Concrete Repair and Protection (1)

Concrete Repair
Contents
Importance of concrete deterioration in general Concrete as building material Reasons for concrete deterioration Concrete Repair
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Importance of Concrete Deterioration in general

The economic loss related to concrete deterioration is significant. Valuable resources must be spent for concrete repair Concrete deterioration can endanger the lives of people

The life of a concrete structure

Phase A Phase B Design, construction and concrete curing Deterioration initiation processes are underway but damage is not yet obvious Deterioration is underway and starts becoming visible Deterioration process is advanced, extensive damage is visible 4

Phase C

Phase D

Law of Fives
1 $ spent in Phase A
= saving = saving

5 $ repair expenditure in Pahse B 25 $ repair expenditure in Phase C

= saving 125 $ repair expenditure in Phase D

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Reasons for Concrete Deterioration Concrete as Building Material

What is concrete? Sand + Aggregate + Cement + (Additives) + (Steel) => Hydration => + Water

Conctere

What makes concrete perform? Design

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Concrete as Building Material

Aggregate Concrete Surface

Cement Skin Fine Mortar Zone Coarse Mortar

Zone Fine
Reinforcement

Concrete Zone Concrete according to design with normal cement content and planned aggregate distribution

Typical cross section of reinforced concrete

Reasons for Concrete Deterioration Concrete as Building Material

Classification according to compressive strength classes 5 to 10 MPa 20 to 30 MPa 40 to 50 MPa 60 to 120 MPa Lean concrete, provisional structures Structural components in housing and industry Concrete for higher requirements in housing and industry High performance concrete for special structures
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Reasons for Concrete Deterioration Concrete as Building Material

If concrete is produced according to international stand of technique, it is a very long lasting material, wear resistant and relatively cheap. Important is the proper design of the concrete components and the proper handling of the material during the casting process at site.
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Reasons for Concrete Deterioration

Reasons, which already exist before the concrete component has been finished
- Mistakes during planning and design - Mistakes related to concrete technology - Mistakes during production at site

Reasons, concrete building

which attack after finishing

the the

- Environmental influence - Extraordinary stress

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Reasons for Concrete Deterioration

Main damages to concrete components Corrosion of the reinforcement Expansion reaction Dissolving deterioration Spalling, cracking and weakening of composite 11

Reasons for Concrete Deterioration

What is the reason for corrosion of the reinforcement?
Inside a healthy" concrete, the steel is imbedded in an alkaline environment of pH 13.On the surface of the steel this produces a protective passive layer, which prevents the steel from corroding. Reducing of this alkaline milieu < pH 11 causes corrosion of the reinforcement.
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Reasons for Concrete Deterioration

Entrance of harmful agents Entrance of chlorides Carbonation

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Reasons for Concrete Deterioration Existing before finishing the Building

Mistakes during planning and design
Design of minimum measurements as design measurements. Too slim concrete components Wrong load assumptions Construction situations are not being taken into consideration Insufficient investigation of the construction ground 14

Reasons for Concrete Deterioration Existing before finishing the Building

Mistakes during planning and design
Form deviations are not being considered sufficiently Wrong joint design Disregard of !Stand of Technique

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Reasons for Concrete Deterioration under Responsibility of the Designer

Concrete Composition Building Shape

Measurements

Designer
Reinforcement Concrete Cover

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Reasons for Concrete Deterioration Existing before finishing the Building

Insufficient concrete technology

Wrong concrete composition Wrong cement class Wrong kind of cement Too low cement content

Too high water/cement (W/C) ration

Insufficient quality of aggregates
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Reasons for Concrete Deterioration

Mistake No. 1: Too much water! W/C > 0.5 Why? Makes life easier at site!

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Reasons for Concrete Deterioration

Consequences of too high W/C ratio
Too much Water W/C > 0.5 Too many Pores Easy access of Harmful Substances

Rusting of Reinforcement Steel

Loss of Steel Passivation

Carbonation Chloride Contamination

Spalling, Delaminating, Cracking of Concrete

Weakening of Concrete Components

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Reasons for Concrete Deterioration

Effect of W/C on (type GP cements):
a) Compressive strength b) Concrete permeability

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Reasons for Concrete Deterioration Existing before finishing the Building

Mistakes during concrete production at site

Unauthorized a

Reasons for Concrete Deterioration Existing after finishing the Building

Physical influences

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Reasons for Concrete Deterioration Existing after finishing the Building

Chemical influences

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Reasons for Concrete Deterioration

Consequences of Carbonation
CO2 enters concrete

Carbonation
CO2 + Ca(OH)2 CaCO3 + H2O

Alkalinity drops pH < 12 Depassivation of steel

Spalling, delamination, cracking of concrete Weakening of concrete components

Corrosion of steel

Note: Carbonation usually stops at a certain depth

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Reasons for Concrete Deterioration

Consequences of Chloride Attack
CL- enters concrete
CL- > 0.4% total chloride W/W cement Spalling, delamination, cracking of concrete

Depassivation of steel

Weakening of concrete components

Corrosion of steel
Note: Chloride attack does not stop at a certain depth
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Reasons for Concrete Deterioration

Influence of humidity and concrete quality on critical chloride content

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Damages

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Damages

Cracking

Spalling

Delamination

Corner Effects

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Requirements for Good Quality Concrete

Dense, not too many pores (total pore volume < 16 Vol.-%) Water/cement ratio W/C < 0.5 Cement content > 300 kg/m3 Alkalinity pH > 12 Water dispersible chlorides < 0.35 % related to cement in compacted fresh concrete Concrete cover > 2 cm (3 cm)
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Requirements for good Quality Concrete Proper grading of aggregate Proper aggregate quality Use good quality cement Correct cement type (GP, HE, LH, SR, SL)
(GP = general purpose, HE = high early strength, LH = low heat, SR = sulfate resistant, SL = shrinkage limited)

Limit fly ash content

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Measures to achieve good Quality Concrete Carry out proper compacting procedure Carry out the necessary quality checks Check the batching plant Control the mix at site (Slump Test) Do not trust documents without checking
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Measures to achieve Quality Concrete

Slump Test

good

1) Filling

2) Compacting

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3) Lifting

4) Measuring

Damage Analysis
Formation and types of cracks Inspection techniques Visual inspection Cover meter
Cylinder compressive strength test Phenolphthalein indicator Half-cell potential mapping
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