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GUIDELINES
Prepared by the International Concrete Repair Institute December 2008
This document is intended as a voluntary guideline for the owner, design professional, and
concrete repair contractor. It is not intended to relieve the professional engineer or designer
of any responsibility for the specification of concrete repair methods, materials, or practices.
While we believe the information contained herein represents the proper means to achieve
quality results, the International Concrete Repair Institute must disclaim any liability or
responsibility to those who may choose to rely on all or any part of this guideline.
310.1R2008 Guide for Surface Preparation for the repair of Deteriorated Concrete resulting from reinforcing steel corrosion
Contents
1.0 Introduction...............................................................................................................................1
2.0 Definitions ................................................................................................................................1
3.0 Exposure of Reinforcing Steel...................................................................................................1
4.0 Anodic Ring (Halo) Effect..........................................................................................................2
5.0 Removal Geometry ..................................................................................................................2
6.0 Configuration of Repair Area . ..................................................................................................3
7.0 Concrete Removal/Surface Preparation....................................................................................3
7.1 Exposing and Undercutting of Reinforcing Steel...................................................................3
7.2 Preparation of the Repair Perimeter . ...................................................................................4
7.3 Cleaning of the Concrete Surface and Reinforcing Steel ......................................................4
8.0 Inspection and Repair of Reinforcing Steel . ............................................................................5
9.0 Final Surface Inspection ..........................................................................................................5
10.0 Special Conditions at Columns ................................................................................................6
11.0 Summary .................................................................................................................................7
12.0 References................................................................................................................................7
12.1 Referenced Standards and Reports.....................................................................................7
Guide for Surface Preparation for the repair of Deteriorated Concrete resulting from reinforcing steel corrosion 310.1R2008
310.1R2008 Guide for Surface Preparation for the repair of Deteriorated Concrete resulting from reinforcing steel corrosion
1.0 Introduction typically extends to a depth of 0.13 to 0.38 in.
(3 to 10 mm) and, if not removed, frequently
This guideline provides owners, design profes results in lower bond strengths as compared with
sionals, contractors, and other interested parties surfaces prepared with nonimpact methods.
with a recommended practice for the removal of Carbonation: The conversion of calcium ions
deteriorated concrete caused by the corrosion of in hardened cementitious materials to calcium
reinforcing steel, including the preparation of the carbonate by reaction with atmospheric carbon
removal cavity to provide a clean sound surface dioxide. Carbonation reduces the pH of the
to bond a repair material. concrete and its ability to protect reinforcing steel
This guideline outlines removal geometry, and embedded metal items from corrosion.
configuration, removal process, edge preparation, Chloride contamination: Contamination of
reinforcement repair, surface preparation, and concrete with chloride ions commonly used in
inspection prior to placing a repair material. An deicing salts and accelerating admixtures such as
engineer should evaluate the impact of concrete calcium chloride and sodium chloride. Chloride
removal on structural capacity prior to performing contamination above thethreshold for corrosion
concrete removal and repair. The repair methods can result in corrosion of the reinforcing steel.
involve saw cutting and concrete removal using Chloride threshold: The amount of chloride
impact tools, hydrodemolition, and other removal required to initiate steel corrosion in reinforced
techniques. Special caution should be taken to concrete under a given set of exposure conditions;
locate and avoid cutting or damaging embedded commonly expressed in percent of chloride ion
reinforcing bars, prestressing strands, post- by mass of cement.
tensioning tendons, or electrical conduits. Cutting Corrosion: Degradation of concrete or steel
into these items can be life threatening and may reinforcement caused by electrochemical or
significantly affect structural integrity. chemical attack.
This guideline also contains a discussion of Microcrack: A crack too small to be seen with
concrete removal and preparation for the repair the unaided eye.
of columns where the concrete is in compression. Tensile pulloff test: A test to determine the
Special consideration must be given to the repair unit stress, applied in direct tension, required to
of concrete in compression as the load-carrying separate a hardened repair material from the
capacity of the element may be permanently existing concrete substrate. The test may also be
compromised during the concrete removal and used to determine the maximum unit stress that
preparation process. the existing concrete substrate is capable of
While the procedures outlined herein have resisting under axial tensile loading and the near-
been used to successfully remove concrete and surface tensile strength of a prepared surface
prepare the removal cavity on many projects, the (refer to ICRI Technical Guideline No. 210.3
requirements for each project will vary due to 2004 [formerly No. 03739] and ASTM C1583).
many different factors. Each project should be Substrate: The layer immediately under a
evaluated individually to ascertain the applicability layer of different material to which it is typically
of the procedures described herein. Refer to ACI bonded; an existing concrete surface that receives
506R-05, Guide to Shotcrete for surface prepar an overlay, partial-depth repair, protective coating,
ation prior to shotcrete application. or some other maintenance or repair procedure.
Guide for Surface Preparation for the repair of Deteriorated Concrete resulting from reinforcing steel corrosion 310.1R2008 -
repair cavity is achieved by providing a uniform can result in accelerated corrosion of the
chemical environment around the reinforcing surrounding reinforcing steel leading to future
steel. If noncorroded reinforcing steel is exposed concrete deterioration. To assess existing concrete
and the concrete is chloride contaminated, conditions beyond the repair area, chloride
removal of the concrete around the reinforcing content and pH of the concrete at the level of the
should occur or other corrosion-reducing means reinforcing steel should be determined. Where
should be considered. Reinforcing steel partially the chloride content exceeds the threshold level
embedded in chloride-contaminated concrete is for the initiation of corrosion or where the
susceptible to future accelerated corrosion. reinforcing steel is susceptible to corrosion as a
If, for structural reasons, the concrete cannot result of carbonation, a corrosion inhibiting
be completely removed from around the corroded system should be considered to minimize future
reinforcing steel or if a corrosion inhibiting corrosion. Other measures may also be considered,
system is not used, the repair may be compromised such as the application of sealers and coatings, to
due to continued corrosion. If there is a potential slow the corrosion process. In severely chloride-
trade-off between durability and structural contaminated or carbonated concrete, the
capacity, structural capacity should always take complete removal and replacement of the
priority. When reinforcing steel is not fully contaminated concrete at and beyond the repair
exposed through the concrete removal and area may be necessary to provide a successful
preparation process, alternative corrosion inhib long-term repair.
iting systems should be considered. These
systems may include use of corrosion inhibitors,
sacrificial anodes, or cathodic protection. 5.0 Removal
Geometry
4.0 Anodic Ring Examples of the removal geometry for several
- 310.1R2008 Guide for Surface Preparation for the repair of Deteriorated Concrete resulting from reinforcing steel corrosion
6.0 Configuration
of Repair Area
Deteriorated and delaminated concrete should be
located and marked prior to starting the removal
process. Delaminated concrete can be located using
sounding or other suitable techniques. The repair
area should extend a minimum of 6 in. (152 mm)
beyond the actual delaminated concrete. Note that
during concrete removal, repair areas can grow
Fig. 5.3: Beam or rib repair, elevation in size beyond the areas identified due to incipient
delaminations that are not readily identifiable
by sounding. Repair configurations should be
kept as simple as possible, preferably square or
rectangular with square corners (Fig. 6.1). This may
result in the removal of sound concrete. Reentrant
corners should be minimized or avoided, as they
are susceptible to cracking.
7.0 Concrete
Fig. 5.5: Column repair, elevation
Removal/Surface
Preparation
7.1 Exposing and
Undercutting of
Reinforcing Steel
Remove concrete from the marked areas and
undercut exposed reinforcing steel (Fig. 7.1) using
impact breakers, hydrodemolition, or another
suitable method. Undercutting will provide
clearance under the reinforcing steel for cleaning
and full bar circumference bonding to the repair
Fig. 5.6: Column repair, section material and the surrounding concrete. Bonding
Guide for Surface Preparation for the repair of Deteriorated Concrete resulting from reinforcing steel corrosion 310.1R2008 -
the repair material to the full circumference of the to minimize damage to the substrate, reinforcing
reinforcing steel will secure the repair structurally. steel, and surrounding concrete.
Provide a minimum of 0.75 in. (19 mm) clearance Concrete removal should extend along the
between exposed reinforcing steel and surrounding reinforcing steel until there is no further delam
concrete or 0.25 in. (6 mm) larger than the coarse ination, cracking, or significant corrosion and the
aggregate in the repair material, whichever is reinforcing steel is well bonded to the surrounding
greater. Sound concrete may have to be removed concrete. Care should be taken to avoid significant
to provide proper clearance around the reinforcing and sudden changes in the depth of concrete
steel. If impact breakers are used for partial depth removal, as the repair material is more susceptible
concrete removal, the breaker should not exceed to cracking at these locations.
30 lb (12 kg). A 15 lb (7 kg) breaker is preferred If noncorroded reinforcing steel is exposed
during the removal process, care should be taken
to not damage the bond to the surrounding
concrete. If the bond between the reinforcing
steel and concrete is broken, undercutting of
the reinforcing steel is required.
Remove all deteriorated concrete and additional
concrete as required to provide the proper
configuration and/or the minimum required
thickness of repair material as required by the
manufacturer of the repair material and/or the
project specifications.
- 310.1R2008 Guide for Surface Preparation for the repair of Deteriorated Concrete resulting from reinforcing steel corrosion
saw-cut edge of the repair area should also be damaged/deteriorated steel or placing supple
blasted to roughen the polished vertical surface mental reinforcing steel in the affected section
caused by the saw-cutting. (Fig. 8.1). Supplemental reinforcing steel may be
All concrete, corrosion products, and scale lap-spliced or mechanically spliced to existing
should be removed from the reinforcing steel by reinforcing steel. The supplemental reinforcing
oil-free abrasive blasting or high-pressure water steel should extend (lap length) beyond the
blasting. Verify that the reinforcing steel and damaged/deteriorated area in accordance with
concrete surface are free from dirt, oil, cement ACI 318, Building Code Requirements for
fines (slurry), or any material that may interfere Structural Concrete.
with the bond of the repair material. Inspect the
repair cavity to verify that all delaminations and
deterioration have been removed. If hydro
demolition is used, cement fines (slurry) must be
9.0 Final Surface
completely removed from the repair surface. A
tightly-bonded light rust build-up on the reinforcing
Inspection
Immediately prior to placing the repair material,
surface is usually not detrimental to bond. If a inspect the repair cavity to verify that all bond-
protective coating is applied to the reinforcing inhibiting materials (dirt, concrete slurry, loosely
steel, follow the coating manufacturers recom bonded aggregates, or any material that may
mendations for steel surface preparation. interfere with the bond of the repair material to the
existing concrete) have been removed. If bond-
Guide for Surface Preparation for the repair of Deteriorated Concrete resulting from reinforcing steel corrosion 310.1R2008 -
10.0 Special Condition at Columns
Fig. 10.1: Column load path Fig. 10.2a: Column repair Fig. 10.3: Column load
path following repair
- 310.1R2008 Guide for Surface Preparation for the repair of Deteriorated Concrete resulting from reinforcing steel corrosion
Undercutting of reinforcement is a best practice
in tensile zones of concrete. In columns, the
11.0 Summary
primary loading condition is compression. From The repair of deteriorated concrete resulting from
a design perspective, the concrete section reinforcing steel corrosion is necessary to extend
contained within the reinforcing cage is considered the service life of the structure. Performing
to carry the compressive loads (Fig. 10.1). The concrete repairs using industry-best practices will
concrete outside of the reinforcement is considered ensure the success and longevity of the repair.
as protective concrete cover for fire and corrosion Understanding the existing conditions and cause
protection of the reinforcement. Removing the of corrosion will assist the engineer in specifying
concrete within the column reinforcing steel the type and extent of the repair required, and the
(Fig. 10.2) can greatly increase the compressive type of corrosion mitigation systems and/or
stress in the reinforcing steel and the remaining preventative measures that should be considered
concrete. Upon concrete removal, compressive to protect the structure from future deterioration.
load paths redistribute around the repair
(deteriorated) sections (Fig. 10.3). Depending on
the size of the concrete removal area behind the 12.0 References
column steel, buckling of the column vertical
reinforcing bars can occur. In the majority of 12.1 Referenced
cases, shoring systems will not unload the
compressive stress in the column section.
Standards and Reports
When new repair material is placed in the The following standards and reports were the
prepared area, the new material cures and most latest editions at the time this document was
materials undergo drying shrinkage, which results prepared. Because these documents are revised
in the new material being put into a tensile stress frequently, the reader is advised to contact the
state. The new material will not carry compressive proper sponsoring group if it is desired to refer
loads until the original concrete compresses further, to the latest version.
forcing the repair material into compression. If
further compression is beyond the capacity of the American Concrete Institute (ACI)
existing concrete, failure of the column may ACI 506R, Guide to Shotcrete
occur. This key concept affects the concrete
preparation process. In normal concrete repair ACI E706 (RAP 8), Installation of Embedded
(other than columns), removal of the concrete Galvanic Anodes
surrounding the corroding reinforcement (also
known as undercutting) is a normal and necessary American Society for Testing and
process to provide for a long-term durable repair. Materials (ASTM International)
To remove concrete around vertical reinforcing ASTM C1583, Standard Test Method for Tensile
steel in a column (removing concrete inside the Strength of Concrete Surfaces and the Bond
reinforcing bar cage) can cause the remaining Strength or Tensile Strength of Concrete Repair
concrete and/or reinforcement in the column to and Overlay Materials by Direct Tension (Pull-
become overstressed. From a structural point of off Method)
view, this condition may not be desirable. If
concrete is to be removed inside the reinforcement International Concrete Repair
cage, a qualified structural engineer should Institute (ICRI)
determine the impact of the repair on potential
reinforcement buckling and overall structural ICRI Concrete Repair Terminology
capacity of the column. Note that the discussion ICRI Technical Guideline No. 130.1R2008
in this section is also applicable in concept to (formerly No. 03735), Guide for Methods of
compression zone portions of other structural Measurement and Contract Types for Concrete
members such as beams, slabs, and walls (with Repair Work
or without compression reinforcement) where
on-going compressive stress exists and where ICRI Technical Guideline No. 210.3-2004
adequate shoring cannot be installed prior to (formerly No. 03739), Guide for Using In-Situ
repairs to prevent displacements and corresponding Tensile Pull-Off Tests to Evaluate Bond of
stress redistributions during repairs. Concrete Surface Materials
Guide for Surface Preparation for the repair of Deteriorated Concrete resulting from reinforcing steel corrosion 310.1R2008 -
ICRI Technical Guideline No. 310.32004
(formerly No. 03737), Guide for the Preparation
of Concrete Surfaces for Repair Using Hydro
demolition Methods
ASTM International
100 Barr Harbor Drive
West Conshohocken, PA 19428
www.astm.org
- 310.1R2008 Guide for Surface Preparation for the repair of Deteriorated Concrete resulting from reinforcing steel corrosion
3166 S. River Road, Suite 132
Des Plaines, IL 60018
Phone: 847-827-0830
Fax: 847-827-0832
Web site: www.icri.org
E-mail: info@icri.org