNde of the OperatQr.
The process has a number of disadvantages:
Al1 the detenorafed or unsound concrete m y not be
- removed;
The surface of the remaining concrete may be ex-
sively microcracked by the blows from the breakers;
* Striking the reinforcement with the breakers may nlclr
the bar and, of greater concem, may desmy the bond
adjacent to the removal area; and
The pmedure is slow, noisy, and dusty.
production rates fall in a wide range and are influeiwedih,
the quaiity of the concrete, the ease of accew, acd tbe rnoüüí
of concrete that should be removed.
43.1.3 Bush h m r i n g - B n s h hammerhg is WpkaUY
perfonned using a chipphg hammer with a bushing tool @itf
 REMOVAL AND REUSE OF HARDENED CONCRETE
having a s e d face with rows of pyramidal points or of
palie1 V-shaped grooves (Fig. 4.2).
Bu& hatnmeMg can also be accomplished with hammer
blows nn a cbisel-Mce tool or with a gang bammer that uses
multiple independent bits. A gang hammer for horizontal
surfaces is o h n kwwn as a scabbler.
The depth of ptnoeation and the roughness of the finished
surface is mntrolled by the size and sharpness of the points
on the bits.
Operations are noisy and dusty but good control of remov-
al deptb is nomally acbieved. Again “bruising” is a concern
but excelient meshanical roughness for bond of subsequent
layers can be acbieved.
43.1.4 Needle scalers-Needle scalers are twls primaxily
used for metal cleaning; however, they also fmd use in selec-
tive concrete surface removal. These tools are nomially pneu-
m a t i d y &ven and have upward of 20 steel needles
approximately iRl h.(3 mm) in diameter. Some models have
medies of more iban one size. The tools range in size from
models weighing 3.5 Ib (1.6 kg) and delivering 4850 blowimin
in a model weighiag 11 Ib (5 kg) and deüvering 2900 blowimin.
T k tods yuire appmxhately 5 dmUn (0.14 rn3/min)of com-
pressive air at 90psi (620Wa). ”hey are also avaiiahle as hy-
draulic tools deiivering about 2100 hlowdmin.
Needle scalers are especiaiíy well suited for use on uneven
surfaces because the needles confom to the contour of the
work. Tbe main appücation for concrete work is the removal
of small quantities of concrete in areas where access is dift-
cult of where speciai care is required. In such cases, the üght-
weight of the tool is a distinct advantage and the low
production rates are aceptable. The twls can also be fitted
with achisel point so that the concrete can be removed to
almost the full depth using the chisel, with only the final
concrete being removed by the needles.
One effective use of needle guns is in the touch-up of non-
unifom exposed aggregate arcbitecturai concrete. In the
hands of an expenenced cement mason, color and texture
variations can be reduced.
43.13 Scanfiersscarifiers. sometimes called miüing
machines. remove concrete by applying a rotating cutting
wheel to tbe surface. in some of the early models, the cutting
head was held against the concrete surface by hydraulic pres-
SU aad WBSmtated by the forward motion of the machiie. In
refent models, however, the cutting head mtates independently
usuaUy in a dinction pducing an upward cutting action on the
CoIMete. Scariflersrange in size from walk-tehind units with
a 2 OT 3 in.(50 m 75 mm) cutting path designed primarily for
the removal of pwement markings and s u r f a coatings to
mck-mauoted units h t weigh in excess of lM),WO Ib
(45,000 kg) with a CuCtiOg head np to 14 ft (4.3 m)wide.
Figure 3.4 sbows a b - m o u n t e d , hvin-drum mtary head
cutter that was adapted in the mid 1980s froma mining tool
tn a tool for removal from mast comete sIN&s. Figure 3.5
shows a singie-dmm wüer (planer) used fmremoval from
botimntal surfaces. Both the units utilized iungsten-carhide
bits.
Scarifiers are widely used in bridge rehabiiitation. espe-
c i d y <o prepare the concrete surface before the application
Chlpplng Hammer Electric Hammer
Bushlng Tool Bushing Tool
Fig 4.2-Bush hammers.
of a concrete overlay. The single largest prohlem in using a
scarifier on reinforced concrete is in areas of low concrete
cover, where the scarifier may flp out the reinforcing hars.
and the unit may be damaged. Scarifiers are not suitahle for
vertical or overhead surfaces, except for boom-mounted ro-
~ ~ cutters that have been used to remove concrete
t a head
ftom lock chambers and wall faces.
Tbe depth of a cut can be more easily controlled with a
scarifier than a scahhler hecause tbe cutting head can be ad-
justed to a reference position, either on the machine or. for
the large units, by a profile line. The surface roughness is de-
termined by the spacing and shape of the teeth matched to ita
use, such as removing various surfacing, cleaning, and light
or heavy milling. The teeth. which usuaiiy have tungslen car-
bide tips, wear out and should he replaced. cometimes after
only a few hours of use.
Scarifiers are noisy. and some machines may create signif-
icant vihration. The larger machines are equipped witb water
tanks for cooiing bits (preventing t h e d damage) and con-
veyor systems for loading the scarified material directly into
trucks. The use of water can result in a tightly adhenng iayer
of surface dust that is difficuli to remove.
Miliing is a capital-intensive method of concrete removal
ushg bigb-production macbines 10 strip contaminated and
detenorated concrete from above the reinforcing steel. Mill-
ing machines are ideally suited to bridge deck rebahilitation
projects requinng the removing of large volumes of con-
crete. Tbeir inability to remove detenorated concrete from
below the reinforcing steei or from inaccessihle arcas such as
at joint faces, drains. or around other ohstacies means that
methods such as pneumatic hreakers are invariahly required
10 suppon the operations and complete the detail work.
Vorster et al. (1992) presents a detailed descnption of mill-
ing operatiws.
43.2 Particle impact removal-A feature of systems in-
volving particle impact is that removal is predominantly by
abrading of the mortar phase of the concrete. Therefore, two
aspects are: