Seminar Report

On

CONCRETE REPAIR TECHNOLOGY

NAME:
ROLL:

INTRODUCTION
Though concrete is a relatively durable building material, it may suffer damage or
distress during its life period due to a number of reasons. Because of the varying conditions
under which it is produced at various locations, the quality of concrete suffers occasionally either
during production or during service conditions resulting in distress. The structural causes of
distress of concrete may include externally applied and environmental loads exceeding the
design stipulations, accidents and subsidence. Sometimes distress in a structure is brought
about by poor construction practices, error in design and detailing, and construction overloads.
The other causes may be drying shrinkage, thermal stress, weathering, chemical reactions and
corrosion of reinforcement. In addition to the distress in hardened concrete the plastic concrete
may also suffer damage due to plastic shrinkage and settlement cracking. Sometimes on
stripping off the forms a number of surface defects such as bulges, ridges, honeycombing, boltholes, etc. are noticed on the fresh concrete members. Such defects can be avoided to a
large extent by providing a watertight and rigid formwork in such a way that stripping can be
done without the use of crowbars or other tools. In Addition to these defects, blow-holes
develop during concreting operations due to improper design of formwork.

COMMON CAUSES OF CRACKS:

1. Cracking of Plastic Concrete.
2. Cracking of Hardened Concrete
3. Thermal Cracking
4. Cracking due to Chemical Reactions.
5. Cracking due to Weathering
6. Cracking due to Corrosion of Reinforcement
7. Cracking due to Poor Construction Practices
8. Cracking due to Poor Construction Overloads
9. Cracking due to Errors in Design & Detailing
10. Cracking due to Externally Applied Loads.

EVALUATION OF CRACKS
The evaluation of cracks is necessary for the following purposes:
(i)
(ii)
(iii)
(iv)
(v)
(vi)

To identify the cause of cracking.

To assess the structure for its safety and serviceability.
To establish the extent of the cracking.
To establish the likely extent of further deterioration.
To study the suitability of various remedial measures,
To make a final assessment for serviceability after repairs.

Visual Examination
The appearance of concrete surface may suggest the possibility of chemical attack by a
general softening and leaching of matrix, or in case of sulphate attack by whitening of concrete.
Rust stains often indicate corrosion of reinforcement but they may also be caused due to the
contamination of aggregate with iron pyrites. The crack pattern may be informative, a mesh
pattern suggests drying shrinkage, and surface crazing may indicate frost attack or in rare
cases alkali-aggregate reaction. The cracks in concrete may be evaluated at macro, micro,
submicro, and atomic levels (Angstroms A). In the present discussion the macrostructure
cracks having a size (i.e. width/depth) in the range of 0.1 to 03 mm are of interest.

Non-destructive Testing
Non-destructive tests may be performed to determine the presence of internal cracks and
voids, and the depth of penetration of cracks that are visible at the surface. Useful information
can often be obtained by tapping the surface of concrete with an ordinary hammer. The
difference in sound when concrete is struck may identify areas of delamination of concrete that
has been damaged, say by fire.

SELECTION OF REPAIR PROCEDURE

The repair of concrete structures may vary between just giving a cosmetic
treatment and a total replacement. By a proper investigation and by using welldesigned equipment, tools and materials, a number of structures which may appear
to have been damaged beyond repair can be reinstated econom ically. An appropriate
repair method can be selected depending upon the e and extent of damage,
importance of the structural element, and its location . The choice of the method will
determine its success.
(i)
(ii)
(iii)

To increase strength or restore load bearing capacity

To restore or increase stiffness.
To improve functional performance.

(iv)
(v)
(vi)
(vii)

To provide water tightness.

To improve appearance of concrete surface.
To improve durability.
To prevent access of corrosive materials to reinforcement.

Depending upon the nature and extent of the damage, one or more repair
methods may be selected, e.g. tensile strength can be restored across a crack by
injecting it with an epoxy. However, it may be necessary to provide additional strength by
adding reinforcement. Epoxy injection alone can be used to restore flexural stiffness if
further cracking is not anticipated. Cracks causing leaks in water retaining structures
should be repaired unless the leakage is considered minor. They can be repaired when
cracks result in an unacceptable appearance. However, if the crack location is still
visible, some form of coating over the entire surface may be required. To minimize
further deterioration due to corrosion of reinforcement, cracks exposed to a moist
environment should be sealed.
Success of the long-term repair procedures chiefly depends on the nature of
cracks as well as their cause. For example, if the cracking is primarily due to drying
shrinkage, it is likely that after a period of time the cracks will stabilize. On the other
hand, if the cracks are due to continuing foundation settlement, repair will not be
effective until the settlement problem is corrected. The repair procedure also depends on
the capabilities and facilities available with the builder, and on the availability of the repair
materials.

REPAIR OF CRACKS

Preparation of Surface
Prior to the execution of any repair, one of the essential requirements common to all
repair techniques is that all deteriorated or damaged concrete should be removed. This
can be accomplished by using tools and equipment, the type of which depends to a
large degree on the size, depth, and extent of repair.

The preparation of a surface for repair involves the following steps.

(i) Complete removal of unsound material.
(ii) Undercutting along with the formation of smooth edges.
(iii) Removal of the cracks from the surface.
(iv) Formation of a well-defined cavity geometry with rounded inside corners.
(v) Providing, rough but uniform surfaces for repair.

SPECIAL TYPES OF REPAIRS

Polymer-based Repairs
The polymer concrete includes composite prepared by one of the following methods.
Polymer Impregnated Concrete (PIC)

This is a Portland cement concrete impregnated by a monomer system which is

subsequently polymerized by radiation or heat, and the use of a catalyst.
Polymer Cement Concrete (PCC)
This is a concrete in which the monomer is added during the mixing of Portland cement,
water and aggregate, followed polymerization or curing of the replaced material after its
placement.
Polymer Concrete (PC)
This is a composite material obtained by adding a polymer or its precursor to the
aggregate and polymerizing or curing the material after its placement.
The concrete polymer materials provide high strength and improved durability under
aggressive conditions as compared to conventional concretes. PIC has proved to be
the most successful concrete polymer material for construction. Liquid and gaseous
monomers can fully penetrate concrete by external pressure and can be polymerized.
To obtain maximum polymer loading in the concretes and hence maximum improvement
in the desired properties, it is necessary to dry the concrete to constant mass, remove air,
soak in a low viscosity liquid monomer, pressurize with nitrogen and wrap the specimen
in polyethylene sheet to reduce evaporation prior to polymerization, the polymer
systems commonly used are the following.
(a)Methyl-methacrylate (MMA)
(b) MMA + 10 per cent trimetholpropane trimethacrylate (TMPTA)
(c) Styrene and polyester styrene
(d)Methanol
(c)Vinyl monomer

The polymer-based crack repair can be affected as described in the

following sections.
(a) Polymer Impregnation The technique consists of flooding the cleaned,
dried cracked concrete surface with a monomer which is then polymerized in place,
thus filling and structurally repairing the crack. A monomer system is a liquid that
consists of small organic molecules capable of combining to form a solid plastic. The
monomer systems used for impregnation contain a catalyst or an initiator and the basic
monomer. They also contain a cross-linking agent. When heated the monomers join
together or polymerize becoming a tough, strong and durable plastic that greatly
enhances a number of concrete properties.
b) Drilling and Plugging The method is only applicable for the cracks hrunning in
reasonably straight lines and accessible at one end. It consists in drilling a hole down
the length of crack and grouting it to form a key. A hole 50 to 60 mm in diameter should
be drilled, centred on and following the crack as shown in Fig. 17.7.

Resin-based Repairs.
Cracks in reinforced concrete wider than approximately 0.3 mm may require sealing
to prevent the entry of moisture, oxygen and other materials, or for other reasons.
The choice of the method and materials will depend upon the cause of cracking and.
whether a permanent structural filling of crack is needed to carry out any other
required strengthening. For restoring the structure to its original strength, the lowviscosity epoxy resin may be injected. Using pressure injection techniques it is
possible to completely fill cracks finer than 5 mm with epoxy resin system. However,
the work should be carried out skillfully to avoid blowing o f surface seals due to
backpressure that may develop in case of very fine cracks. Sustained pressure for
several minutes may be required to completely fill a fine crack. out any other
required strengthening. For restoring the structure to its original strength, the lowviscosity epoxy resin may be injected. Using pressure injection techniques it is
possible to completely fill cracks finer than 5 mm with epoxy resin system. However,
the work should be carried out skillfully to avoid blowing of surface seals due to
backpressure that may develop in case of very fine cracks. Sustained pressure for
several minutes may be required to completely fill a fine crack.
The resin and the hardener are generally in a liquid form and each by itself is
stable for an indefinite period. When these are mixed a chemical reaction takes place,
which converts the system from liquid to a tough plastic solid at ambient
temperatures. They develop excellent strength and adhesive properties, and are
resistant to many chemicals. They have good chemical and physical stability; they
harden rapidly and resist water penetration. In all, they provide a toughness that
couples durability with crack resistance. The resin mortar may be obtained by adding
fillers such as coarse sand.
The epoxy-based compounds are invariably formulated with plasticizers,
extenders, diluents and fillers to produce a large number of products, which have a
wide range of properties. A specific formulation may thus be made available for each
application. The fast setting properties, excellent adhesion characteris tics, high
strength and chemical stability have led to their extensive use in the concrete
construction.
Qeneral Applications
Expoxies in concrete construction have been used in various ways, e.g. in providing
skid resisting overlays and wearing surfaces on concrete floors, as waterproofing
membrane, to bond new concrete to old, to bond precast units, to anchor dowel bars,
etc. However, they have been most extensively used in the repair of pot-holes and
other defects on concrete floors and to seal cracks in the structural members.
The cleaned and dry surface is painted with epoxy compounds before placing
the repair materials. The cracks may be sealed with epoxy compound, an epoxy
mortar or a Portland cement mortar after priming the surface with epoxy compound.
The polymer or resin overlays can be put back into use quickly due to faster
curing. Being seamless they are more hygienic, and are chemical resistant.

Materials
Epoxy, polyester and acrylic resins are as a class designated as thermosetting
Materials because when cured the molecular chains are locked permanently
together. Unlike thermoplastics they do not melt when heated but lose strength with
an increase in temperature. They are generally supplied as two or three component
systems: resin, hardener and fillers. The resins are broadly classified as: (a) Epoxy
resins
(b) Unsaturated reactive polyester resins
(c) Unsaturated acrylic resins
Acrylic resin systems form high strength materials and are based on monomers of very
low viscosity or blends of monomers with methyl-methacrylate monomer.
Polyester and acrylic resins contain volatile constituents which are inflammable. Most
acrylic resins are highly inflammable with a flash point below 10 C, and vapours also cause
toxic reaction. The properties of commonly used resins are:
Epoxy resins
These have high strength, good bonding characteristics, high impact resistance, high
chemical resistance and may be made to provide a non-slip finish.
Polymer resins
These differ from epoxy resins in that these can be laid over wider temperature range and
have a better resistance to heat. They are mixed with cement and fine hard aggregate, and
laid in thickness up to 15 mm.
Polyvinyl acetate (PVAc)
It is used as a bonding aid when thin mortar overlays are applied to existing concrete. The
liquid can be applied straightaway onto a clean, sound surface and-allowcd to dry. The slight reemu 1 sification of the film on being re-wetted by application of fresh mortar topping provides a
good bond.
Natural rubber latex
It is an admixture with excellent adhesive properties and is difficult to mix with ordinary
Portland cement. It is often used with less alkaline high alumina cement for patching or for
underlayments on floors which are to receive vinyl tiles.
Styrene butadiene rubber (SBR)
It is an effective alternative to PVAc with high water resistance. Unlike PVAc, the dried film
does not develop grab on re-wetting so it will act as a bonding layer if allowed to dry out.
Therefore, mortar mix should be applied while the tack coat of SBR is still wet.
Acrylic resins
These admixtures have excellent water resistance and improve bond strength when mixed
with mortars. Seamless, non-dusting thin floor overlays can readily be produced with acrylic
resins.
Styrene-acrylic resins
A mixture of tough styrene with acrylic resin using 1:3 cement-sand mortar can be used to
produce hard-wearing floor overlays at a reasonable cost.
Repair Procedure
(a) Resin-mortar The surface preparation requirements are similar to those for cementbased repairs. The constituents of resin-based material must be mixed together thoroughly by

use of mechanical mixers or stirrers. Most of the failures of resin-based repairs have been
traced to improper proportioning or inadequate mixing. For smaller repair jobs, to obtain
correct proportions the constituents are normally available in pre-batched packs. After the
preparation of surface a primer or tack coat of unfilled resin is applied to the freshlyexposed surfaces of concrete and reinforcement. In general one coat will be enough, but two
may be needed if the substrata is porous. If two coats are used, the second must be applied
while the first is still tacky.
The patching material must be applied while the primer is still tacky, and each successive
layer of patching material must be applied before the previous one has cured too much. The
resin-based materials cure by chemical reaction which starts as soon as the constituents are
mixed, so they have a limited pot-life. The quantity of materials to be mixed in any one batch
is precalculated such that it can be used before it becomes too stiff. The resin-based patches
should be well compacted and impermeable.
Normal safety precautions should be observed while using the resins and hardeners, i.e.
gloves should be worn, splashes should be washed off the skin but solvents should not be
used for this purpose; adequate ventilation should be provided; and smoking, eating or
drinking should be prohibited.
(b) Resin-injection The injection of p'olymer under pressure will ensure that the sealant
penetrates to the full depth of the crack. The technique in general consists of drilling holes at
close intervals along the length of cracks and injecting the epoxy under pressure in each hole
in turn until it starts to flow out of the next one. The hole in use is then sealed off and
injection is started at the next hole and so on until full length of the crack has been treated.
Before injecting the sealant it is necessary to seal the crack at surface between the holes with
rapid curing resin. For repair of cracks in massive structures, a series of holes (usually 20 mm
in diameter and 20 mm deep spaced at 150 to 300 mm interval) intercepting the crack at a
number of location are drilled. Epoxy injection can be used to bond the cracks as narrow as
0.05 mm. It has been successfully used in the repair of cracks in buildings, bridges, dams
and other similar structures. However, unless the cause of cracking is removed, cracks will
probably recur possibly somewhere else in the structure. Moreover in general this technique is
not very effective if the cracks are actively leaking and cannot be dried out.

CRACK REPAIR OF CONCRETE ROADS

5. SUMMARY OF CRACK REPAIR
5.1. Sealant Selection. Select the proper sealant material for
the area being repaired ;however, the sealant selected must
conform to appropriate specifications and be authorized by base
engineers before use. Normally, it should match adjacent sealants.
However, neoprene compression seals should not be used for
cracks. The repair should be timed such that sawed-out cracks are
not exposed for more than 24 hours before sealing. If the cracks
get wet, the repair operation must stop until the cracks are
completely dry. The cracks may be dried with a heat lance (Figure.5.1).

Fig 5.1

5.2. Shape Factor and Recess. Saw or rout (Figures 9.1. and 9.2.) the crack to the proper
width and depth to reach the desired shape factor and recess recommended by the manufacturer of
the sealant to be used. For silicone sealants, use of a backer rod in lieu of separating tape is
recommended. Small cracks may be sawed by hand (Figure 10.1.).

Fig 10.1

Fig 9.2

Fig 9.1

5.3.
Sandblasting.
Clean the crack faces by sandblasting using the multiple pass
technique (Figure 10.3.). While standing to one side of the crack, pass
the wand along the crack face at an angle to allow a strong blast on
one crack face; then step to the other side of the crack and reverse
direction.

5.4. Removing Loose Material. Blow debris out of the crack

using compressed air; then clean the crack with high-pressure water
(Figure 9.4.). There must be no loose material in the bottom of the
crack.

5.5. Vacuuming. Clean the area around the crack with a broom or
vacuum sweeper to prevent debris from reentering the crack before
sealing (Figure 9.5.). Compressed air may be required to clean crack
after the power broom is used.

5.6. Cleanliness. Remember that the cleanliness of both crack faces is extremely important!
Dirty crack faces are a major cause of loss of adhesion of the sealant to the crack face and
subsequent failure of the crack repair. Place the sealant within 24 hours after sandblasting. If sealant
is not placed within 24 hours sandblast the face again, clean the crack with high-pressure water and
air, sweep and vacuum the surface around the crack, and then seal. If a finger wiped along the joint
face picks up dirt or dust, the joint or crack face is dirty and must be cleaned.
5.7. Backer Rod. Place the backer rod immediately prior to sealing the crack (Figure 9.6.). The
backer rod must be at least 25 percent larger in diameter than the width of the crack and must be
placed at the proper depth for the shape factor of the sealant being used (Figure 7.1.). Seal the
crack from the bottom up and from beginning to end in one stroke without interruption, when
practical (Figure 11.1.).

Fig 11.1

Fig 9.6

Fig 7.1

5.8. Foreign Object Damage. After the crack repair operation is complete, clean the
surrounding pavement and sweep away all potential materials that may cause Foreign Object
Damage (FOD). Clean, lubricate, and properly store all equipment until the next repair operation.

6.0 SUMMARY OF SPALL REPAIR

6.1. Selecting Repair Materials and Procedure. Refer to Figures 3.1. through 3.6. for
details on spall repairs in various slab locations and spall repair boundaries. Select the spall repair
materials and the spall repair procedure(saw and patch is recommended). However, use of these
materials (concrete, joint sealer, joint filler, etc.) must meet specifications and/or be authorized by
base engineers. As with any repair operation, the cleanliness of the area to be patched is one of the
most important factors in a long-lasting patch. Extra care must always be taken to ensure the repair
area is clean before repair. The timing of the repair should be such that the prepared spall recess is
not exposed to the elements for more than 24 hours without additional cleaning.

6.2. Removing Old Sealant. Remove any sealant present in the joint or crack adjacent to the
spall .
6.3. Boundaries. Cut a boundary around the area to a depth of
at least 2 inches (50 millimeters)
using a concrete or a hand saw (Figure 14.1.). The spall repair area
should be sized.

6.4. Concrete Removal. Remove the concrete inside the boundary to a depth of at least 2 inches
(50 millimeters), or 1/2 inch (13 millimeters) into visually sound
concrete, which ever is deeper. Use a light jackhammer (less than
30 pounds (14 kilograms)) equipped with a chipping hammer

(Figure 14.2.), scarifier, or high-pressure water blaster (Figure 9.4.). If a dowel is exposed during the
concrete removal, it must be replaced. If more than 90 degrees of the perimeter of reinforcement is
exposed, a space at least 1/2 inch (13 millimeters) completely around the bar or wire must be
exposed.
6.5. Concrete Soundness. Visually check the underlying concrete for soundness and remove
any concrete found to be unsound.
6.6. Cleaning. Clean out the spall recess using high-pressure water and compressed air.
6.7. Sweeping. Sweep the area to prevent debris from reentering the spall repair area.
6.8. Joint Filler. Install preformed joint filler to provide a rigid boundary next to the joint or crack
and to retain the shape of the joint. This filler must extend the full length of the joint or crack for
the full depth of the spall repair area.
6.9. Bonding Agent. If required for the repair material, apply bonding agent to the spall repair
surface (Figure 16.1.). Always ensure that the spall repair is clean before adding bonding agents
or any repair material. If the spall repair
area is large and portland cement concrete
(PCC) is the repair material to be used, be
sure to place the grout rapidly so areas do
not begin to dry prior to filling the area.
Place the spall repair material (Figure
16.2.), finish the surface (Figure 16.3.),
and follow the curing procedure recommended by the manufacturer of the repair material.
6.10. Sawing. Where the spalled area abuts a joint, an insert or other bond-breaking medium
shall be used to prevent bond at the joint face. After the curing is complete, a reservoir for the
joint sealant shall be sawed with a small-diameter saw blade to the dimensions required for other
joints, or as required to be routed for cracks. Sandblast each face of the fresh sawcut, wash with
high-pressure water, airblast, and sweep the area. Place the proper width backer rod at the
required depth for the sealant. Place the sealant from the bottom up and in one smooth operation
from the beginning to the end of the joint or crack.
6.11. Cleanup. After the spall operation is complete, clean and sweep the surrounding
pavement of all potential materials that may cause FOD. In addition, clean, lubricate, and
properly store all equipment until needed

Finishing the patch surface

A completed spall repair that bridges an expansion joint

CONCLUSION

Depending upon the nature and extent of the damage, one or more repair
methods may be selected

An appropriate repair method can be selected depending upon the e and extent
of damage, importance of the structural element, and its location .
The choice of the method will determine its success.
Normal safety precautions should be observed while using the resins and hardeners,
i.e. gloves should be worn, splashes should be washed off the skin but solvents
should not be used for this purpose; adequate ventilation should be provided; and
smoking, eating or drinking should be prohibited
Epoxy injection is a highly specialized job requiring a high degree of skill for satisfactory
execution.
The repair procedure also depends on the capabilities and facilities available with
the builder, and on the availability of the repair materials.

Reference:
(i)

Concrete Technology,Gambhir

(ii)

Properties of concrete,Neville

(iii)

ASTM codes

(iv)

UBS manuals