1

RETROFIT OF CONCRETE IN PIER STRUCTURES

Sumargo
1*
, Ariyadi Basuki
2
, Raja Nasrul Fuad
3
, Meri Sri Wahyuni
3

1
Civil Engineering Department, Bandung State Polytechnic, Bandung Indonesia
2
Center for Material and Technical Product, The Ministry of Industry
3
Medan Institute of Technology, Medan
*Corresponding author. Tel : +62 812 219 8097, Fax : +62 22 2013889
E-mail address : sumargo2004@yahoo.com (Sumargo)

Keywords: FRP, moment capacity, patching, grouting, injection.
ABSTRACT
Composite construction involving relatively new material system is used at pier of Jetty I
PT. Petrokimia Gresik, where damages occur due to tides, corrosive environments, and
the addition of the load on the pier that cause cracks. Additional loads on the structure
of pier also accelerate the occurrence of cracks on pier structures such as beams, cross
beams, and pier head. Cracks bring adverse effects to the structure in the form of
corrosion of reinforcing the structure, where improvements can be made in the form of
patching, grouting, injection, and strengthening with Fiber Reinforced Polymer material.
Structural analysis showed that the 500 mm x 1200 mm beams need additional
strengthening of 2 layers Mbrace CF 230/4900 as to increase the moment capacity of
68%, for 450 mm x 1550 mm beams need 1 layer CF 230/4900 to obtain additional
moment capacity of 64%, for 500 mm x 1400 mm beams need 1 layer Mbrace CF
230/4900 for increase moment capacity of 62%, and for 1000 mm x 1200 mm beams
need 1 layer Fiber Reinforced Polymer Laminate Mbrace 165/2500 as to increase the
moment capacity of 69%.

INTRODUCTION
The port of PT. Petrokimia Gresik, East Java is a special port that supports the
company's activities so that port is only reserved for loading and unloading
items. It has a pier with a length of 620 meters and 36 meters wide and can
accommodate ships weighing 40,000 to 60,000 DWT and capability of loading
and unloading ships 185,800 tons/day. Cracks, spalling, and reinforcement
corrosion are occurred mostly due to the aggressive environment to the
structural material. This paper shows that the performance of the pier can be
improved without disturbing daily operational by repairing and strengthening with
advanced material technology.
2

METHODOLOGY
Stages were done for the preparation of this study such as (a) visual observation
and inventory of failures, (b) secondary data collection and a series of inspection
and testing activities, (c) analysis for the reconditioned and strengthening of the
structures, followed by (d) apply of proposed analysis. The first two steps is
given ini Figure 1.

Figure1. Inspection And Testing Activities Series
LITERATURE REVIEW
Strengthening with Fiber Reinforced Polymer (FRP)
The main advantages of composites are complementary elements of the
property. For example, glass fiber with a high tensile strength is very susceptible
to bending and failure due to the environment. It is equipped with polymer which
is weak against stress, but the fiber is easily formed and can protect the fiber
STRUCTURALDAMAGE
INVESTIGATION
REINFORCED CONCRETE
PRELIMINARYINVESTIGATION
SELECTION(RANDOM)
ELEMENTSTRUCTURE
REGISTRATIONDATAFOR
CONCRETEBLANKETDETERMINE
WITHR-METER
DETERMINATION OFLOCATION
CONCRETESTEEL
REINFORCEMENT WITHR-METER
TESTINGFORCORROSIONRATE
CHIPPING WITHPOTENTIALMETER
CORROSIONRATEOF RECORDING
DATA REINFORCEMENT
CHIPPINGFORVISUALINSPECTION
OF DAMAGESSUSPECTED
DIAMETERMEASUREMENTRE
INFORCEMENT
MEASUREMENT
OF CONCRETEBLANKET
DETERMINATIONOF
CORROSION
ONCONCRETESTEEL
REINFORCEMENT
EXAMINATIONOF
QUALITYCONCRETE
CONCRETECORE SAMPLE
(COREDRILLED)
POWERFULTEST
PRESS
TESTCHLORIDE
CONTENT
SELECTIONPOSITION
CONCRETECORE SAMPLING
DETERMINATION
OFLOCATION
CONCRETEREINFORCEMENT
HAMMER TEST
CONCRETECORE SAMPLING
C
O
N
C
L
U
S
I
O
N
D
A
T
A
A
N
A
L
Y
S
I
S
A
N
D
R
E
P
O
R
T
I
N
G
DOCUMENTATION
FOLLOW-UP
RETROFITTINGIMPROVEMENT
SPRAYINGPHENOLPTHALEIN
&
MEASUREMENTSOLUTIONS L
EVELCARBONATION
PUNCHT
3

surface. Composite Fiber Reinforced Polymer (FRP) consisting of three essential
elements of fiber, polymers, and additives. A high ratio of strength and stiffness
to weight and high energy absorption is an important properties of the composite
to increase load on the structure service life. Good corrosion resistance and
fatigue resistance of FRP composites has the advantage on the life-cycle cost of
structures. Carbon fiber composites are ideally suited to add strength, stiffness,
and energy absorption. Unlike glass and aramid fiber, carbon fiber shows no
corrosion or rupture due to failure at room temperature.
[1]

Beam flexural capacity is based on ultimate strength limit, which is
determined by limit compressive strength of concrete, reinforcing steel yield
stress, and effective stress of FRP, Figure 2. The flexural strength required given
as
[3]
: N
n
N
u
(1)
The required Carbon Fiber Reinforced Polymer (CFRP) is determined by using
environmental reduction factor (C
E
) of 0.95. Calculating FRP stress through
f
Iu
= C
E
f
Iu

(2)
in which,
C
E
= environmental reduction factor and f
Iu

= ultimate tensile strength

Calculate FRP strain as e
]u
= C
L
e
]u

(3)
in which e
]u

= ultimate rupture strain

The area of FRP is calculated using A
]
= nt
]
w
]
(4)
in which,
n = number of layers t
]
= thickness of layers
w
]
= length of layers

4


Figure 2. The Stress-Strain Diagram of Beams with FRP Reinforcement
The neutral axis depth (c) is determined by the equilibrium equation:
C
s
+C
c
= I
s
(5)
To protect the bonding ability of FRP, use the following bonding coefficient
For nt
]
E
]
180000; m =
1
60s
]u
[1
nt
]
L
]
360000
u.9u (6a)
For nt
]
E
]
> 180000 m =
1
60s
]u
_
90000
nt
]
L
]
] u.9u (6b)
By giving the assumption that the ultimate strain in concrete for 0003, the FRP
effective strain can be calculated by e
]c
= e
cu
[
h-c
c
e
b
me
]u
(7)
in which,
e
cu
= strain of concrete = depth of beam
c = depth of neutral Axis e
b
= strain of concrete with FRP
e
]u
= strain of FRP

Nominal flexural moment capacity of strengthened beam using FRP can be
calculated by: H
n
= jA
s

s
[J
u
2
+V
]
A
]

]c
[
u
2
[ (8)
in which,
A
s
= reinforcement area
s
= reinforcement stress
V
]
= reduction factor = 0.85 A
]
= area of FRP

]c
= effective Stress of FRP;
]c
= E
]
e
]c
E
]
= elastic modulus of FRP

RESULTS OF THE OBSERVATION
Inspection performed on
beams, the beam path cranes
the form of spalling which
surfaces. Triggers cracks
to corrosion caused by
stressing concrete covers
expanded into structural
or unanticipated design
concrete.
a. Slab and Pier Head
The pier head experiences
presence of cracks due to
Figure 3. The failure is categorized
much as 24.76%, light
repaired concrete of 7.62
number of pier head in the
Figure 3. Spalling

F THE OBSERVATION
performed on pier head structural elements, such as
cranes, plate on area Jetty I. In general,
which preceded the occurrence of cracks in
cracks can be categorized into two causes. First,
the swelling volume of reinforcement in concrete
concrete covers out and become cracked. Second, spalling
structural caused by an excessive stress (related to the
design load or due to insufficient compressive strength

experiences some concrete surface spalling. It is triggered
due to corrosion processes that occur in the
categorized as light failure at new or repaired
failure at old concrete of 9.52%, moderate
7.62%, moderate at old concrete of 4.76
in the structure.
and Triggered Corrosion Cracks at Slab and Cross
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such as beams, cross
failure occurs in
cracks in concrete
First, cracks due
in concrete that
spalling and cracks
related to the loading)
compressive strength of
is triggered by the
in the reinforcement,
new or repaired concrete as
moderate at new or
4.76% of the total

Cross Beam

b. Cross Beam
There are delaminations
is categorized as light
concrete 19.7%, moderate
concrete 25.76%, and heavy
Jetty I.
c. Beam Element Structure
The bottom part of beams
found failures in the former
in new concrete repair
concrete repair 15.6%,
concrete repair 0.61% of
TESTING RESULTS
Concrete compressive strength of
kg/cm
2
. Such values are comparable with
design of 27 MPa 275.3


s of new concrete layer at the bottom surface
as light failure in new concrete material 19.07
moderate in new concrete material 25.76%, moderate
heavy in new concrete 3.03% of the total
Structure
The bottom part of beams show flaking and cracks, even in some places
in the former repair or strengthening, Gambar 4. The failure
21.4%, light in old concrete 7.95%, moderate
, moderate old concrete 3.98%, and
of the total number of beams in Jetty I.
Figure 4. Spalling and Crack at Beam
compressive strength of structural elements in Jetty I
are comparable with the original compressive strength
275.3 kg/cm
2
.
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the bottom surface. The failure
19.07%, light in old
moderate in old
cross beams in
some places are
The failure is light
moderate in new
heavy in new

ranges 265-322
compressive strength
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DATA STRUCTURES AND ANALYSIS
Pier of Jetty I was modeled as a 3 dimensional structure with longitudinal and
transverse beams in accordance with drawings, Figure 5. It has a total length of
282 meters and 24.5 meters wide.

Figure 5. Three Dimensional View of Jetty I
There are four concrete beams with the dimension: 1000mm x 1200mm as cross
beam, 450mm x 1550mm as a crane beam, 500mm x 1400mm as longitudinal
beam 1, and 500mm x 1200mm as an longitudinal beam 2.
The leg of the pier are steel pipe of 322 MPa of yield stress, concrete filled with a
diameter of 1270 mm with of thick 12.7 mm.

STRUCTURE ANALYSIS
a. Pier Loading
The analysis covers all the possible loadings such as self weight, conveyor,
pipeline, live load, crawlers, trailers, trucks, cranes, earthquake loads, and load
the ship docked.
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b. Structure Analysis
Beams have concrete cover of 40 mm and 29 mm diameter of reinforcement.
Properties of FRP are: thickness of layers (t
]
) = 0.17 mm, ultimate tensile
strength (
]u

) = 4.9 kN/mm
2
, ultimate rupture strain (e
]u

) = 0.021 mm/mm, and

elastic modulus (E
]
) = 230 000 N/mm
2
.
The computed moments are: ultimate moment(H
u
) = 2244.46 kN-m and service
moment (H
s
) = 1549.65 kN-m. Structural analysis shows that H
n
= 578.157 kN-
m < H
u
= 2244,46 kN-m. So the 500/1200 beam require strengthening structures
using FRP. Two layers of FRP may increase the capacity of the beam as N
n
=
Su76.622 kN-m > N
u
= 2244,46 kN-m. The resume of analysis is given in Table 1.
Table 1. Beams Nominal Moment


PIER REPAIR
Cracked, spalled, and chipped were occurred in pier structure of PT. Petrokimia
Gresik.
a. Cracking and Spalling
Cracking occurs at the plate, beam, pier head and pier. This repair method aims
to fill the cracked concrete with Emaco Nanocrete R4 and Resin material
Concresive 2525, Figure 6 and 7.
Ultimate Moment Service Moment Nominal Moment ( Mn)
Nominal Moment ( Mn)
(Mu) (Ms) without FRP with FRP
2244.46 kNm 1549.65 kNm 578.157 kNm 3076.622 kNm 2 layer
1316.004 kNm 963.017 kNm 755.308 kNm 3411.12 kNm 1 layer
1192.16 kNm 914.096 kNm 578.157 kNm 2447.735 kNm 1 layer
3009.9 kNm 2191 kNm 585.258 kNm 3186.263 kNm 1 layer
450 mm x 1550 mm
500 mm x 1400 mm
1000 mm x 1200 mm
Number of Layer FRP Beam Size
500 mm x 1200 mm

Figure 6. Injection Process
b. Chipped
This repair method aims
with Special cement
2525
[2]
, Figure 8.
c. Wrapping Beams
The beam dimensions
using CFRP Mbrace CF 230/4900
improved with FRP Mbrace Laminates 165/2500
material is applied.

QUALITY CONTROL
Quality control (QC) is intended
retrofitting is in conformity
standardized QC will result in dispute among owner, consultant, and applicator.
Equipment such as Ultra
usually used for patching, grouting, and injection. While pull
for the coherence between


9
Injection Process Figure 7. Chipped on the beam Figure 8.
aims to improve the chipped concrete elements
MASTERFLOW 830
[2]
and Resin material
Beams with FRP
dimensions 450x1550, 500x1200, 500x1400 were strengthened
Mbrace CF 230/4900
[2]
, while for the beam with 100x1200 were
Mbrace Laminates 165/2500
[2]
after 2525

is intended to see whether the implementation of
is in conformity with existing standards. Without applying
standardized QC will result in dispute among owner, consultant, and applicator.
Ultra Sonic Pulse Velocity meters/UPV and core drill are
usually used for patching, grouting, and injection. While pull-off test is the QC
between 2525 Concresive resin material used

Figure 8. Grouting Process
elements by grouting
material Concresive
were strengthened
, while for the beam with 100x1200 were
2525 Concresive resin
whether the implementation of repair and
Without applying
standardized QC will result in dispute among owner, consultant, and applicator.
and core drill are
off test is the QC
used to bond FRP.
10

CONCLUSION AND STUDY IMPACT
a. The results of visual observations revealed structural deterioration as shown
in Table 2.
Table 2: Percentage Rate of Structure Damage

b. Most of the beams on the structure has been cracked, but the capacity of
cross-section is still above the ultimate moment, meaning that the condition
of the structure is no longer elastic.
c. Advanced material technology has proven its ability in strengthening
concrete structures without major disturbance to the daily operational of the
pier. This can contribute to the acceleration of economic development in a
region with port infrastructures such as North Sumatra. However, with more
than 90% of local content of this material but still high price, is a challenge
for future research.
REFERENCES
1. Vijay, P.V., Hota Gangarao, Narendra Taly. Reinforced Concrete Design
With FRP Composites. CRC Press. New York. 2006.
2. PT. BASF Indonesia. Product Selection Guide Building Systems.
Jakarta. 2011.
3. SNI 03-2847-2002 Tata Cara Perhitungan Struktur Beton untuk
Bangunan Gedung
4. Bank, L.C. (2005). Mechanically-Fastened FRP (MF-FRP) A Viable
Alternative fo Strengthening RC Member, FRP Composites in Civil
Engineering CICE 2004 Seracino (ed), pp. 3-14.
Mild Medium Weight Mild Medium Weight
19.70% 25.76% 3.03%
Structure Element
Old Concrete New Concrete
Plate - - - - - -
Beam 7.95% 3.98% - 21.40% 15.60% 0.61%
Pier Head 9.52% 4.76% - 24.76% 7.62% -
Cross Beam 19.70% 25.76% -