SECTION 03740 CONCRETE REPAIRS

PART 1 GENERAL 1.1 A. DESCRIPTION This section covers the requirements for repair of deteriorated concrete. It includes removal of damaged concrete, cleaning and coating of exposed reinforcing bars, replacement of corroded reinforcement, concrete substrate surface preparation and bonding, placement and curing of repair materials. It also includes total and partial replacement of damaged concrete members. Related Work Specified Elsewhere: 1. 2. 3. 4. 5. 6. 1.2 Section 01420: Quality Assurance / Quality Control Section 03200: Concrete Reinforcement Section 03210: Epoxy Coated Concrete Reinforcement Section 03300: Cast-In-Place Concrete Section 07100: Waterproofing & Dampproofing Section 07110: Membrane Waterproofing for Concrete Structures

B.

APPLICABLE CODES & STANDARDS The codes and standards listed below are intended to provide an acceptable level of quality for materials and products. The requirements of the latest edition of these codes and standards shall apply. In case of conflict between these standards and the text of this specification, the specification requirements shall govern.

A. B.

MARAFIQ Building Codes ACI American Concrete Institute 1. 224.1R Causes, Evaluation and Repair of Cracks in Concrete Structures Recommended Practice for Concrete Formwork Use of Epoxy Compounds with Concrete Standard Specifications for Bonding Plastic Concrete to Hardened Concrete with a Multi-Component Epoxy Adhesive

2. 3. 4.

347 503 503.2

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503.4

Standard Specifications for Repairing Concrete with Epoxy Mortars Guide to Sealing Joints in Concrete Structures Recommended Practice for Shotcrete

6. 7. C.

504.R 506

ASTM American Society for Testing and Materials 1. C 109 Standard Test Method for Compressive Strength of Hydraulic Cement Mortars Standard Test Method for Length Change of Hardened Hydraulic Cement Mortar and Concrete Test Method for Time of Setting of Hydraulic Cement by Vicat Needle. Restrained Expansion of Shrinkage Compensating Cement Standard Specification for Epoxy-Resin Base Bonding Systems for Concrete Standard Specification for Packaged, Dry, Rapid Hardening Cementitious Materials for concrete Repairs

2.

C 157

3.

C 191

4.

C 878

5.

C 881

6.

C 928

D.

BSI British Standards Institution 1. BS 4652 Specification for Metallic Zinc Rich Priming

1.3

QUALITY CONTROL The Contractor shall be responsible for the quality control of materials, equipment and methods of construction. The on-site quality control shall be in accordance with Section 01420 Quality Assurance/Quality Control. The MARAFIQ shall be notified twenty-four (24) hours in advance of all required hold and witness points requiring inspection. No work shall proceed prior to the release of hold points.

1.4 A.

SUBMITTALS The Contractor shall submit to the MARAFIQ, the following information for review and approval at least twenty-eight (28) working days before commencing work: 1. 2. 3. Recommended suppliers and/or sources of all repair materials. A quality control procedure that covers all aspects of concrete repairs. Example of a typical quality control report in accordance with Section 01420 Quality Assurance / Quality Control, covering concrete repairs.
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Test reports from an independent testing laboratory showing that the repair materials meet the specification. Detailed repair method statements covering sequence of repair operations and hold points.

5.

B.

The Contractor shall prepare working drawings and, when requested, shall submit the following to the MARAFIQ: 1. 2. 3. 4. Design calculations and details of formwork and falsework systems. Methods of form construction and erection. Locations of form joints, form-ties and construction joints. Design calculations and details of any necessary temporary support systems.

C. D. 1.5 A.

Work schedules showing dates and duration of repairs. Certification and test reports by independent testing laboratory. PRODUCT HANDLING All repair materials shall be delivered in sealed original labeled containers, bearing manufacturers name, brand name, date of manufacture, batch numbers and instructions for mixing and/or preparation. Adequate weather tight and environmentally controlled storage facilities shall be provided and materials shall be stored in accordance with the manufacturers recommendations. Containers of materials shall not be opened except for immediate use. Old materials which have exceeded the manufacturers recommended shelf life shall not be used and these materials shall be removed from the site. Solid and liquid wastes from repair work shall only be disposed as directed by the MARAFIQ.

B.

C.

D.

PART 2 PRODUCTS 2.1 A. GENERAL All goods and products covered by these specifications shall be procured from an in-Kingdom manufacturer, or from a manufacturer located in another Gulf Cooperation Council State. All such procurement shall be in accordance with current applicable policies and regulations of the Saudi Arabian Government. Procurement of goods and products manufactures elsewhere must be approved by the MARAFIQ.

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B.

Proprietary products proposed by the contractor to meet the Specification requirements are subject to approval by the MARAFIQ. No materials shall be used in permanent work without the prior approval of the MARAFIQ. MATERIALS Portland Cement Concrete: All reinforced and plain concrete for replacement shall be Class J30 with Type I cement and silica fume in accordance with Section 03300 Cast-In-Place Concrete. Reinforcement: Reinforcing steel for replaced concrete members shall be grade 60 epoxy coated in accordance with Section 03210 Epoxy Coated Concrete Reinforcement. Latex Modified Concrete: Shall incorporate a latex polymer dispersion with 50% average solids content. All latex modified mixes shall be non-air-entrained. The proportion of the polymer and curing of concrete shall be in accordance with the manufacturers recommendations. Grout: Shall be a pre-packaged nonshrink, nonmetallic cementitious grout. Grout shall be effective at consistencies from extremely fluid to plastic, and shall be capable of developing full strength without confinement. Grout shall comply with ASTM C928, Rapid Hardening Type or equivalent, with the following additional properties: 1. Minimum compressive strength, tested at 20C in accordance with ASTM C109, shall be 35 Mpa for both plastic and fluid consistency mixes. Maximum shrinkage shall be 0.10% measured in accordance with ASTM C 157. 10 mm maximum size aggregate conforming to Section 03300 Cast-In-Place Concrete shall be used for repairs exceeding 75mm in thickness.

2.2 A.

B.

C.

D.

2.

E.

Patching Mortars: 1. Type A: Shall be pre-packaged polymer modified cementitious non shrink, non-metallic repair mortar suitable for vertical and overhead repairs by hand application. It shall have minimum compressive strength of 35 Mpa after seven days of curing when tested in accordance with ASTM C109 or equivalent. Type B: Shall be two or three component pre-packaged epoxy based, moisture insensitive repair mortar. It shall have a minimum compressive strength of 45 Mpa after seven days of curing when tested in accordance with ASTM C109 or equivalent.

2.

F.

Plugging Compound: Shall be a pre-packaged cementitious, rapid-setting mortar with graded filler material and chemical set control characteristics suitable for sealing leaks under flowing water conditions. It shall have the following minimum characteristics when tested in accordance with ASTM C109 and C191 or equivalent:
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Compressive Strength (ASTM C109 or equivalent): a. b. After 6 hours : 10 Mpa After 28 days : 25 Mpa

G.

Bonding Agent: Shall be two-component high solids, epoxy based, moisture insensitive bonding agent suitable for use under dry and wet conditions. Coating for Reinforcing Steel: Shall be one-component zinc rich epoxy coating manufactured to meet BS4652 Specification for Metallic Zinc-Rich Priming or equivalent. It shall be applied to give a minimum total dry film thickness of 40 microns. Injection Compounds: 1. Type A: Shall be two-component, rapid foaming and setting liquid polyurethane resin suitable for exposure to saline groundwater and for stopping flowing water when injected into leaking cracks. Type B: Shall be two-component liquid polyurethane resin suitable for exposure to saline groundwater and for application in dry or damp conditions to form a closed cell elastic seal. Type C: Shall be two-component, solvent free, low viscosity, moisture insensitive injection liquid, based on high strength epoxy resins.

H.

I.

2.

3.

J.

Concrete Crack Sealer: Shall be polymer modified, cement based slurry surface coating suitable for concealing hairline cracks. Joint Sealant: 1. 2. Type A: Shall be pitch-polyurethane elastomeric sealing compound. Type B: Shall be one component rubber based elastomeric sealing compound.

K.

L.

Back Materials and Preformed Joint Fillers: Filler materials shall be resin impregnated cork board or expandable cork board as recommended by the manufacturer of the sealant. Backup material shall be closed cell polyurethane foam rods. Material impregnated with oil, bitumen or similar materials shall not be used. Sealant shall not adhere to backup material. Form materials, curing compound and other materials shall be in accordance with Section 03300 Cast-In-Place Concrete.

M.

P.O. Number : 7200018725

PART 3 EXECUTION 3.1 REMOVAL OF UNSOUND CONCRETE The Contractor shall remove all unsound concrete. Unsound concrete is defined as loose concrete detached from the main body of concrete due to reinforcement corrosion, sulfate attack, scaling or other causes of deterioration. Removal of concrete shall be carried out using the following steps: A. Concrete affected by reinforcement corrosion: As identified by the Contractor and approved by the MARAFIQ, the unsound concrete shall be marked as a rectilinear shaped area enclosing the damaged concrete. The marked area shall be saw cut to a depth of 25mm and concrete shall be removed in this area up to a depth of 25mm behind the rebars and as shown in Appendix A. Chipping tools, such as small jack hammers, shall be used to avoid damage to surrounding sound concrete. When any of the exposed rebars show corrosion at their interface with adjacent sound concrete, removal of concrete around the bar shall continue until no signs of corrosion are present. For cracks wider than 0.5mm in concrete caused by rebar corrosion and as determined by the MARAFIQ, the concrete shall be removed to expose the corroding rebars in a manner described above for concrete affected by corrosion. B. For concrete affected by sulfate attack or scaling: As identified by the contractor and approved by the MARAFIQ, the unsound concrete shall be marked as a rectilinear shaped area. The marked area shall be saw cut to a depth of 12mm and concrete shall be removed from this area to reach sound concrete, by sand blasting or other suitable means acceptable to the MARAFIQ and as shown in Appendix A. If mechanical tools are used, damage to surrounding sound concrete shall be avoided. If rebars are corroded, the concrete shall be removed to a depth of 25mm behind the rebars. TREATMENT OF EXPOSED REINFORCING BARS Exposed reinforcing bars shall be cleaned of corrosion products by abrasive blasting in accordance with SSPC-SP10 near white blast cleaning. When the loss of cross-section of the bars due to corrosion is significant, the Contractor shall inform the MARAFIQ. Additional uncoated reinforcement shall be added as directed by the MARAFIQ using either lap splices with sufficient lap lengths or full tension mechanical connections. The sand blasted and replaced reinforcing bars shall be washed thoroughly with potable water and coated with the coating specified in Item 2.2.H, except where cathodic protection is applied. Where a cathodic protection system is used, replaced reinforcing steel shall be bonded to the existing steel by welding. 3.3 SURFACE PREPARATION OF EXISTING CONCRETE Prior to the application of repair material, the surfaces of existing substrate shall be roughened to provide an adequate key for bonding agent or repair materials and shall be free of loose, broken and unsound material. The substrate shall be thoroughly washed with potable water.
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3.2

For repairs using cementitious materials, a bonding agent may be used. Alternatively, the substrate may be saturated with potable water and kept wet for 24 hours prior to placement of the repair material. For repairs using epoxy patching mortar, bonding agent shall be used. Repair material shall be placed when the bonding agent is still tacky. 3.4 A. PLACEMENT OF REPAIR MATERIAL Concrete specified in Item 2.2.A & C shall be used for partial or complete replacement of members or their components. Placement of concrete shall be performed in accordance with Section 03300 Cast-In-Place Concrete. Consolidation of concrete may be done with form vibrators if accessibility is a problem. Grout specified in Item 2.2.D shall be used for repairing concrete affected by reinforcement corrosion, and sulfate attack and scaling to a depth greater than 550 mm. It may be applied by hand or by use of forms. Hand application shall be used for floor surfaces only. Forms shall be used for repair of vertical surfaces and slab and beam soffits and the following guidelines shall apply: 1. Formwork shall be mortar tight and the form surfaces in contact with the repair material shall be coated with de-bonding agent. Grout material shall be deposited in such a manner that no air pockets are present. Vent holes at suitable locations shall be provided in irregular shaped cavities to eliminate air entrapment. Repairs to walls, columns and vertical surfaces shall be performed in stages with each stage not exceeding 500 mm in height. For the uppermost part, the grout shall be deposited through letter box shaped forms with open end slightly higher than the upper limit of the repaired area. Repairs to slab soffits shall be performed by placing the repair material from the top of the slab through drilled holes, by pumping or by other means acceptable to the MARAFIQ. Suitable vent holes shall be provided to release entrapped air. Consolidation of the repair material in small areas may be accomplished by tapping the forms with a rubber hammer. Forms shall not be removed until the repair material has gained specified strength or as recommended by the manufacturer of the material. In no case the horizontal forms shall be removed before seven (7) days after placement. Any projections left after form removal shall be trimmed.

B.

2.

3.

4.

5.

6.

7.

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C.

Patching mortars specified in Item 2.2.E shall be used for repair of concrete affected by sulfate attack and scaling to a depth less than 50 mm. These shall be used for hand patching of horizontal, vertical and overhead surfaces. The repair materials shall be placed in layers, maximum thickness of each layer shall be as recommended by the manufacturer of the material. Shotcreting may be used for repairs as approved by the MARAFIQ. The shotcreting operation and materials shall conform to ACI 506 Recommended Practice for Shotcrete. HOT WEATHER Temperature of concrete and cementitious repair materials shall not exceed 25C at the time of placement. The reinforcement a nd formwork shall be cooled by spraying water or by other approved means.

D.

3.4

3.5

CURING Continuous moist curing, as recommended by Section 03300 Cast In-Place Concrete or by manufacturer of repair material, shall be performed for areas repaired with cementitious repair materials and concrete in case of full replacement of members. In no case the moist curing shall be less than seven (7) days.

3.6

REPAIR OF CRACKS Cracks resulting from reinforcement corrosion shall be repaired using the procedure described in Items 3.1 through 3.6. Other cracks such as flexural, shrinkage and construction and thermal joints which are wider than 0.5mm shall be repaired using one of the following methods: 1. All leaking cracks shall be repaired by injection method using crack injection materials specified in Item 2.2.I. Type A injection material shall be used to stop the leak and then followed by Type B material to seal the crack. Flexural non-leaking cracks wider than 0.5mm shall also be repaired by injection. Type B material shall be used for non-dormant cracks and Type C material shall be used for dormant cracks. Non-structural and non-leaking cracks wider than 0.5mm shall be repaired by routing and sealing method. All non-leaking cracks less than 0.5mm wide shall be repaired by surface seal method.

2.

3.

A.

Injection Method: Injection of cracks shall be performed as recommended by the manufacturer of the injection material. The following procedure shall be used as a guideline: 1. Cracks shall be cleaned of dirt and loose material with oil-free compressed air. The surface of the crack shall be sealed and injection nipples installed.

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Cracks shall be injected with the specified material. For horizontal cracks the material shall be injected onto the nipples from one end to the other. For vertical cracks injection shall be done from the lowest nipple and moved upwards. Injection in each nipple shall be continued until the injection material comes out from the next nipple. The nipple shall then be capped and injection continued in the succeeding nipples. After the injected material is cured, the surface seal and caps shall be removed by grinding or other means acceptable to the MARAFIQ.

3.

4.

B.

Routing and Sealing Method: The crack shall be grooved by routing to a minimum depth of 10 mm having approximately the same width. The groove shall be U shaped for non dormant cracks and V shaped for dormant cracks. The groove and crack shall be cleaned of dirt by oil-free compressed air. Non dormant cracks shall be repaired by applying a de-bonding tape to the bottom of the groove and filling it with the material specified in Item 2.2.K. Dormant cracks shall be repaired by filling the groove with the material specified in Item 2.2.E, Type B. Surface Seal Method:: The area surrounding the crack shall be cleaned of dirt by oil-free compressed air. Material specified in Item 2.2.J shall be applied following manufacturers recommendations. HOLD POINTS The Contractor shall notify the MARAFIQ for inspection at the following hold points: 1. 2. 3. After marking the unsound concrete and before chipping it. Before coating the exposed rebars. Before placement of the repair material.

C.

3.7

3.8

INSPECTION BY CONTRACTOR In addition to the requirements for inspection by the Contractor in compliance with Quality Control, the Contractor shall carry out the following inspection to ensure conformance of the work with the specification: 1. 2. 3. Checking concrete substrate prepared to receive repair material. Checking rebars after sand blasting Checking concrete surface before placing repair material

Inspecting repaired areas after curing to detect any defects and delaminations. The repaired surface shall be tapped with a 500 g hammer. Areas showing hollow sound shall be repaired by following the repair procedures described in Item 3.1, 3.2 and 3.4.
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P.O. Number : 7200018725