Silanes JH Clients

Repair Systems
27-28 March 2012

Jakarta
Özgür Afacan
Marketing Manager CS, ASEAN
Definitions
ACI 364.1
The following definitions are defined here as in ACI 116R:
Preservation-The process of maintaining a structure in its present condition and arresting

further deterioration
Rehabilitation-The process of repairing or modifying a structure to a desired useful condition
Repair-To replace or correct deteriorated, damaged, or faulty materials, components, or
elements of a structure
Restoration-The process of reestablishing the materials, form, and appearance of a structure
to those of a particular era of the structure
Strengthening-The process of increasing the load-resistance capacity of a structure or portion
thereof.
Analyzing the damage
ACI 364.1
The scope and methodology of a preliminary investigation can involve one or more of the
following steps, depending on the size and complexity of the project.
1. Review of plans, specifications, and construction records

2. Site observations of conditions
3. Measurement of geometry, deflections, displacements, cracks, and other damage
4. Nondestructive testing
5. Exploratory removal
6. Sampling, testing, and analysis
It should be noted that only a limited amount of investigation within each step is generally
required to establish the feasibility of the rehabilitation project. Detailed studies are generally
deferred until the detailed investigation phase, if such investigation is deemed
desirable.
Repair Scheme
Analysis Determination
Diagnosis
of Structure of Repair System
Crack Repair
Non
Structural Repair Strengthening
Structural Repair
Protection
Causes and Control of Cracking
Formwork movement
Construction
Movement Sub-grade movement
Plastic shrinkage
Before Plastic settlement
Hardening
Plastic
Autogenous shrinkage
Frost Premature Freezing

Damage Scaling, Crazing
CRACKS Drying shrinkage

Volume Thermal change
Instability
Creep
Design load / over load

After Structural /
Design / subgrade
Hardening Design
Fatigue
AAR / ASR / DEF
Physico -
Steel corrosion
Chemical
Freeze – thaw cycling
Cracking of plactic concrete

• Plastic shrinkage cracking



• Plastic settlement cracking

• Plastic settlement cracking
Cracking of the hardened concrete

• Drying skrinkage

• Drying skrinkage - Crazing

• Thermal Stresses

• Chemical reactions (Alkali – Silica Reaction)

• Weathering (D – Cracking)

• Corrosion of reinforcement

• Poor construction practices – adding more water

• Errors in design and detailing





• Externally applied loads – Vertical loads (live and dead)

• Externally applied loads – Seismic loads

• Foundation Settlements



• Externally applied loads – Shear Cracks

• Externally applied loads – Shear Cracks

• Externally applied loads
Shear Cracks
Evaluation of Cracking
Direct and indirect observation
• The locations and widths of cracks should be noted on a sketch of

the structure.
• Crack widths may also be estimated using a clear comparator card

having lines of specified width marked on the card.
Non destructive testing

• Nondestructive tests can be made to determine the presence of
internal cracks and voids and the depth of penetration of cracks
visible at the surface.
Test on concrete cores

• Significant information can be obtained from cores taken from
selected locations within the structure.
Reviewing of drawings and construction data

• The original structural design and reinforcement placing or other
shop drawings should be reviewed to confirm that the concrete
thickness and quality, along with installed reinforcing, meets or
exceeds strength and serviceability requirements noted in the
governing building code(s).
Structural Type of Cracks
Formwork movement
Sub-grade movement
Plastic shrinkage
Plastic settlement
Autogenous shrinkage
Premature Freezing
Scaling, Crazing
Design load / over load

Design / subgrade
Fatigue
Drying shrinkage
Thermal change
Creep
AAR / ASR / DEF

Steel corrosion
Repair Procedures
Selection of repair procedures – ACI 224-1R

• Restore and increase strength
• Restore and increase stiffness
• Improve functional performance
• Provide watertightness
• Improve appearance of the concrete surface
• Improve durability
• Corrosion repairs and protection
Repair Procedures
Concrete injection is used as a method for the

following principles defined in EN 1504-9:
• principle 1 [IP]: Protection against ingress and waterproofing;
 Filling cracks (method 1.4).
• principle 4 [SS]: Structural strengthening;
 Injecting cracks, voids or interstices (method 4.5).

 Filling cracks, voids or interstices (method 4.6).
Repair Procedures
Concrete injection is used as a method for the

following principles defined in EN 1504-9:
• Injection is used to avoid the harmful consequences of voids

and cracks in concrete:
 to achieve impermeability and hence watertightness;

 to avoid penetration of aggressive agents that might induce
corrosion of steel reinforcement;
 to strengthen the structure by strengthening the concrete.
Repair Procedures
Corrosion repairs and protection
AAR / ASR / DEF
Steel corrosion
Repair Procedures
Improve functional performance
Thermal change
Drying shrinkage
Design / subgrade
Repair Procedures
Restore and increase strength / stiffness
Structural repair of the cracks

Structural Repair of the Cracks
Selection of repair techniques
• Epoxy injection
• High pressure injection

• Low pressure injection
• Gravity feed with epoxy

Epoxy Injection
• Selection of the material, EN 1504-5
Epoxy Injection
• Surface preparation – Preparing the crack surface
Epoxy Injection
• Selecting the entry ports / packers / nipples
• Surface mounted ports

• Socket type ports
Epoxy Injection
• Surface mounted entry ports / packers / nipples
Epoxy Injection
• Socket type entry ports / packers – For high pressure
Epoxy Injection
• Drilling holes for entry ports/packers – For high pressure
injection
Epoxy Injection
• Entry ports holes
Epoxy Injection
• Entry ports holes
Epoxy Injection
• Cleaning the packer holes
Epoxy Injection
• Placing and fixing the packers
Epoxy Injection
• Installing the cap seal – Use proper Concresive®,
Masterflow® Resins
Epoxy Injection
• Installing the cap seal – Use proper Concresive®,
Masterflow® Resins
Epoxy Injection
• Injection Pumps for 1 K - Concresive® 1366
Epoxy Injection
• Adjusting the pressure and injection with 1 K
Epoxy Injection
• Injection application with 1K pumps
Epoxy Injection
• Injection with hand held pumps
Epoxy Injection
• Cleaning the crack surface– For low pressure injection
Epoxy Injection
• Placing the entry ports/packers – For low pressure
injection
Epoxy Injection
• Placing the entry ports/packers – For low pressure
injection
Epoxy Injection
• Placing the entry ports/hoses – For low pressure injection
Epoxy Injection
• Cap seal application with Masterseal® 590 / Waterplug® –
For low pressure injection
Epoxy Injection
• Creating entry ports by using tapes – For low pressure
injection
Epoxy Injection
• Cap sealing of the crack – For low pressure injection
Epoxy Injection
• Injection Pumps for 2 K
Concresive® 1380
Epoxy Injection
• Preparing the injection pump – For low pressure injection
Epoxy Injection
• Injection application with Concresive® 1380 – For low
pressure injection
Epoxy Injection
• Injection application with Concresive® 1380 – For low
pressure injection
Gravity Feed with Epoxy

• Saw cut grooves and cleaning

• Inserting screed ties for stitching


EN1504, pt. 3
Product performance requirements for repairs
Performance requirements for cementitious structural and non-structural repair products*
Performance Test Requirement (Table 3 in EN 1504 part 3)
characteristics method Structural Non-Structural
Class R4 Class R3 Class R2 Class R1
The norm does not imply good, better or best quality.

Compressive strength EN12190 ≥ 45 Mpa ≥ 25 Mpa ≥ 15 Mpa ≥ 10 Mpa
Chloride ion content ≤ 0.05% ≤ 0.05%

It indicates which repair mortar class should be used
Adhesive bond
EN1015-17
EN1542 ≥ 2 Mpa ≥ 1.5 Mpa ≥ 0.8 Mpa
for different applications based on the fundamental Bond strength after test No
principle of repairing “like with like”

Restrained shrinkage/expansion requirement
EN12617-4 ≥ 2 Mpa ≥ 1.5 Mpa ≥ 0.8 Mpa
Durability - Carbonation Resistance EN13295 dk ≤ control concrete No requirement (1)
Durability - Thermal compatibility Bond strength after 50 cycles Visual

i.e. Freeze/thaw high strength concrete
EN12617-4
with ≥high
2 Mpa
strength/E-modulus
≥ 1.5 Mpa ≥ 0.8 Mpa
mortar
inspection
medium strength concrete with medium

Durability - Thermal compatibility
E-modulus
Bond strength after 30 cycles repairVisual
material
low strength concrete
Thunder/Shower
EN12617-4with lower
≥ 2 Mpa strength≥ 1.5 Mpa repair ≥ 0.8mortar
Mpa
inspection
Durability - Thermal compatibility Bond strength after 30 cycles Visual

Dry Cycling inspection
EN12617-4 ≥ 2 Mpa ≥ 1.5 Mpa ≥ 0.8 Mpa
Elastic Modulus EN13412 ≥ 20 Gpa ≥ 15 Gpa No requirement
Class I: > 40 units wet tested Class I: > 40 units wet tested
Skid resistance Class II: > 40 units dry tested Class II: > 40 units dry tested
EN13036-4 Class III: > 55 units wet tested Class III: > 55 units wet tested
Capillary absorption EN13057 ≤ 0.5 kg.m-2.h-0.5 ≤ 0.5 kg.m-2.h0.5 No requirement
(1) No carbonation resistance required if covered by carbonation resistant coating

09.11.201075
Repair Systems
Structural Repairs
 Emaco® Nanocrete R4
 Emaco® T288
 Emaco® S322M
Substrate Preparation
Common Techniques
Manual methods: Mechanical methods:

 Needle gun  Grinding
 Grinding  Shot blasting
 Mace and chisel  Sand blasting
 Brushing  High pressure water jetting
Chemical methods: Thermal methods:

 Chemical (soap) cleaning  Thermal shock
 Acid etching
27/03/201277
Recommended Procedures
Reinforcing steel Concrete
Sand Blasting
Big
Sand blasting Grinding
Surfaces
High pressure water jetting
Small
Brushing Hand-held breakers
Surfaces
27/03/2012 78
Substrate preparation Substrate preparation
Chiselling Hand held breakers
Suitable for small areas

Widely available
Can be used in limited work space
Disadvantages:
Damages surface (microcracks)
White fingers – HAVS Syndrome
Needs to be followed by non-impact
method (e.g. with sand blasting or
water jetting)
Yield: 1 - 5 m2/h
27/03/2012 79
Brushing
27/03/201280
Sandblasting
Efficient method for roughening the

surface and exposing aggregate
Cleans reinforcing steel
Removes surface contamination
Disadvantages:
Dry sandblasting procedure produces
large volumes of dust
Wet sandblasting is slow and is difficult to
operate within legal emission
requirements
27/03/2012 81
High Water Pressure
Applicable for removal of larger concrete

sections and surfaces. Up to 150mm High Pressure Cleaning Movie
easily.
Yield: 5 - 25 m2/h
Advantages:
No damage to concrete
Partial cleaning of steel rebar Sa 2
Disadvantages:
Not every area is suitable due to the large
quantity of water / humidity
Waste water
27/03/2012 82
Scarifier
Advantages:
Easy removal of coatings
Good concrete removal
Adjustment of depth
Disadvantages:
Removal not suitable where steel
reinforcement is placed
Can damage concrete  microcracking
Noise, vibration, and dust are produced
water jetting)
Yield: 2 - 75 m2/h (depending on equipment)
27/03/201283
Substrate preparation
Horizontal shot blasting
Advantages:
Uniform texture
Excellent yield
For EP/PU coatings and self levelling
application
Disadvantages:
Only horizontal surfaces
 Yield: 20 - 400 m2/h (depending on

equipment)
27/03/2012 84
Substrate preparation
Shot/Grit blasting
Advantages:
Uniform texture
Good yield
For coatings and surface repair
application
Disadvantages:
Extra precautions for inhalation
Dust formation
 Yield: 5 - 20 m2/h (depending on Silicosis
equipment)
Application Movie
(robot)
27/03/2012 85
Grinding
Advantages:
Reduces roughness
Removes laitance
Disadvantages:
Does not create rough surface
Can block concrete pores
water jetting)
Yield: 2 - 75 m2/h (depending on
equipment)
27/03/2012 86
Thermal Shock
Advantages:
Removal of fat and oils
Removal of linings and elastomers
Disadvantages:
Fumes
Creates microcracks, even through
gravel/sand
water jetting)
Yield: 5 - 50 m2/h
27/03/2012 87
After this!  Cleaning required
Sweeping
Cleaning with water
Vacuuming
With pressurized air
27/03/201288
Removing damaged concrete (1)
Minimum clearance
15 mm
or
Grain size of repair product
Chloride
+ 5 mm
contamination
Minimum 50 mm
clearance along rebar
90º Angles
Chloride contamination
Minimum 20 mm clearance
around rebar
Expose steel if
corrosion evidence
27/03/201289
Proper edge preparation

90° Cut in depth = Minimal thickness of repair mortar
Example: Emaco Nanocrete R4

Thickness = 5 - 50 mm
 Cut in depth = 5 mm
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The simplest possible layouts:
27/03/201291
Repair Systems
Structural Repairs
 Substrate Preparations
• Saw-cut of the concrete
Repair Systems
Structural Repairs
• Removing the loose particles
Repair Systems
Structural Repairs
• Removing the loose particles
Repair Systems
Structural Repairs
• Proper substrates prior to repair
Repair Systems
Structural Repairs
Repair Systems
Structural Repairs
Repair Systems
Structural Repairs
• Cleaning the substrate
Repair Systems
Structural Repairs
• Preparing the epoxy based primer – Concresive
Repair Systems
Structural Repairs
• Priming the surfaces prior to repair application
Repair Systems
Structural Repairs
 Cement Based Structural Repair Mortars
• Material Preparations
Emaco Nanocrete R4
Ease of application
Easy mixing
Rather fluid consistency, but highly

thixotropic
Easy application/spraying with e.g. worm-

driven pump, thus long delivery length and
head
Easy application/finishing by hand

Emaco Nanocrete R4
Features
- Reduced crack tendency due to shrinkage compensation systems,

shrinkage reducing agents and PAN-fibres
- Highly thixotropic - can be applied up to 50 mm
- No need for secondary reinforcement
- High early and ultimate strengths
- High modulus and excellent adhesion to host concrete ensuring load transfer
- Excellent freeze/thaw resistance
- High carbonation resistance

Emaco Nanocrete R4
- Sulphate resistant Spray Application
Movie
- Very low permeability to water and chlorides
Repair Systems
Structural Repairs
• Application – Emaco Nanocrete R4
Repair Systems
Structural Repairs
Repair Systems
Structural Repairs
Repair Systems
Structural Repairs
Repair Systems
Structural Repairs
Repair Systems
Emaco Nanocrete R4 Application Movie

Structural Repairs
Repair Systems
Structural Repairs
• Application – Emaco T288
Repair Systems
Structural Repairs
• Fast Applications – Emaco T288
Non Structural Repair Systems
Surface re-profiling and non structural repairs.
 Emaco® Nanocrete FC
Repair Systems
Non structural repairs

• Shallow segregations
Repair Systems

• Shallow segregations
Repair Systems

• Inadequate cover concrete
Repair Systems
Non Structural Repairs / Surface preparation

• Mark the damaged area in rectangular shape and remove the
plastic inside the tie rod hole.
Repair Systems

• Removing residue and laitance
Repair Systems

• Cleaning of the substrate
Repair Systems
Non Structural Repairs

 Filling with mortar gun.
Repair Systems

 Finishing
Repair Systems

Emaco Nanocrete R2
Ease of application
Creamy, butter-like consistency
High thixotropic
Light weight
(1.8 kg/dm³ v. 2.2 kg/dm³)
High-build patch repair
Thin layer fairing coat
Fast setting
09.11.2010 122
Emaco Nanocrete R2
Features
- Smooth, creamy but non-slump mortar

- Excellent high build capacity
- 80 - 100 mm in horizontal or vertical applications in one layer,
- 70 – 80 mm overhead
- As large area fairing coat: minimum layer thickness of 3 mm

- Easy to create profiles and corners without formwork
- Multi-use: Fairing coat and patch repair mortar in one
- Fast setting: can be over-coated in only 4 hours
- Low modulus of elasticity
123
09.11.2010
Repair Systems

Emaco Nanocrete R2
Repair Systems

Emaco Nanocrete FC
Fields of application
For levelling and fine finishing of concrete

elements
For thin section reprofiling

As a pore filler material or for the repair of
honeycombs
As a blowhole filler in the prefab industry

For inside and outside use, on vertical or
overhead applications
Typically used on:

• Balconies
• Building facades
• Parapet walls
• Precast panels
126
09.11.2010
Emaco Nanocrete FC
Ease of application
FC Movie
Easy mixing
Very creamy consistency
Wide range in water demand allows to
adapt the consistency to the job to be done
Easy application by hand, easy finishing

Used as fairing coat in thickness from 0.5 to
7 mm in one layer.
Small edge reprofiling, blowhole or

honeycomb filling can be done up to a
thickness of 10 mm
Self-curing under most conditions

127
09.11.2010
BASF Construction Chemicals

Silanes JH Clients

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Repair Systems

27-28 March 2012

The following definitions are defined here as in ACI 116R:

Preservation-The process of maintaining a structure in its present condition and arresting

1. Review of plans, specifications, and construction records

Frost Premature Freezing

CRACKS Drying shrinkage

Design load / over load

Cracking of plactic concrete

Cracking of plactic concrete

Cracking of plactic concrete

Cracking of plactic concrete

Cracking of plactic concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Cracking of the hardened concrete

Direct and indirect observation

• The locations and widths of cracks should be noted on a sketch of

• Crack widths may also be estimated using a clear comparator card

Non destructive testing

Test on concrete cores

Reviewing of drawings and construction data

Design load / over load

AAR / ASR / DEF

Selection of repair procedures – ACI 224-1R

Concrete injection is used as a method for the

• principle 1 [IP]: Protection against ingress and waterproofing;

 Filling cracks (method 1.4).

• principle 4 [SS]: Structural strengthening;

 Injecting cracks, voids or interstices (method 4.5).

Concrete injection is used as a method for the

• Injection is used to avoid the harmful consequences of voids

 to achieve impermeability and hence watertightness;

Corrosion repairs and protection

Freeze – thaw cycling

AAR / ASR / DEF

Improve functional performance

Restore and increase strength / stiffness

Structural repair of the cracks

Selection of repair techniques

• High pressure injection

• Gravity feed with epoxy

• Surface mounted ports

Gravity Feed with Epoxy

Gravity Feed with Epoxy

Gravity Feed with Epoxy

Gravity Feed with Epoxy