MODULE 3

LIFECYCLE OF BUILDINGS
DAMAGES & REPAIRS, AND
RETROFITS OF STRUCTURES

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MODULE 3
TYPES OF REPAIRS

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 Overview
• Introduction to Repair- Repair methodology
• Materials for crack repair
• Crack repair techniques
• Cracks repair by routing and sealing Crack repair by stitching
• Cracking repair by prestressing steel Grouting
• Cracking repair by grouting
• Column jacketing
• Beam jacketing
• Causes of damage in masonry building

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 REPAIR OF STRUCTURES
Repair: To bring back the position of the structure to its previous
condition so it gives performance same as previously.
It doesn’t cover the strength aspect of the structures.

Some examples of repair are:

• Replastering of any wall if required
• Repairing of damaged flooring
• Repair of door and window
• Checking or repairing of pipe line connections, gas line connections
and plumbing serveries.
• Relaying disturbed roof tiles
Decoration of structure,Painting,White Washing

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 REPAIR METHODOLOGY
• Evaluation
• Relating observation to causes
• Selecting methods and materials
• Preparation of drawings and specifications
• Selection of a contractor
• Execution of the work
• Quality Control

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 MATERIALS FOR CRACK REPAIR
The various materials used for repairs of cracks are:
• Cement Slurry
• Cement Mortar
• Epoxy resin
• Polymer Modified Cementitious Products

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 CRACK REPAIR TECHNIQUES
1) Epoxy-injection Grouting
2) Routing and Sealing
3) Stitching
4) Providing additional Reinforcement
5) Drilling and plugging
6) Prestressing steel
7) Grouting
8) Column Jacketing
9) Beam Jacketing
10) Plate Bonding

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 CRACK REPAIR TECHNIQUES
1. Epoxy-injection Grouting

• Cracks as narrow as 0.002 in. (0.05 mm) can be bonded by the

injection of epoxy. The technique generally consists of establishing
entry and venting ports at close intervals along the cracks, sealing
the crack on exposed surfaces, and injecting the epoxy under pressure.
• Epoxy injection has been successfully used in the repair of cracks
in buildings, bridges, dams, and other types of concrete
structures. However, unless the cause of the cracking has been
corrected, it will probably recur near the original crack.

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 CRACK REPAIR TECHNIQUES
The general procedure are:
Clean the cracks:
• The first step is to clean the cracks that have been contaminated; to
the extent this is possible and practical.
• Contaminants such as oil, grease, dirt, or fine particles of
concrete prevent epoxy penetration and bonding, and reduce the
effectiveness of repairs. Preferably, contamination should be removed
by vacuuming or flushing with water or other specially effective cleaning
solutions.
Seal the surfaces:
• Surface cracks should be sealed to keep the epoxy from leaking
out before it has gelled.
• A surface can be sealed by applying an epoxy, polyester, or
other appropriate sealing material to the surface of the crack and
allowing it to harden.
• If a permanent glossy appearance along the crack is objectionable and
if high injection pressure is not required, a strippable plastic surface
sealer may be applied along the face of the crack.
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 CRACK REPAIR TECHNIQUES
When the job is completed, the surface sealer can be stripped away
to expose the gloss-free surface. Cementitious seals can also be used
where appearance of the completed work is important. If extremely high
injection pressures are needed, the crack can be cut out to a depth of 1/2
in. (13 mm) and width of about 3/4 in. (20 mm) in a V-shape, filled with
an epoxy, and struck off flush with the surface.
Install the entry and venting ports. Two methods are in general use:

Fittings inserted into drilled holes:

• This method was the first to be used, and is often used in conjunction
with V-grooving of the cracks. The method entails drilling a hole into the
crack, approximately 3/4 in. (20 mm) in diameter and 1/2 to 1 in. (13 to
25 mm) below the apex of the V grooved section.
Bonded flush fitting:
• When the cracks are not V grooved , a method frequently used to provide
an entry port is to bond a fitting flush with the concrete face over the crack.
The flush fitting has an opening at the top for the adhesive to enter
and a flange at the bottom that is bonded to the
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concrete.
 CRACK REPAIR TECHNIQUES
Mix the epoxy: This is done either by batch or continuous methods.
In batch mixing, the adhesive components are premixed according to
the manufacturers instructions, usually with the use of a mechanical stirrer,
like a paint mixing paddle. Care must be taken to mix only the amount of
adhesive that can be used prior to commencement of gelling of the material.

Inject the epoxy: Hydraulic pumps, paint pressure pots, or air-

actuated caulking guns may be used. The pressure used for
injection must be selected carefully. Increased pressure often does little
to accelerate the rate of injection. If the crack is vertical or inclined, the
injection process should begin by pumping epoxy into the entry port at
the lowest elevation until the epoxy level reaches the entry port above.
For horizontal cracks, the injection should proceed from one end of the
crack to the other in the same manner. The crack is full if the pressure can
be maintained. If the pressure can not be maintained the epoxy is still
flowing into unfilled portions or leaking out of the crack.

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 CRACK REPAIR TECHNIQUES
Remove the surface seal: After the injected epoxy has cured, the
surface seal should be removed by grinding or other means as appropriate.

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 CRACK REPAIRS
2. BY ROUTING AND SEALING

• The Crack sealers should ensure the structural integrity and

service ability. In addition they provide protection from the ingress
of harmful liquids and gases.
• Routing and sealing of cracks can be used in condition requiring
remedial repair and where structural repair is not necessary. The
method consists of enlarging remedial repair and where structural
repair is not necessary. The method consists of enlarging the crack
along its length on the exposed surface, called chasing or routing,
and sealing it with a suitable joint sealant.

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 CRACK REPAIRS
2. BY ROUTING AND SEALING

• This is a common technique for crack treatment and is relatively simple

in comparison to the procedures and the training required for
epoxy injection. The procedure is most applicable to flat horizontal
surfaces such as floors and pavements. However, this
method can be accomplished on vertical surfaces as well as on
curved surfaces.
• This method is used to repair both fine pattern cracks and larger,
isolated cracks. A common and effective use is for waterproofing
by sealing cracks on the concrete surface where water stands, or
where hydrostatic pressure is applied.

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 CRACK REPAIRS
2. BY ROUTING AND SEALING

• The sealant may be of several materials, including epoxies,

silicones, urethanes, polysulfides, asphaltic materials polymer
mortars. Cement grouts should be avoided due to the likelihood of
cracking. For floors, the sealant should be sufficiently rigid to support
the anticipated traffic.
• The procedure consists of preparing a groove at the surface ranging
in depth, typically from 6 to 25 mm. A concrete saw, hand tools
or pneumatic tools may be used. This groove is then cleaned by
plastic or sir blasting and allowed to dry. A sealant is placed into the dry
groove and allowed to cure.

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REPAIR BY ROUTING AND SEALING

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CRACKS REPAIR BY ROUTING AND SEALING

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 3. Crack repair by stitching
• The stitching procedure consists of drilling holes on both sides of
the cracks, cleaning the holes and anchoring the legs of the stitching
dogs that span the crack, which either a non-shrink grout or an epoxy-
resin- based bonding system. The stitching dogs should be variable
in length and orientation or both, and should be so located that
the tension transmitted across the crack is not applied to a single
plane but spread over area.
• Stitching may be used when tensile strength must be
reestablished across major cracks. Stitching a crack tends to stiffen
the structure and the stiffening may increase the overall structural
restraint, causing the concrete to crack elsewhere.

REPAIR OF CRACK BY STITCHING

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https://www.slideshare.net/NayanaD123/crack-repair-techniques/10?src=clipshare
Crack repair by stitching
4. Providing Additional Reinforcement
• The cracked reinforced concrete bridge gird can be successfully
repaired by using epoxy injection and reinforcing bars.
• This techniques consists of sealings the crack, drilling holes of 20
mm diameter that intersect the crack plane at approximately 90 0,
filling the hole and crack with injected epoxy and placing a
reinforcing bar into drilled hole. Typically, 12 to 16 mm diameter bars
extending at least 500 mm on each side of the crack are used.
• The epoxy bonds the bar to the sides of the hole. The epoxy used to
re- bond the crack should have a very low viscosity.

Repair by providing additional steel

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 5. Crack Repair by Drilling and Plugging
• This method consists of drilling down
the length of the crack and grouting it
to form a key. A hole, typically 50 to
75 mm in diameter should be drilled,
centered on and the following the
crack. The drilled hole is then
cleaned, made tight and filled with
grout. The grout key prevents
transverse movements of the sections
of concrete adjacent to the crack.
The key will also reduce heavy
leakage through the crack and loss
of soil from behind a leaking wall.
• When structural strength is not
the criteria but water-
tightness is essential, the drilled
hole, should be filled with a
resilient material of low modulus in CRACK REPAIR BY DRILLING AND PLUGGING
lieu of grout. If the keying effect is
essential, the resilient material
can be placed in a second hole,
the first being grouted.
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6. Crack Repair by Pre-stressing Steel
• When a major portion of a
member is to be strengthened, or
a crack is to be closed, post-
tensioning is often the desirable
solution.

• The technique uses prestressing

strands or bars to apply a
compressive force. Adequate
anchorage must be provided for
the prestressing steel.

• The method of correction crack

in slab and beam.

TO CORRECT CRACKING OF SLAB

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 7. Grouting
Grouting is a process of injecting mixture of cement, sand water at
high pressure in the cracks, joints, voids etc.

Purpose of grouting:

• To strengthen the porous Concrete

• To prevent the seepage in dam and water retaining structures
• To reduce uplift pressure below dam
• To fill the cracks in concrete structure

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Grouting
7. Grouting
PROCEDURE FOR GROUTING
Drilling of Grouting holes:
For drilling grouting holes, equipment's like jack hammer, diamond drill,
shot drill etc are used. The choice of type of drilling equipment depends
upon the type of stone, size of hole and depth of hole.

Arrangement of grout pipes:

Grout pipes of 4 to 5 cm dia and 45 to 90 cm length are inserted in the
grout holes. The space surrounding the pipe is filled with cement mortar.
The top end of the pipe is connected to the pump.

Cleaning of cracks:
Before injecting grout mixture in the cracks, it is necessary to clean
the cracks.

Inserting grout in holes:

Normally grout is inserted in the holes at a pressure 0.65kg/cm2 per m depth
hole. 25
Grouting Procedure for Repair of Cracks in Concrete
Structures
7. Grouting
TYPES OF GROUTING

1. Consolidation Grouting:
This type of grouting is used for shallow depth grouting
holes. Normally pressure below 3 kg/cm2 is known as low pressure
grouting.
2. Stage grouting:
When thick layers are to be grouted the total thickness of layer is divided
into stages of 1m each and grouting of each layer is carried out one
by one. Grouting of upper layer is started only after the grout in the lower
layer had properly set.

3. Curtain Grouting:
This type of grouting is done to prevent the seepage of water
below foundation of dam. Grouting holes are drilled in the upstream side of
dam in the bed rock and impermeable grout wall is created. It will
prevent seepage of water through dam foundation.
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7. Grouting
Based on grouting material used, there are three methods:

• Portland Cement Grouting

• Chemical Grouting
• Epoxy Grouting

PORTLAND CEMENT GROUTING CHEMICAL GROUTING EPOXY GROUTING

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 7.a. Portland Cement Grouting
• Wide Cracks, particularly in gravity dams and thick walls may be
repaired by filling with portland cement grout.
• This method is effective in preventing water leakage, but will
not structurally bond cracking sections.
The procedure consists of:
• Cleaning the concrete along the crack by air jetting or water jetting
• Installing grout at suitable intervals, sealing the crack between the
seats with sealant
• Flushing the crack to clean it and test the seal and then grouting
the whole area.
• Grout mixtures may contain cement and water or cement plus sand
and water, depending upon the width of the crack.
• Water reducers or admixtures may be used to improve the properties
of the grout.
• For large volumes, a pump is used and for small volumes, a
manual injection gun may be used.
• After the crack is filled, the pressure should be maintained to
ensure proper penetration of grout.
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 7.b.Chemical Grouting
• Chemicals used for grouting are sodium silicates, urethanes
and acrylamides.
• Two or more chemicals are combined to form gel, a solid precipitate or
a foam as opposed to cement grouts that consists of suspension of
solids particles in a fluid.
• The advantages of chemical grouts include applicability in
moist environments and their ability to be applied in very fine cracks.

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 7.c. Epoxy Grouting
Epoxy grout consists of epoxy resin, epoxy hardener and sand/aggregates. In fact, there are various
types of resin used in construction industry like epoxy, polyester, polyurethane etc. Though epoxy
grout appears to imply the presence of cement material by its name, it does not contain any
cement at all. On the other hand, epoxy hardener serves to initiate the hardening process of epoxy
grout. It is commonly used for repairing hairline cracks and cavities in concrete structures and can
be adopted as primer or bonding agent.

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 8. Column Jacketing
Column Jacketing is done to
improve the load carrying
capacity of the column.
The procedure followed is:
• Open the footing of the column by
excavating soil around it.
• Remove the plaster from the surface of
the column.
• Make the surface of column concrete rough
by sand blasting.
• Remove the corroded bars by cutting them.
Add new bars from footing to the slab as per
the instruction of engineers.
• Apply bonding agent on the old concrete for
proper bonding between old and new concrete.
• Erect necessary shuttering around the column.
• Pour minimum M-25 grade of concrete, vibrate
and cure it.
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8. Column Jacketing

COLUMN JACKETING
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 9. Beam Jacketing
• Before taking up the strengthening of a beam, the
load acting on it should be reduced by removing the
flooring tiles and bed mortar from the slab.
• Props are erected to support the slab. After
clipping off the existing plaster on the beam,
additional longitudinal bars at the bottom of the
beam to- geather with new stirrups are provided.
• Stirrups are inserted by making holes from the
slab. The longitudinal bars are passed
BEAM JACKETING
through the supporting columns through holes
of appropriate diameter drilled in the columns.
• The spaces between bars and surrounding
holes are filled with epoxy grout to ensure a good
bond.

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9. Beam Jacketing
• The surface of old concrete
is cleaned by air jetting.
• Expanded wire mesh is fixed on
the two sides and bottom of the
beam.
• To ensure a good bond
between old concrete and new
polymer modified concrete, an
apoxy bond coat is applied to the
old concrete surface. SPRAYED CONCRETE
• The polymer modified mortar is
applied, while the bond coat is still
fresh. Sometimes 2 to 3 coats of
polymer modified mortar are
applied to achieve desired
thickness.
• The mortar is cured for
appropriate period in water.
Epoxy resin grout is injected in
the cracks along top of beams. SPRAYED CONCRETE
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10. Plate Bonding – Carbon Fibre
Carbon fibre fabric is now also used to strengthen columns and beams using a wrapping
technique. Single or multiple layers of uni or bi-directional fabric are impregnated with resin
adhesive and applied to sections such as beams and columns to improve strength.
This plate bonding system is also totally corrosion resistant and provides a long term
maintenance-free solution, yet it is often incredibly cost effective versus traditional steel or
additional reinforced concrete strengthening and rebuilding options for the owner.

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Plate Bonding
 10. Plate Bonding – Steel Plates

This consist of connecting mile steel plates to concrete surfaces mechanically by

bolting or glowing with the epoxy as we can see here in this picture fixing a plates on
the concrete surface would enhance the flexure strength and the plates can be held
imposition by either bolting them to the concrete or fixing them using an epoxy.

So, what primarily is being done is that we have what we have in this method is that if
we have a concrete beam which has deteriorated, what we want to fix is mile steel
plate here and then if you apply load on this beam this plate takes all the tension. So,
this increases the load carrying capacity of the repaired beam now what has to be
ensured in this process is that this plate is properly held into position either by glowing
at the concrete surface or by appropriately encoring the plate into existing concrete
and that is what is mean by saying bolting or glowing with epoxy and we have a steel
plate which has been placed here for the tensile face we can place these plates even
on the shear faces and so on.
10. Plate Bonding – Steel Plates
CAUSES OF DAMAGE IN MASONRY BUILDING
• Heavy Weight and verystiff buildings, attracting large seismic
inertia forces.

• Very low tensile strength particularly with poor mortars

• Low shear strength
• Brittle behavior in tension as well as in compression
• Weak connection between wall and wall
• Weak connection between roof and wall
• Stress connection at corners of doors and windows
• Overall asymmetry in plan and elevation of buildings

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Source
Concrete Technology by: R.P. Rethaliya Atul Prakashan
Concrete Technology by . M.S. Shetty
Thank You
Images from google
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