STUDYIS IN

no. (1) 23/0lJ2007, in Arabie:

report entitled
me no, (2)
L
2. l Temporary Supporting Systern .... , .
RCHiOVa! Reconstruction
2.2.1 Precast Concrcte Slabs., .......... .
Concrete Slabs Supporting th Wall<
4
2.3.1 Precast Capping
7
2.3.3 Concrete Abuttnent .......... > 16 > ....... " .. ,. > ..... " ,
15
Renat'
2 shotcrete................. , .......... ", .. > > ..
.. . l
usmg specHl con crete, .... .,."." .. ", ... , .. > > "' > > , > > > ........ ..
Surfa finishing ImH'taL. > > > > ......... > ............. , > , > .. ..
2.5
19
.2. l mprcssed
ofDamaged Steel Structures. > ... > .. ' >
Repairs for some Damaged
2.7.1 Piles.. > , > > ., > " " " .......... , > > , "." ..... ..
'[rus::>.. > > " > > ........ > > " " > > " ... .'
2
Guide lIU'[UU'," ofjeHy
4
18
18
20
3.1
lards with! therut rubber
Control, . , , .. , , ...... , ..... , .. .
3.2 Quality
')
4, 'Rcpai:rs ...... " ...... ,. H '" , " " ., " , , " ",
5. to
25
( ~ o n d i t i o n s .. , .... " , ......... , ..... , , .... , ..... , .. .
7. SpcI:ific Conditions... , , .. , ...... , ..... , . . . . . . . .. ,., ......... , .. 2
8,
of
9,
Kammash
follows
guidance
Reinfi.Hced
specifications schcmes prcsented
report are both onsidercd as
LIBYAN AN])
Repair
L INTRODUCTION
repaJr
suftkicnl guidance on
of
contractor
to the
HPatch R.epair
lI], a copy of which is
tl1at the
uu
recornmcndations,
Marine
H is important to state
concrete to amOlmt
works rI].
considered
to
unfbrcsecn
bill
- 1
1. Supporting of ail were
60 mm.
1.2 Supporting piles rnovemenlS
rcpair of the precast concrete beams.
2.1.3 tn!ss as
screws, nuts .....cet.
and
states
concrete
is considered necessary,
mainly on
The
execlition:
2, 1 Precast Concrete
Humber of Precast
detcrioration
reduction
addition to
to 0),
Fixing new
to the
- :2
--- ----- ----------- - - - - - - - ~ - - - - - - - - - - - -
c
report, subjed
foUO\ving
a ~ Ali f1xing steel
b- supporting of the walk
to the
supporting shaH
and approvt:d by SE.
2.
in cross-sectional reduction of up tn
this '\-'lm
hoHow
of the sal
sprayed
rein forcement
corrosion,
signs of
eieroents,
efer.nent;:.;
elements
abmrnent
General view t h ( ~
ofthe
arro','vs refer to sever
Red 81OWS l'cier to the stcel
~ ~ ~ ~ _ ...__.._---- - - ~ . _ . _ ~ - ~ _ ..._-_._--..._--_..
Hol!m',' part of the bcams
- ~ - ~ , ~ . _ ~ , . ~ . , _ . - . ~ ~ ~ . , ..
,
Sied Piles
Provision for temporary support
before starting the cb
'-,
1 and h<:nce be rernoved upon
and the
Due to
provision
and approvcd by
Prinr to chipping an area
sounding survey of
location of
l
'
,>
(l- Capping Beams
to a distance Hot
and corners of
as possible.
contractor is to give
in axes nos. l,
precautions during the
Upon compktition of
contractor is
adhering COl1crete
appears sound.
a
u!ppmg Bearn
--,
a
1),;; mol ished
ConGrete
m

!
L __
;:,ectwn
l
r_ . _",.,_"" .. __ _ >< <._". , ,1.
>60mm 20mm
Apparcm Concrete
> 6()mm" lhick!less of concrete cover to be chipped.
20mm = Chipping depdl reinJorcement
Sec a-a shows the extent of removal
Repair the
-8
Fig. (5): Typical detedoutnon of the Sh. vfater intake support
blue anows refcr to th(;;; con-osion deteriorations spread over the extemal faces
of the lOOmm thickness slabs.
red arrows point at the corrosion deteriorations of the extemal f2ces li""
capping beams.
-9
- ~ - _ ..--,,---- ---_...~ - ~ - - ~
.Reinibn::ng bars must be
examined
Rebars experiencing
are retained,
foHovving [3]:
A.s shown in (6), the contractor is to en:;<:l ne'\-\'
omlitudinal reinforcement of 16 mfn
tn the
connectors 10
the
"nIe .::onneetrs is 1.0
coyer rI!;;:'W is not to
than 50 mm.
Bcams are reprofiled
those
shotcrete according
to
,- Concrete must be fully
- Beams a n ; ~ to
ihicknes$
- Repaired beams are f(I
(7)
- lJpper surface the beams axe tn
concrete as d(;scribed item no.
- iO
Additional Grid 0
Similar to "'-J""\l!JlIC
New Stinups (0 Hlmm
Apparent Concrcw
Beam

70mm 40mm
180mm
20mm
", ",
40mm"
40mm "oc. Anchorage of
2Umm Depth of CllrVllt:u concrete behtdRcinJofmenr
70mm Distance betwcen new rcinfbrcemem ilnd c;dsing
m21.i"1) jjnforCClilent
Stimrp
Fig. (6):
180mm Di<;tance
-11
Special Concrete
Concrete (Shotcrete)
Fillishing t.:Jortar
lOmm l40mm
new reiniorcemcnL
of shotcrete layer.
1 'fhickl1ess of Hnishing InOliar
.',
.Fig, (7):: beams
- Bond
Hnishing mortar is ln
an
- Concrete coyer of repaired
60 mm.
a!6 Choice of repair method
intakewill main!y
concrete
mm depth will he repaired by a
of 10 Inm,
is ln not
ce.mentitious mortar to bc
cxceeding thickn.css by
Repair ofPrecast Ca,oping Bearns
as tr .
above. Chipping of
faces of a depth more
vievy' of one of the beams
are some points to
these
contractor is to
repar of anchor
pipes to pi.!es,
Anchor
new
"", '
1"J ~
only:
e!crnents sufter from corrosion type
fOp sidt: only, The extent. of chipping
CX!)C1cre:(1 10 reach dcpths beyond 60 Bun
surface area of the slabs,
clements are to bl::' aecording to thc
aIl Ail deteriorated cncretc t bi,:
con crete
appears sound,
loosely adhering
concrete
in these elernents shaH
not less than 20 nun,
corners of chipped areas must
This
ternnon'!fV support
the chipping
must be supportee!
slabs carrying
wil 1 be removee!
required
Upon the cmnpletion
tbe ontractor 13
concrele
to
and
concrete appears sound,
bars must be cleaned by
reduction,
concrete L
be a
\ '
- l5
arc t
original shape and leveL
r,:,epaired slabs are to be
days watcr or other
instruction
h- Rq7air
bottOfrt
!lOS. as fi;)llowed
bl2 Rians are
the foHowing procedure:
Con crete surfaces must be ln a
condition.
Repar
in Fig (9),
entrapment of
- Repaired
days
instruction
water or
chernical
23.3 Reinjbrced concrete abutrnent
These clements are ta be
1'br
than
using Shotcrete
to must
Type of "'''"uv"", or l{)r
enviromnent
..
- Addition

Dot
(6.5 '" j.
". Maximum w/c
16
Apparent
deteriorated concrete remova!
of
view of con crete
sec b-b method of casting
of
envimnmenL
to
to the
superplasucizers [8,
- Coarse shaH
to AG 506.
IS to of
rnerre
.. Continuously al nc"v concrete must
(7) days .
.. Cube comnI
than
at
2.4,2 using ,)peciaI
Specia to
- Type of cement:
fbr
- Cement content
w/c 0.45
lS to
superplasticizers 9},
condition vibrator(s) 1 be of
concrete,
- Continuously c.uring of new
least (7)
- Cube compressive at
40 MPa.
2.4.3 Repair using Expanding [6].
material shall be
and abutment as an
above. It i5
d;:;pth exceeding 60 mm and
is ta
al
not
2.4.4
l
. 8
Marine . contaminated
hrnits to a depth
'1"1 1
. I!.. OV1.. ...... uL,
frmation of
surfaces.
('athndic
system he
"-Ji:'
",,),1 acrr/,Cl,
the rnarlne
in this report, in
and help in prolonging
fJ['}ti"d'l' 'If'
S.;

l.Jt-"..-J.t ,,-, il' .\.. ...
Protection [3, l !.l l,
is an dectrochemkal
anodes at different
") li' 7 l'
L,1J U, j /.1 ,
This system
structure from
manufacturer
l)rolong the service
10" 20 depending
used. The main idea
on introducng more
in the
cementitious mortar
rein forcemen t
,/ '.
. -9
2.5.2 fmpressed current {3, 10, ! 1/
ln impressed enrrent system a I1l0re reactive rnatcrlaI the
reinl'orment is intmducccL, the anode Hm,terial. itsclf he inclt
but is maintained in an <mocHe statc relative to the stnJCt.UH: by
bdng connccted to the correctpoIe of a direct currenl! power
supply :::;: 10 mA. 'rhis system requires a frequcnt monitoring and
inspection program in order to achieve il prolonged tife,
2. 6 ..
Due t the severe corrosion damage observed on sorne steel truss
structures, plates and most of the connecting bolts and nuL:; marine
jetty, which lcd to il rernarkable loss in cross section and heaviJy
effecting the structural performance n:quimd to withsmd existing
loads, 'l'lwse heaviIy darnaged sections must he rernoved rep.!p,ced by
nev\! as buih sections as described in the recolTlrnendcd bill qunntitie:;,
Based on the structural. analyses discussed in the Jll,ain report and from
q "'l'>"u ,; ,. !'" ! 't "" .0 t, d tt, l,> l, ,. () ..,',,, ,'t! !,o' j"
h1C C,.Sl
b
!1 pLO! \lev\, 1. \"lS rc,\C.1le, .lIa, no """,,1..,1\(. ,)dUH
1
:. l,;)".O)
existed in ail steel sections, Bence., although the structure je; considered
sah:, any los5 or reduction in the clement sections cm be aHo\vcd.
Fur!hennore, tcmporary supports shaH
rcmovaJ phase and mounting of the nev/ clements
proposed lIy the eontractor and approved by the SE.
coated as per coating specification presented in item 2/7
__ ___, __ ___ ______, ______ __ .._'___""__,_n_____.___ 2,7 Limitee! Ref)airs for some darnaged steel structures
l" " '1 ,.,", .',,., t ,,,t',!
I,urn JAl. ...:orrOSlOn {amh,C WdS Ot1St,I\CU "lB scrnt ;, CL
et>"f',:l tr'1"3'" "nid p'!p,< "\{Jj'l!'l 11" . 'lIo. '-'%.. '" ..-h ....J .. L.J (.,t, , "-........ ,Ll'l,,/ ...., 'l,", ... J:.h;i.\',.,1...'\'.."<... .. h..,.' t.", '" "j,3
1',1;;',;, "'(}'l'C'Ctl'\"" fr"'l'li'r o>('t i ()f1 1111'St' l)l"- ' P1q l("n1 f'ptcd :". tjf:( ttw:
1. '\..' ....', .. ....." \"" .J ,,' {Y. '-'J... "- .... ",.li.", v \...... ... ,,,',.'.....;<",1 >..,;' ..... .,... ..
folkrwing details:
"/.f., ., .....
2,7.1 Steel Piles
Recommendcd repairs can be das:51{1ed hascd CUl CW l'nain
categories:
Cl. Atrno.spheric zones or areas no! covered by wa[er
envlronmental conditions.
New proper coating shaH he applied including aH l'ft/visions
f
",(',,,S";,>"'" ti) 'tl'1" '''l''(Q(',,, '''l')(j ,'P"""!,;';! Il''1' ''''j:'l' {)l'-'f
c
,(!
.n...., .... '"',. .t" "" .fL." "-, .1. .lt.... ,,,", U t vLc.P.... C... ,"t..,," \., ct"l-\......
t:")'Xt;'1g' l'n ""I(')S't 'H'''' "! " 'l'l'le "lll'jivJ[''',') "',.,Ij 1-),,,
...... '\. u .... U., lE ... '-u"","' l\ !t. " lS "t.,..
') ,! f')\
".J
j.",
H,J a.l Rem(}vai of old coating by blast d;;:;aning to (
insure removal of aU C01TOsionj2wshl,!::,:, etc as the
- 20
beim.pkIllcnted the
he
shaH be
to
!"
112 or
standard.
a3 he applied
international standard l
In addition to above, the for Iowing
coating shall adhered to:
~ l-ligh abrasion
curng.
to arnbient T''''''''''':"O'
equivalent
b. SplI;h Zones areas.
nr.',n,c',- coating
coating and
b. 1 prepared
2/7/1. Areas to
above
Ctass
2. 2 T'russ
Proper protective
preparation
sections fbrming
be1o\v main marine
/
a. as
,. (, ,
21 .,
induding
and applying the nevi
b,
..n,,.'rH' as weil as s ~ e e l elements
west walk ways, ladders, cable
foHo\ving:
replaccd
2.8.2 Guide Boards
Steel
2.8.1 Flour panels on walk 1vays
lJamaged Flour on wall<
2.8.3 Bollards with/ without
of
zemc areas as
(IO,c): Bollard mbber fender
Fig (1
k1,,,,,,,,"tt:! canying the
.... _-_._-
:t CONTROL
3.0 Routine
H is al.so important to state that
implernented during
of testing is to be "'''''-'''-'-<''''U
SE \:vhich tS a
to
equipm.cnts
source,
Quality Control tests
n:pair materials
undertakcn
No, 340/97, or
1980
- Compressive strength of the hardened rnortar
he tcstcd to 188]: 1
-, of reinfrcemcnt bars
bars in 10
special concrct.e grout and
testing of workability
testing compressIve
concrett::, mortar grout [4,
- T'he contractor i5 to submit method of
coatng ln
international
be

- The contractor not
conditions e,g. rain fi:dL
v",,,-.u,,-, Cores for
Unertaking pull
the
RIB3PAIRS:
[22}_
including the
undCl1akcn
requred sta.ndards
by coutractor [ 1J.
S, RF;PAlR
REPAIRS):
Repair irnplcmcntation sequence
cOlltractor obligated to assemble a
personal possessing good cxperience
addition to a programmcd QC/QA throughout
project
Tu darit); the
repair
fix imp!ernentation,
(.,
25
10
presentcd this report, the eontract
arc consideree!
contractor is
doemnents
compared with ...."-...".n"' ....
client to assign a weB
the saicl repairs. H is
""'n.. ,.'.> supcrvising
whole perind of the said c()me any
that rnay occur or ailer !h;; hnplernentlttion
to put
10 the fact
process in \vhich
BQ prescntcd in
the listed
rnixng
tn achievc up to
:3
a
slated abovc,
dassi.fied as rH",.,.."",
the faet that it is 1,0 aceurately quanl.ily
to he repaired befre actual executron of
% 15 for additional works normally spedl1cd
cover the md{m;seen work::; caused by any
from those table (1) o1'tls
"1 ii.. ",1 ",;
works

to coyer
l'he contractor
slrm:,tural clements
based on the
The
relevant
said
6.6 The cont.ractor lS obligated t
rcpaired the approval
personne! t()r control of <",""",-"",,"'C"''Y,p,nh'
the as well a,') to rend cr
with perfonnam:e of
whah;oever.
!l1aintain a
meters fuHy
machine, colored printers,
al,1 office
msurance and
costs in
be bome by
a
shall flot
contract
origin\-vhcn
to the
27
-,.. __
table !) are bascd
l'nentioned
partcularly
considercd as useilt! starter for
mobilization 'l'he exact
evaluated a fJer
13 of BQ an of 1(1 % Cluantitv ro
'\t"P<".I)';.f.>.t'\ "o.u'-1zc f-'f.'f.t any increases
ill

1/3
''l'
'"'
211
') J,
t-,.,! ,,:;,
prepared hy
blasting as per item 392
1392
1392
",
- 28
HE 200 A profile
ln
4700
p;
HE 160 A profile
m
2240
C, LLIOO*lO
ln
4000
D,
m
168
E 182
L 70*7 5700
C, IPl:: !80 profile
m
1120
1sections carrying
walk way Ilom
m
840
panels
coatcd as
pei item in
A. HE 20() A profile
B. HE 160 A profle
rri
2240
C. LU 00* 1 0 proi!le
1'n
4000
D, IlC 200 B profile
ln
168
LL 70*7
tH
182
F, 70*7
III
5700
G. IFE 180 profile:
III
1120
H. 1sections carrying
wall< way flom
III
340
to be finally
as peT 2!7i2 clause (b) in
this report
Profi!es as 1'ollow:
"r"1
),L,
A, HE 200.A
ni
4700
B. HE 160 A pronle
m
2240
C. LU 00* 10 profile
ln
4000
D, HE 200 B
ni
168
- 29"
F. L 70*7 profle
rn
Jf':l G. IPE 180 profile
HI
Il
IL 1 sections carryng
waik way nom
rn
840
30
- 3 J
a.,
Rernove guide board
tubes in heavily corroded
amas and new
bar tubes as
170
described in item 2/8!2 in
111
5/1
this report
disposaI of remOVCG
items.
!-l..
Repat and maintain ail
boards tubing as
described in item Hl
ni
5250
this report.
Ladders
Rerlloval of ladders in dam<1ged
amas and mounng of new
5/2 ladders, using of proper
Il!
40
pel' instruction
nduding ofold
WaJkway unde, mlltn
Rernovai of damaged floor
and of ne\'! Boor
5/3 ilS desrib'.::d in item 2/8/l Hl t h i ~ rH
inc:luding disposai of olt!
1100!" panels
Remnval of destroyed
S!4 i support and m 1760
Ifenders
l
' T'realment,' and maintenance of
, as describeJ in ilern
515
i :.18/3 iIl this
- 32
6/1
6/3
inc Imling
supports to pl'cvcnt
rnovement of ste!;!
i as slted in c![llSe (2/1)
including disposai of n;tnoved
ofremoved
provision
supports and disposal of
rcmoved items as
Capping beams with no
anchor plates, as
in item no.
) dause (a),
b ~ Capping heams with
anc!Jor
no.
.,
m"
90
90
1200
140
713
7i4
and
b- Slabs \vith no cClI)so!e
Rt:construction of removed in
\0 original
detai1s
itern;:; as fi)llows:
a, Slabs with console
with no console
b-
console
induding provision of
c" "wV,,",1' ..
sJabs from bttom side
only ilS dcscrihed in item
clause ir:clwJing
removed tems HS follows:
lI- Shlbs with "on<:,'''{'
provision of
for the
pipes and accessories.
b- Slabs \Vith console
pcs
pcs
Pcs
95
106
95
532
34 ..
9/1
9/3
9/4
~ o
10l!
f',wrr,,,;nn deteriorated
as foHows:
using shotcretc
using special
COlluete
l- Rcpair usng modificd
mortar
of deteriorated con crete
thiclS5locatcd
induding disposal
removed items
Reconstructon of removcd
concreie shb n accordancc to
, :1 '!
proJ'::ct ( eli:l!iS as
described in item no. (2/3/2)
clause
m"
nt"
!11
mi
nl'
97
200
200
Lump Sum
125
., .cc
.1,;
40
0/2
Jon
Due to the fact that
dift1cult to
total
concrete to
bcfre actual
wor<s ! l},
th!s item
is
increase in quantity to coyer
any un foreseen work:>
caused any inereases in
J-epair works,
~ n mnnbers
AND TOTAL in iette:t's
~ 36
9.
British
Society,
('rroson H
Institution, "BS
& Society
repair of Concrete Structures in the
Special Publication 137,
Institute,
European
Structures,
, UK, t996.
l ,
:3
tn
6- American fr ;:md
Speci fiation Packaged Dry, Hydraulic-Cemcm
Am.erican f()f
Specification f(Jr
of
London,
International standard
corrosion protection of
surface
...--_.._-_... ...
organization,
-")
k of structun::s bv
. "
1998.
Specification
Standards lnstitution, 882:
tc,r
992.
3 l
Standards Institution, i;
strength of concrete
Institutioll,
x assessment
1
21
Intemationa[ standard
''';!,
,w"",,,.:/,,,, protection steel structuresby
" .
and supervision of 1998,
.. 3B ...
1
UO!S1JO:J u.:mr<lJJo}UFIl
-- JO
.. on t
M ; Rh BQ:
PART3-METHOD OFMEASUREMENT
INTRODUCTION
l. GENERAL ITEMS
2. SURFACE CLEANING AND INSPECTION AND TESTING
3. REPAIR
4. PROTECTION
PART 4 - BILL OF QUANTITIES
PREAMBLE TO THE MEASUREMENT OF PATCH REPAIR OF
REINFORCED CONCRETE
BILL 1 General
BILL 2 - Surface Cleaning, Inspection and Testing
BILL 3 - Repair
BILL 4 - Protection
Page
Number
47
49
50
53
56
59
60
62
69
83
.
"-i
t
mt
tt"H **
PART 1- INTRODUCTION
hM mMtrttttM!
''t!
,
GENERAL INTRODUCTION
Concrete has long been renowned for Hs strength and durability. There are many examples of good
practice which have stood the test of Ume. Unfortunately there have also been too many examples of
early deterioration in recent years and the image of concrete, particularly reinforced concrete, has become
tarnished. Tt is fair to point out that the vast majority of concrete structures have had and continue to
have excellent records of trouble-free service.
The performance of a structure, in durability terms, is dependant both on its condition of exposure and
on the "quality" achieved in design, detailing and construction. There are wide variations in the
expectations of structure owners and these lead to different judgements of what is considered to be
acceptable performance. As an example industrial structures may have a usefullife of only ten or twenty
years because of changes in processes or markets whereas churches and other public buildings are
expected to last for generations.
There are many causes of untimely deterioration. In sorne cases the causes can be traced back to failure
to achieve "quality" because of constraints on finance or time. Quality and durability may have been
compromised by the more immediate needs of economy and expediency. Another cause may be that the
local environment to which the structure 1S subjectcd has changed. An example of this is the increased
use of de-icing saIts on highway structures. In other cases the use of a building may continue long after
the period originally intended as with the case of pre-cast houses constructed in the late 1940s and early
1950s. In other cases there may have been failure to appreciate the consequences of a particular local
environment. '
The deterioration experienced by sorne concrete structures has generated much activity and interest in
the field of repair. This interest was recognised by the Society in the publica tion of its Technical Report
No 26 - Repairofconcrete damaged by reinforcement corrosion -and the publication of BS 6270 Cleaning
and surface repair of buildings, Part 2 Concrete and pre-cast concrete masonry. Technical Report No 26
gives general guidance on many aspects of concrcte repair. Since Hs publica tion there has been continued
interest in the topic and the Materials Group of the Society has become aware of a necd for uniforrnity
in approach to specifications Jqr repair contracts. The extensive range of repair materials which is
available has also given rise, to a need for guidance on properties, testing and use.
With these factors in mind, the Materials Group set up a working party with the objective of producing
a specification for patch repair which could become a standard and model for the industry. The
document which has been produced relates specifically to the repair of concrete which has suffered
damage because of reinforcement corrosion. The working party was able ta draw on a wide range of
expertise and included representatives from contractors, consultants, materials suppliers and the PSA.
Representatives from FeRFA and late.r the Concrete Repair Association were includcd. The resulting
document attempts to coyer most:aspects of the specification of repair contracts including access,
processes, materials and testing. . .
These last two topics are particularly difficult to address because of the lack of national standards for
repair materials. It is hoped that the situation with regard to test methods may improve within the near
future because of the moves towards standardisation in Europe and there may be a need to revise certain
clauses or to add new clauses. Il is feH that the need for the specification is so urgent that it is better to
publish in the present form rather than delay until new information becomes available.
As far as the method of specifying materials is concerned, at the present time it is feH that a suitable
approach is for the specifier to name one material manufacturer in the document or give a list of several
manufacturers whose products have been found to be suitable in similar situations in the past. This
could be taken as a guide to the standard of material required. Specifiers may also wish to consider the
advantages of the use of those materials which have British Board of Agrment certificates.
As work on the specification progressed the working party became aware of the urgent need to provide
guidance on means of drawing up bills of quantities for repair contracts. The task of drawing up a
suitable method of measurement was, therefore, added.
The document which has been produced relates specifically to repair of damage caused by corrosion in
reinforced concrete elements or structures. Although the processes could be applied, for instance, to
secondary reinforcement in prestressed members, a much more carefuI overall approach would be
appropria le in this Case.
G
44

APPROACHTOREPAIRS
It is worth repeating sorne of the avice given in Technical Report No 26. The approach to repairs
recomrnened in TR26 was sumrnarised as follows:
a) Carry out sufficient investigations so that the rea$Ons for and the extent of the problem
are identified and understood.
b} Considercarefully the wayin which structural and operational considerations will affect
the choice of repair method.
c) Prepare a full specification for the work.
It is anticipated that the following document will assist greatly in the last named task. It is hoped that
most sections of this specification can be used without change and that the specification can become a
standard for the industry, as far as this is possible.
The necessity for the pre-tender investigation cannot be over emphasised and, again, it 1S pertinent to
quote TR26:
"It is important to distinguish between chloride-induced corrosion and that simply following from
carbonationof the concrete. Whilst the repair methods will usually be similar in the two cases, the details
may be different and, most importantly, the likely future performance will be different."
Patch repair cannot be considered to be a reliable long term method of preventing continued deteriora
tion in concrete structures containing high chloride concentrations.
Another point which needs to be borne in mind when considering repair options is that patch repairs
may be visually obtrusive. It may be difficult to ob tain a good colour math with the existing concrete.
The repairs may have a different surface texture and rnay weather differently to the rest of the structure.
Protective or decorative renders or coatings may go some way to m ~ n i m i s i n g these problems.
THE MODEL SPECIFICATION
Technical Report No 26 includes four different repair options as follows:
(i) Re-casting.
(ii) Spraycd concrete and mortar.
(Hi) Hand-applied cementitious mortar.
(iv) Hand-applied resin-based mortars.
The Society has an existing specification and code of practice for sprayed concrete and it was realised
that a similar document for hand-applied mortars would be useful to consultants, repair contractors and
others. The great majority of con crete repair work is carried out on relatively small areas using polymer
modified cementitious mortars but proprietary pre-bagged fine aggregate concretes, generally placed
using a letter box technique, are used in some instances especially for deeper repairs. Sprayed concrete
can also be used for patch repairs if a sufficient number of patches can be made ready at the same time
within a convenient area. Sprayed concrete may also be the most appropria te technique for repairing
large areas of $Offits, for instance, following fire damage.
For the purposes of this specification, patch repairs are generally considered to be hand applied and to
have an area of less than 0.5m
2
and a depth less than 100 mm. The repairs rnay assist in reinstating load
carrying ca pacity in sorne instances but their usual function is to reinstate protection to the reinforcement
locally rather than to act structurally. Patch repairs are frequently ernployed in the effort to prolong the
life of structures where carbonation has caused corrosion of reinforcement.
The mode! specification is in thirteen sections. Each section has accompanying user notes which give
general guidance on the topie of the section or guidance relevant to a particular clause. In Appendix B
there isa general checklist which maybeofassistance whencompleting the specification on eachoccasion
on which it is issued.
'7
,
4C$iMi@ WW' #Ai;' i.
MM e
Two alternatives are given for Section 4 Survey and Location of Defects. The standard form specifies
tha t the Contractor will undertake the survey work during the Contract and also locate and mark up the
defects to be repaired and the Engineer monitors these activities. An alternative form is given in
Appendix A to coyer the case when the Engineer undertakes the bulk of the survey work and marks up
the areas to be repaired.
THE METHOD OF MEASUREMENT
The section on method of measurement is in two parts:
a) General principles
b) Specimen bill of quantities
The method of measurement is compatible with that drawn up by a working party of the Concrete Repair
Association which has already been published.
It has to be understood that at tender stage, bills of quantities for repair work can never be considered
as more than a guide to the amount of work required. The number of repairs, the area of individual
repairs and the depth of individual repairs cannot be established until close access is provided. The
documentation, therefore, needs ta provide a mechanism for the inevitable changes in quantities that
will occur as work progresses. The fact that quantities and costs are uncertain should be made clear to
the client 50 that he can make suitable budgetary arrangements.
8
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*P Sijio Hf F*bilMMtfMt'f 4
PART 2 MODEL SPECIFICATION
..1'
9' 1
ss
WkiU%#li iE
NOTES ON THE USE OF THE SPECIFICATION
a) It is suggested that the specifica tion should be reproduced in full each time
that it is used rather than merely listing amendments
b) When clauses are not used the original numbering system should be
maintained by including the clause number and inserting the word
"Deleted"
c) Where additional clauses are required they should be, if possible, placed
at the end of the appropriate section using the next number in sequence
with an"A" to show that itis an additional clausee.g. 2.1OA. The wording
of the clause should be underlined. Where it is not appropriate to place
the additional clause at the end of the section, it should be placed in the
most suitable position and the numbering system exteded e.g. 8.4.1A. The
wording of the clause should be underlined.
d) When a clause is replaced in its entirety the numbering system should be
retained but an S placed after the number e.g. 5.45. The wording of the
new clause should be underlined. This procedure (the underlining of the
whole clause and the use of an "5" after the clause number) should be
followed even if only one or two words are substituted or added.
e) The specification refers to "the Engineer" throughout. For some forms of
contract il may be necessary to substitute "Architect" or "Supervising
Officer". This can be done without following the mie on underlining
changes above.
S JI AW&
1. GENERAL
1.1 General description of structure
. 1.2 Details of problem
1.3 Details of any restriction on or phasing of access
1.4 The general sequence of operations and events will be
as follows:
a) Work area made available to Contractor.
b) Contractor provides access.
c) Carry out trial sample:repairs.
d) Acceptance of trial sarriple repairs.
e) Surface c1eaning by Contractor.
f) Contractor surveys and marks out areas for repair.
g) Engineer inspects and agrees.
h) Contractor removes conaete in repair areas.
i) Engineer inspects and agrees or indicates
requirements for; additional concrete removal,
additional reinforcement, and movement of
existing rein forcement.
j) Engineer agrees measurement of work.
k) Cleaning of rein forcement.
1) Engineer inspects.
m) Completion of repair.
n) Carry out pull-off testing.
0) Preparation of concrete surface for protective treatment.
p) Acceptance of area for protective treatment.
q) Application of protective treatment.
r) Acceptance of protective treatment.
s) Removal of access.
This clause should give ageneral descrip
tion of the structure and the form of con
struction. If repairs are being carried out
to occupied structures then the Specifica
tion should clearly state this and define
the points of access and the areas which
will continue ta be in use during the
works and which will require special pro
tective measures.
This clause shauld describe the defeds in
general terms. A pre-tender investiga
tion must have been carried out. Refer
ence shauld be made ta any relevant
information in the form of survey or in
spection reports or results of tests. The
results of surveys, inspections and tests
should be made available ta Tenderers in
report form. The reports should clearly
ident ify the area of the survey, location of
defects and results of tests. It shouid also
be noted that changes in condition could
have occurred if there is an extended peri
ad between the lime of the survey and the
repair contract.
This clause should be used ta infarm the
Contractor of any phasing requirements,
restrictions on warking hours, access ta
the structure etc, naisy working and pro
duction of dust etc.
Amend sequence of operations if pull-off
lests are not specified.
Amend sequence of operations ifstandard
version of Section 4 is not being used e.g.
fJ Engineer undertakes inspection, sur
vey and testing work.
g) Engineer mIlrks out area for repair.
The period required lJy the Engineer ta
undertake theseactivities should bestated
keeping in mind the time required ta ob
tain the results of any laboratory testing.
11
4iheW.'
2. ACCESS
General Notes
Abseiling is not considered ta be a suitable rneans of access for undertaking patch repairs. ft is considered ta be a useful and
economic means of access for suroeys and inspection but ils use may be restricted in poor weather conditions. Use of abseiling
could pose problems of access for the Engineer.
A useful guide to safety regulations is given in the Building Advisory Seroices publication Construction Safety. This publication
is available from Building Advisory Services or the Building Employers Confederation.
The Contractor should normally be allowed freedom in the choice of means of access with agreement from the Engineer.
The specification should clearly state any limitations that would restrict choi or if any one form of accef!s is mandatory.
The documents shouldaIso indicate in Section 1 of the Specification any phasing requirements if free access is not granted to
al/ areas for the duration of the Contract.
Should there be any imposed or physical restraints upon the means of access to and from the structure then these should be
clearly stated.
If, forenvironmental reasons, it is reqrred that working areas are enclosed, then th!s should be slated in the specification so that
the Contractor can make adequate provisions and ensure lhat scaffolds and platforms are appropriately designed for the extra
loads imposed (including wind loads).
Where additionalloads imposed upon the structure by scaffolds or platforms are expected to be significant, the Engineer should
require that temporary works details are submitted in order that the effect upon the permanent structure can be assessed.
Any known limitations should be indicated in the Contract.
If there is a requirernent for separate hoists for personnel and goods this should be made clear in the specification.
General
2.1 The Contractor sJiaU pro vide suitable and safe means
of gaining access to ail repair areas to enable the works
described in theContract to becarried out and the Engineer
ta carry out the necessary inspections. Abseiling tech
niques shall not be used. The means of access shaH be to
the approval of the Engineer and to the current safety
regulationsand appropria te British Standards.
2.2 Scaffolds, platforms and. cradles shall be designed,
erected, operated, maintaine:d.nd dismantled so as to
ensure that safe working conditions are provided for aIl
site personnel. In addition, complete protection shaH be
provided to the structure, its occupants and the general
public.
2.3 Scaffolds, platforms and cradles shall be erected, a\
tered and dismantled by experienced operatives who shaH
be under competent supervision.
2.4 Before any access provision is used, and at least every
7 days thereafter, the access provision shaH be inspected.
and appropriately certified by a suitably experienced and
qualified person.
2.5 Where temporary fixings and attachmen ts are made to If there are restrictions on the locations of
the fabric of the structure their locations shan be subject to ties and fixings to the building these
agreement with the Engineer and they shaH be removed should be indicated in the relevant clause
when the work is complete and holes made good to the and/or the drawings.
satisfaction of the Engineer.
2.6 Where ties are required to pass through window open
ings the glazing shaH be carefully removed and replaced
by plywood. The opening shaH be seaed against the ef
M rl&w 4 P' n F!Wfdl
fects of weather and to prevent du st and dirt from entering
the building. The glazing shaD be reinstated after removal
of the scaffold.
2.7 Scaffolds shaH be boarded out to the face of the struc
ture in working areas to prevent material or equipment
falling to lower levels or the ground.
2.8 Boarded lifts or scaffolds shall be positioned 50 as to
allow practical access to the working areas and at such
heights in relation to the working areas that operatives can
safely and efficiently use mechanical hand held tools and
equipment. Where the full height of the scaffold is not
boarded out then an agreed number of lifts and sequence
of movement down the face of the structure shaH be im
plemented to provide adequate access at aIl times to the
working areas.
2.9 The Contractor shaIl provide access facilities for in
spection and testing by the Engineer incIuding the end of
maintenance period inspection.
2.10 The Contractor shaIl provide suitable access facilities
to enable trial sample repairs to be carried out, tested and
inspected.
Should it be necessary to provide access
for testing and sampling in advance ofthe
repairs then this should be clearly stated.
Any particular form ofaccess facility re
quired for the end of maintenance period
inspection should be stated.
13
3. SURFACECLEANING
General Note
Guidance on the c1eaning of the facades of buildings is given in BS 6270.
3.1 Before cleaning work begiT1s the Contractor shaH
remove aU surface attachments (signs, notices, electrical
fittings etc) from the areas to be repaired or from positions
that obstruct access or which may be damaged, Unless
otherwise directed a11 inserts and fixings which have been
cast in or mortared in to pockets or otherwise a ttached to
the concrete shaH be removed from the area to be repaired.
The method of removal shaH be such as to avoid unnecess
ary damage and shaH be subject to the approval of the
Engineer. An electrical supplies to surface attachments
shaH be sealed off and the mains suppl Y shaH be discon
nected. AIl surface attachments shaH be carefully stored
during the course of the works and refixed, including
electrical connections, when aIl other work is complete.
3.2 The cleaning operation shall remove aIl dirt or other
contaminants, previous coatings, laitance, paint, algae, moss,
lichens, plant growth etc.
3.3 Before any repairs are carried out on any area the
surface shaH be prepared by:
a) Grit blasting (wet, dry or vacuum blasting) and or
b) High pressure water jetting, steam cIeaning
employing wax free detergents or biocides together
with power scrubbing as required.
The Contractor's proposed method shaH be such that no
damage is caused to sound concrete. Trial areas shall be
carried out on typicallocations on the site for the appro
val of the Engineer before the main cleaning operation
commences.
The Engineer may instruct a change in the method of sur
face preparation if the Contractor's proposed method
causes damage to the concrete or is otherwise unsui table.
3.4 AH necessary measures shaH be taken to provide pro
tection to the general public, occupants of the building,
furniture, fixtures, fi ttings and fabricof the buildingduring
cleaning operations. The Contractor shaH make good or
rectify any damage caused.
3.5 The Contractor shall provide protection to windows,
window frames, doors, door frames and similar built in
items. Windows shaH be kept clean.
N'Cei51"""f M'MN 5'F'Yf''W''!f..OJi:!mfl:ti......fi54WCt "xr&r
The requirement for and method ofclean
ing may have to be specified if there are
particular constmints imposed by the
site. If the cleaning method is specified it
should be tested prior ta tender.
ln gencral it is anticipated that the Con
tractor will visit site during the Tender
period ta assess the cleaning method(s)
required and will be given the option ta
state the proposed cleaning method(s) in
his Tender. High pressure water }etting
may not be appropriate on heavy deposits
as have ta beso highthat
the con crete substmte is damaged.
There may be sorne situations where fu.ll
. cleaning ofsurfaces is not required. Those
'are considered ta be the exception rather
than the rule as often the full extent of
defects cannat be apprec<ted until after
cleaning. Adequate cleaning is also con
sidered ta be essential if coatings are ta be
applied but manufacturers' requirements
may vary. If full cleaning is not required
Clauses 3.2 and 3.3 should be amendtid.
Any parteu/ar requirements or restric
tions under Clause 3.4 should be indi
cated on the drawings or in the
Specification.
es M
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4. SURVEY AND LOCATION OF DEFECTS
(STANDARD FORM WHERE SURVEY AND LOCATION OF DEFECTS ARE CARRIED OUT BY
AND ARE THE RESPONSIBILITY OF THE CONTRACTOR).
General Notes
The need for patch repair will have been established before Tender by initial surveys and investigations carried out by or on
behalf of the structure owner or tenant or lessee. The area covered by the initial survey will often be considerably less than the
total surface area of the structure, particularly where it can be seen that the nature of the defects and results of investigations
appear ta be similar throughout. The results of the initial surveys and investigations should be made available ta Tenderers in
report form as indicated in Section 1 of this specification. Quantities for repair work cannat in most cases be drawn up with
any degree of accuracy prior to the Contract. They will often only reflect the nature and extent of defeets in the area of the initial
survey and the Bills of Quantities may be drawn up on a pro-rata basis.
During the repair contract if is necessary ta survey aU exposed concrete surfaces and carry out appropriate in situ and laboratory
tests in arder ta locale and assess the nature, position and exient of individual defeds and ta determine the appropriate remedial
work. The Contract programme must allow for the survey work ta be carried out ahead of repairs.
Il is necessary ta define c/early where the responsibility lies for making decisions on the exlent and location of individual repair
areas. The standard form of this Specification is written on the basis that the Contractor undertakes this work and the Engineer
adopts a monitoring role. It is felt that this is the most usual procedure at present. However an alternative Sedion 4 fias been
drafted toallow for the situation where the Engineer undertakes the survey and inspection work and marks up the areas requiring
repair. This version of Section 4 is given in Appendix A. Other alternatives are possible and can be achieved by modifying the
wording but il is necessary that the responsibilities are clearly indicated and Clause 1.4 amended.
The activities carried out in the survey and described in Clauses 4.5 ta 4.11 can be added ta or adjusted as necessary to take
account of Crcumstances for a particular project. Other surveys or tests could be inc/uded such as dimensional surreys, feature
surveys and resistivity testing.
The requirement for documentary records of the survey results should be stated.
Caution needs ta be exercised in arder that the stability and strength of the building or structure is not jeopardised by' survey
and investigation aetivities.
4.1 The location number and extentof defccts shown in the
Contract are indicative only. The true location number and
extent of defects requiring repair can only be assessed
properly by close inspection and other testing once access
has been provided and deaning has been completed.
4.2 Prior to breaking out an area the Contractor shaH carry Add descriptions which give the basis for ::"
out a survey of ail exposed concrete surfaces to determine decision making on locations ta be re
the location of defects requiring repair. This survey will paired. As pointed out in the introduc
include visua! inspection, a soundingsurvey, a covermeter
tion, this document relates specifically ta
survey and testing of carbonation depth, chio ride content
repair of damage caused by corrosion in
reinforced concrete. The limitations and
and where indicated cement content. Additional sur
cautions in the situation where corrosion
veying shaH be carried out during the course of the Con
has been caused by high chloride concen
tract as agreed by the Engineer. The limits of each repair
trations should also be kept in mind. A
shaH be marked by the Contractor as a series of straight
typicallist might include:
lines on the surface. The limits of each repair shaH be
a) Cracked areas
subject to agreement by the Engineer.
b) Spalled areas
c) HolIow-sounding areas
Areas to be repaired may inc1ude:
d) Areas where the existing cover to re
inforcement is less than xx mm.
a)
e) Areas where the carbonation depth is
b)
within yy mm of the reinforcement
c)
f) Areas with cloride content in excess
etc)
ofzz%.
The specifier will have ta add the mini
mum caver depth in d) (possibly related
ta carbonation depth) where repairwill be
required, the distance between the carbo
nation front and reinforcement in e) and
also the critical chIoride concentration in
f) if these conditions are used.
ee w
'm
4.3 Where the acccss under the Contract for
carrying out the works Is not in position the Contractor
shall provide temporary access required to facilitate sur
vey work. The temporary access shall be in a form which
allows close inspection of ail concrete surfaces and which
provides a suitable platform for aIl testing and sampling.
4.4 The personnel to be employed in surveying, sampling
work and marking up of repairs shall be suitably trained
and competent. Operatives found to beunsatisfactory shaH
be debarred From the work of surveying, sampling and
markingup.
4.5 During the course of the survey work photographs
shaH be taken at locations agreed by the Engineer. One set
of negatives and two sets of prints shaH be provided for the
Engineer. Prints shaH be of approxima te size 150mm x
100mm. Prints shan be mounted on plain looseleaf A4
sheets with Htles by typewriter or simiJar means.
4.6 A sounding survey shall be carried out by striking the
concrete surface with a club hammer of 200 grammes
nominal mass and recording the loca tion of hollow sound
ing On plane of concrete the surface shaH be
sounded at approximately 300mm centres in each direc
tion. On columns, beams or othe!' similar members vdth
facesless than300mm wideeach face shan be sounded near
each edge or corner at approximately 300mm centresalong
the member. Where a hollow sounding area is detectecl ils
lt is difficult ta give general guidance on
the values to be inserted in dl, e) and f) as
they depend OI"i exposure conditions, pre
dictions of performance and future life
requirements for the structure. Values of
5-lOmm are thought ta be common for
condition d) and 5mm for condition el.
Guidance on critical chloride concentra
tions is given in BRE Digest 264. The
comments in Concrete Society Technical
Report No 26, quoted in the introduction
ta this document ,expressing reseruat ions
about the perfarTrfance of repaired
chloride-affected should be
borne in mind.
ft should be emphasised lhat carbonated
concrete in ilself is not damaging or dele
tenous and does not need to be broken out
and reinstated as a mattcr of course. lt is
the breakdown in the passivating effect
which is important. In a sitU1tion wherc
uncorroded reinforcement is surrounded
by carbonated concrete the specifier may
make a judgement in certain drcumstan
ces that corrosion is unlikely sa long as
the concrete can be kept dry.
Advice on repair of cracked areas where
patch repair is not appropriate is given in
Concrete Society Tech nica1Report l'{o .22 .
"Non-structural cracks in concretc." .
: ".,
II#&iMM *HiM_
M
' 8
extent sha1l be determined by local sounding and its pe
riphery marked on the surface of the member and the
location and extent recorded on drawings.
4.7 A covermeter survey shall be carried out using meth
ods and equipment as described in B5 1881 Part 204. On
plane members the direction of reinforcement with least
cover shaH be determined. The covermeter head shall be
moved arross the surface of the cancre te along a line in a
direction perpendicular ta the direction of reinforcement
with least caver and with the head oriented in the direction
which enables the caver ta that reinforcement ta be
measured. The Unes along which the covermeter head is
moved shaIl traverse the full width of the member and
shaH be approximately 500mm apart. On columns, beams
or other similar members the cover ta longitudinal bars
shaH be determined and recorded at 1m centres along the
member. The cover to each stirrup or binder shaH be
determined and recorded on each face of the member. The
location and caver of any bar with a caver less than xx mm
shall be marked on the surface and recorded on dra wings.
Where a bar is detected as having less than xx mm cover
the length having less than this caver shaH be determined,
the location and extent shall be recorded on drawings and
the location marked on the con crete surface.
4.8 Carbonation depth shaH be determined and recorded
at locations agreed by the Engineer. Carbonation depth
shaH be determined by breaking off a picce of concrete or
taking a smaH core in a sound area and spraying
the fresh fracture surface with phenolphthalein solution
using a suitable spraying bottle. The perpendicular depth
of the interface betwecn the magenta coloration and the
uncoloured concrete from the surface shalI be measured.
Phenolphthalein solution shall be prepared by dissolving
19 of phenolphthalein powder in 50mI ethyl alcohoI and
making up to l00ml with water. The location of the test
and the average and maximum depth of carbonation at
each location shaH be teC0rded on drawings.
: :.,
Add lhe crilical cover depth (xx) in the
last two sentences.
Taking small diameter cores for carbona
tian tests may cause less damage than
breaking off a piece of concrete. The
sample area will have ta be reinstated and
could be unsightly if a surface coating is
not inc/uded in the Contract. Il should
be remembered that carbonation depth
will probably be greatest at corners.
The phenolphthalein method can give
misleading resuIts on produds such as
cast stone where areas with unhydrated
cement may be exposed by breaking off
test areas. Petrographie examination is
preferred for these products.
Details of the phenolphthalein test are
given in BRE Information Sheet IS
14/78. The phenolphthalein solution
should be only lightly sprayed on the
surface otherwise transport of dissolved
alk,is may obscure the location of the
true carbonation front.
17
JH*PWi 'e tl w&tl'i
4,9 Dust samples of con crete for testing shall be taken at
the locations agreed by the Engineer, The area s:'1all be
surveyed by covermeter and the sample obtained at a
location away from reinforcement. The sample shall be
obtained using a rotary percussion drill with a bit of 12mm
diameter. The concrete surface surrounding the test area
shall be thoroughly cleaned and four holes in a square
pattern drilled. Samples from depth increments 0-25mm,
25-50mm, 50-75mm and 75-100mm shall becollected. The
dust from the four holes in each depth increment shaH be
carefullycollected and combined and placed immediately
in a robust plastic bag which shall be immediately sealed.
The sample bag shaH be marked indelibly with a discrete
sample number on an adhesive label on its outside. The
location and sample number shall be recorded on draw
ings. Chloride determinations shall be carried out in ac
cordance with BS 1881 Part 124 at a NAMAS accredited
laboratory. Results shaH be stated as percentage chloride
ion by weight of sample.
4.10 Concrete cores of xx mm diameter shaH be drilled in
locations and to depths agreed by the Engineer. Unless
specifically requested by the Engineer, it is to be assumed
that the cores are to be drilled away from reinforcement
and before drilling commences a covermeter survey is to
be carried out and the locations of reinforcing bars rnarkcd
on the surface. The cores shall be drilled at positions
chosen by the Contractor 50 as to avoid reinforcement.
Unless otherwise directed by the Enginccr cores shaH be
cut perpendicular to the concrete surface. The coring
equipment shll befixed firml y in posi tion to allow smooth
barrelled cores'to be obtained. If steel is struck coring shaH
be discontinued and the core position moved or aban
doned as directed by the Engineer. Cores shaH be \\'ashed
off in c1ean water the surface dried and the core indelibly
marked with a discrete number, The core shall be mme
diately wrapped in two layers of ding film and placed in a
strong plastic bag. Th.e plastic bag shall be marked in
delibly on Hs exterior \vith the core number on an adhesivc
label. The location frOTh which the core is taken shaH be
recorded on drawings.
4.11 Haif-cell surveys shall be carried out in the areas
agreed by the Engineer generally in accordance with
ASTM C876-80. Continuity of reinforcement shaH be
checked before commencing the survey by breaking ou tas
necessary and measuring the resistance between bars in
locations remote from each other across the area or struc
ture. Readings shaH be taken on the surface over reinforce
ment positions preferably on an .orthogonal grid at a
maximum spacing of 300mm. Equipotential contours
shaH be plotted on drawings of the structure from the
recordcd data.
Sorne authorities suggest that the drill
diameter should be similar ta the nominal
maximum aggregate size in the concrete.
Drill sample depths will have ta be as
signed in re/ation ta the particular struc
ture under repair. For example some
water retaining structures are thin
walled and dri/ling ta a depth of l00mm
may not be appropriate.
Add the required core diarneter (xx) de
pending on structure dimensions, bar
spacing and intended testing.
ASTM C876-BO procedures for imple
menting half-ll surveys should be fol
lowed but the document should not be
followed blindly when interpreting re
sulls. Specialist advice should be ob
tained as ta the need for and the
Interpretation of l'esults of half-ll sur
veys. A forthcoming Concrete Society
Technical Report prepared in conjunc
tian with the Institute of Corrosion will
give additional guidance on the specifica
tion and Interpretation of half-lI poten
tiai surveys.
4.12 Any areas broken out, cored or drilled for the pur
poses of testing or sampling shall be made good using the
repair methods described in this specification.
18
5
+ Mt ,em RffiW't!ff'fBiW**ftiM5##S#itom'Mj
Fe *F'M"1
CONCRETE REMOVAL
5.1 Any temporary propping described in the Contract
shaJl be securely in place before any concrete is removed.
Where additional propping is required duringremoval the
Contractar shall ensure that such propping is securely in
place before the extent of remaval exceeds the limits de
scribed in the Contract. Temporary prapping shaH remain
in place until the member has been fully repaired and the
repair mortar has gained the required strength.
5.2 The power and size of the equipmen t used for conerete
removal shaH be appropria te to the scale of the individual
repairs and shan be subject to the approval of the Engineer.
Where percussive equipment is used particular care shaH
be taken that damage is not caused to concrete substrate
and reinforcement which is to remain in place.
5.3 The amount of concrete removed From a member at
any time shaH be subjeet to the restrictions deseribed in the
Contract and to the approval of the Engineer.
5.4 The limits of each repair area shall be eut as a series of
straight lines at right angles to the surface to a depth of
approximately lOmm (5mm for repairs using epoxy mor
tar) using a dise cutter or similar. The dise eut surfaces
shaH beroughened prior to reinstatement. Feather edging
shall not be perIItted.
5.5 Concrete in repair areas shaH be removed ta the depth
indicated in the Contract or as required by the Engineer.
The Engineer should specify the degree of
propping that will be necessary in car
rying out repair work. ln addition, the
specification or drawings should indicate
the amount of concrete remova/ lhat will
be permissible al any one time.
Where there are environmental eon
stmints it may be neeessary to specfy
partieular methods of removal such as
water jetting.
In describing the removal of concrete,
care should be exercised in the descrip
tion., For example, "defeetive" concrete
suggests that the material is in a redu.ced
physical condition and henee relatively
easy ta remove. Alternatively "contami
nated" concrete will require repair but in
ail probability may be physiClly sound
and involve considerable effort for ils
removal.
The restrictions may be deseribed in the
Contract by drawings, notes on drawings
or a written statement. Examples of re
strictions inc/ude:
a) Limitations on reduction ofcross-sec
tion
b) Limitations on length of break out on
a member
c) Limitations on breaking out adjacent
members at the same time
Where the cover is low, dise cutting will
have la be omi!!ed or limited in order ta
avoid damage ta reinforcement. Care
needs ta be exercised when roughening
the disc-cut surfaces to prevent damage
ta the edges. It is probably best achieved
bygritblasting al the same time as clean
ing the reinforcement.
The depth of concrete removal must be
specified in the Contrad (e.g. on the
drawings). If concrete is removed behind
the bars this will help to lock the repar
into the member and al/ow the full cir
cumference of the bars to be cleaned pro
vided sufficient clear distance is broken
out behind them (say 20mm). Where
concrete is not broken out behind the bars
and also where the repar is ta be built out
from the existing surface it may be con
sidered necessary ta provide aphysical tie
by the use ofresin anchored slainless steel
fixings into the parent concrete. A sug
gested clause is given al the end of the
General Notes in Section 6.
19
5.6 Additional concrete removal shan be carried out along
actively corroding exposed bars until a cantinuous length
of 50mm of bar free from active corrosion is exposed. The
limit of active corrosion shaH be assessed on a visual basis.
The edges of any additional areas removed shall be eut
square as specified above. The extent of concrete removaI
shaH be agreed by the Engineer before any reinstatement
commences.
5.7 AIl necessary precautions shaH be taken to ensure that
dust or falling debris does not constitute a hazard to per
sonnel, equipment, the structure, Hs occupants and the
general public. Effective means of clearing dust and debris
away from the working area shaH be continuausly i ~
plemented. '
5.8 The extent and depth of cancrete removal required
shan be measured and recorded on drawings by the Con
tractor and agreed with the Engineer as the work proceeds.
The degree of removal of carbonated con
crete needs to be defined. If the carbona
lion front is close to or has not yet reached
the reinforcement and corrosion has not
commenced asurface coatingmay suffice.
The Engineer may have to decide the ap
propriate course of action in conjunction
with the structure owner after expiai ning
the risks and economies of the alterna
tives.
If condition e) in the user note for Clause
4.2 has been inc1uded. the following sen
tence should be added immediately afler
the second sentence:
"Additional concrete shall also be broken
out if it is found that carbonation has
reached within yymm of the reinforee
ment".
An additional length of uncorroded bar
(up to 200mm) will have to be broken out
if couplers are to be used for replacement
reinforeement.
; :"
1.0
1 MU ft # bd r=rr
6 PREP ARA TION OF REINFORCEMENT
General Notes
Replacing or Supplementing Reinforeement
The effective replacement or supplementing of corrosion damaged reinforcement is a complex tapie and it is doubtful whether
the subject has been adequately addressed ta date.
In arriving at adecision on the adequacy of the reinforeement the [irst step is ta assess the extent and type of stress in the affected
bar or bars. As a very broad general rule, if a structural appraisal indicates lhat the bar was nearly fully stressed before corrosion
and has lost 10% or more of ils Cross sectional area therr it may be Expedient ta strengthen the member. This broad general rule
applies ta individual bars as most patch repairs will include only one main reinforcing bar. &pairs which include a number of
bars will have ta be eonsidered individually on their merits.
Methods of rep/acing or supplementing reinforeement are described below but it should be emphasised that no significant cutting
. out of either reinforeement or concrete should be eontemplated without a reasonable understanding of the effect this may have
on the member or the structure.
Before cutting out corroded reinforeement the Engineer must check that the structure is made safe by temporary propping or
other suitable means.
Provision of extra reinforeement using straight laps
Where existing eoncrete remains bonded ta stressed main bars, no breaking out should take plaee ta provide lap lengths for
supplementary reinforeement unless applied loads are relieved by temporary propping. If propping is Not feasible then other
methods of strengthening the member should be eonsidered. Lap lengths should be a minimum of 40d and be greater if the repair
mortar does not provide a bond strength equivalent ta that of the substraie concrete.
Provision of extra reinforeement which is anchored
Extra reinforcement may be instal/ed with reduccd laps by anchoring the ends at 9Cf ta the concrete face. The ends should be
embedded using resin or cementitious mortars. Care must be taken ta avoid damaging adjacent areas wJiere' (he existing
reinforcement ta concrete bond remains intact, unless the structure or member can be temporarily propped. Bond and bearing
stresses of the anchors would need ta be calculated.
Provisioll of extra reinforcement using cotmeetors
This method of supplementing reinforeement may require greater access around the bar in arder ta make the connection. The
finished connections will in some cases signi[icantly reduce the caver ta the reinforeement.
The connector should be capable of transferring ail the forees in the bar and the properties of the joined bars should correspond
as c/osely as possible ta those of a continuous bar.:::..
Fr details of reinforeement connectors reference may be made to, "Reinforcement con necto rand anchorage methods", by W S
Paterson and KR Ravenhill, CIRIA Report 92.
Provision of extra reinforcement usi?lg welding
The site wdding of reinforcement should be avoided if alternative methods of repair are available. Doubts rernain as ta whether
thewelded sections can restore the strength properties of the original undamaged bar. The introduction of preheating may induce
thermal stresses on cooling and could damage the bond between the existing reinforeement and concrete substrate.
If site welding is ta be carried out there are several essentlal features ta be inc/uded in every programme of work.
1) A written procedure should be agreed before work commences, covering methods of work, etc" for each type of joint ta be
made.
2) Qualification tests ta certify ail welders should be carried out bath before beginning a project and at intervals during the
work.
3) A quality control programme should be instituted which should include lensile testing and radiographic inspection or other
non-destructive testing.
Referenee should be maae ta the following publications Whel1 preparing a specification.
a) BS 7123 - Specification for metal arc welding of steel for concrete reinforeement.
b) Thewelding ofReinforcing Steels - A guide ta design and proeedures, published by the Reinforcement Steel Services Division
of the British Steel Corporation.
YI
, 1
c) CIRIA Report 92, "Reinforcemcnl conneclor and anchorage methods", by W 5 Paterson an4 KR Ravenhill,
In some cases il may be necessary ta dowel in additional reinforcemenl of small dilmeter bars la anchor back repairs ta corners
and arrises, If adequate caver cannat be obtained these should be of stainless steel. A suitable clause might be:
"Where shawn on the drawings or as directed by the Engineer, additional xx mm dilmeter stainless steel bars shall be grouted
into hales drilled in the existing concrete ta anchor repairs, The method ofgrouting shall be approved by the Engineer."
6.1 Rust scale corrosion products and other deposits shaH
be removed irom reinforcement exposed within the area
of repair by grit blasting or other method approved by the
Engineer to achieve SA 2
1
/
2
quality to BS 7079 : Part AL
The means of removal shaH comply with health and safety
legislation.
Uncantained dry sand blasting is not
permitted as it is a health hazard. Con
tained dry sand blasting may be used
subject ta approval of the device or equip
ment by the Health and Safety Executive.
Wet san4 blasting may be uSed subject ta
approval for use of the equipment by the
Health an4 Safety Executive.
Dry grit blasling may be used but con
sideration should be given ta the protec
tion of the general public and the
Immediate environs from grit an4 dust.
Wet grit blasting may be used and this
process removes dust and reduces the
spread of used grit.
Needle guns are unlikely ta clean adequ
ate/y behind the reinforeement when (lC
cess for the equipment is limited by other
reinforeement or lhe concrete substrate.
Water jetting is eonsidered by the work
ingparty ta bepermissible and.is effective
in mast situations including teinforee
ment junctions. Surfaee preparation by
water jetting may not be good enough for
some epoxy reinforeement protection sys
tems because of incomplete removal of
any localised areas of remainingpassivat
ing layer. Care and protection of the
general public and the Immediate envi
rons against the foree of the wateT jet
needs ta be pravided. :'.
Mechanical reinforcement cleaners
should be lested on site before approval is
given for use. These tools can reach be
hind bars but are not very effective at
reinforcement junetions. Care is re
quired ta avoid polishing rather than
cleaning steel and when rotating serrated
edges are used there is a risk of cutting
into sound steel if tao much pressure is
applied.
Chemical rust removers are also available
and there are differing opinions on their
benefits or otherwise. Their use needs
careful control as they would have ta be
totally removed before application of re
inforcement p1'Otective system and caTe
would have ta be taken that they do not
conlaminate or damage the concrete.
Theil' use is not recommended here.
6.2 Ali necessary measures shall be taken to provide pro
tection to the general public, occupants of the building,
furniture, fixtures, fittings and fabricof the building during
cleaning operations. The work shall be damped down as
necessary to reduce the spread of dust. The Contractor
shaH make good or rectify any damage caused. Windows
shall be kept clean.
6.3 Grit blasting shaH be carried out in such a way as to
include the hidden faces at the backs of bars and at inter
sections of bars.
6.4 Abrasives shaH be new, c1ean and dry and of a grade
suitable for the preparation of steel to the standard indi
cated above. Abrasives shaH he of a type approved by the
HeaIth and Safety Executive. Exhausted abrasive shaH be
bagged up and removed from site after single use.
6.5 Equipment shaH be capable of delivering abrasives at
a nozzle pressure sufficient to achieve the standard of
c1eaning specified above and the air supply shall be free of
entrained oil and water.
6.6 If directed by the Engineer the exposed reinforcement
shaH be thoroughly washed down with clean water as part
of the preparation operations.
6.7 If directed by the Enginecr the existing reinforcement
shall be moved or supplemented or replaced by new bars
in accordaI1ce with BS 4449 welded or spliced to existing
bars. Bprs tobe removed shaH be eut by dise.
6.8 Replacement bars shaH be cleancd if required by the
Engineer to the British Standard specified above. Where
bars are lapped a minimum lap of fort y times the bar
diameter shaH be provided.
6.9 AIl shaH be adequately fixed and tied in
position such tQat'u will not be displaced during reinstate
ment. "
There may be an advantage, particularly
where epoxy barrier coat reinforeement
protective systems are ta be used, in in
c/uding an inhibitor in the wash water
. if. R* i'S!lffl#* i' $@eMW.W&JiEH "eSdM"
7. REINFORCEMENTPROTECTIVE SYSTEM
General Notes
Protective coatings applied to reinforcement in patch repairs nclUJie the following:
Cement slurry orpolymer madified cement based slurI-Y, This serves as a repassivation coating which res/ores the a/kaline
environment around the reinforcement.
Epoxy resin based coatings. These form a physical barrier between the rebar and the repair moTtar.
Zinc rich primers. Il is submitted by the proponents of these primers that when a hostle environ ment exists within the
subsfrate the zinc will provide a sacrificial anode thereby protecting the reinforcement. ,_
Otherprimer treatments.
High standards of surface preparation are essential when using epoxy based materials.
Research 1S currently in progress comparing the different coating systems for bars and results of this are awated before any
further guidance can be given. At present it is suspected that if chloride ions migrate into the repar, the cement slurry m.ay
offer less resistance than a barrier or sacrifcial coating provided. the barrier coating is defect free. However a reinforcement bar
barrier coating may be vulnerable [rom the presence of discontinuities, and at the ends of the repair. At these points ptting and
underflm corrosion may Occur.
When carbonation is the prime cause of damage it is considered that there is little benefit in providing a barrier coating and that
the cement 51urry in conjunct ion with the new alkaline material in the repar will provide a protective environ ment.
Reference may be made to the CIRIA book "Corrosion Damaged Concrete - Assessment and Repair" published by ButterwoTth
and BRE Information Paper IP 18189.
7.1 After cleaning the surface of the bars shaH be coated
with a protective system if such a treatment is part of the
specified e p ~ i r system.
7.2 The exposed area of the reinforcement shaH be com The 3 hour period in this clause may have
pletely covered with the protective system. The first coat to be modified in sorne drcumstances.
shaH be applied within 3 hours of cleaning. Any rein force Where wark is being carried out in highly
ment remaining uncoated at the end of a 3 hour period
humid or chloride rich atmospheres, cor
shaH be recleaned in accordance with the Specification
rosion maY take place an the cleaned sur
face within 3 haurs. Epoxy based systems
prior to applica tion of the reinforcement protective system.
requiregood surface cleanliness and some
manufacturers refer to application "im
mediately" after blasting.
7.3 Number of coats, time between coats, mixing and
application of the reinforcement protective system shall ail
be in accordance with the manufacturer's instructions.
MhEii MM
8. REINST A TEMENT
General Note
Delele Clauses 8.16 to 8.21 if repairs with resin-based mortars are not required.
8.1 Before the application of repair compounds begins the
Contractor shall satisfy himself that the condition of the
surface to be repaired and the weather are such as to allow
the work to proceed. Repairs shaH not proceed if the air
temperature or con crete substrate temperature lS SoC or
less and shaH cease if the air temperature reaches SOC on a
falling thermometer unless the planned procedures speci
fied below are implemented. A higher or Iower tempera
ture than SoC shaH be substituted above if required by the
instructions of the manufacturer of repair compounds.
8.2 Repairs may proceed at low temperatures if specifie
planned procedures are implemented. These include:
i) Provision of heated tenting which enve
lops the repair area and w hich produces
an environment with a sustainable air
temperature in excess of SoC
ii) Warming materials and the substrate to a
temperature above soc. The method of
warming the substrate shaH be such that
the substrate is not damaged and is not
caused to dry out in the case of cernent
based repair materials.
iii) Insulating the completed orpaitially com
pleted repairs in accordance with good
practice for winter concreting
A higher or lower tempcrature than SoC shaH be sub
stituted above if required by the instructions of the manu
facturer of repair compounds.
Preparation
8.3 Immediately before reinstatement aH dust, debris and
loose material shaH be removed from the area of the repair
by air blasting with oil-free air, vacuuming or vigorous
wirebrushing. Waterjettingorbrushingmaybepermitted
subject to compatibility with the repair medium.
8.4 When using cernent based repair mortars the concrete
substrate shaH be thoroughly soaked with water to obtain
a saturated surface dry condition. Any surplus water shaH
be removed before reinstatement begins.
Priming
8.5 Concrete surfaces within the repair area shaH be treated
with a bonding aid or primer in accordance with the manu
facturer' s instruction.
8.6 Priming coats or bonding aids shaH be thoroughly
worked into all hollows and crevices in the prepared sur
face and around the reinforcement if required.
TheMeteological Office can provide local
forecasts.
H
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8.7 Repair mortar shall be applied "wet on wet" when
using a bonding aid or primer unless the manufacturer of
the repair system specifies that the bonding aid or primer
must dry out before the repair mortar is applied.
8.8 If at any time the primer or bonding aid completely
dries out before over-layingexcept as permitted above the
repair surface shaH be re-prepared generally by complete
removal of the dried primer or bonding aid or as specified
by the manufacturer of the repair materials.
Filling - Cementitious Mortar
8.9 The repair mortar shaH be applied in layers not exceed
ing the thickness specified by the manufacturer of the
mortar.
8.10 Each layer shaH be thoroughly worked and com
pacted into the repair zone and around or between rein
forcing bars. The technique employed shaIJ ensure that no
air is entrapped and that full contact with the primed
substrate is achieved.
8.11 Successive layers shaH be applied as soon as the
preceding coat has become sufficiently stiff to support the
weight of the additional build-up layer but is still adequ
ately tacky to pro vide bonding. The time between layers
shaH bein accordance \vith themanufacturer's recommen
dations. If sagging occurs the material shaH be completely
removed and reapplied at a reduced thickness.. .
8.12 If at any time the last layer applied completely dries In the situation where a previous layer of
out before over-Iaying the surface shall be prepared ac cement based mortar MS been allowed ta
cording to the manufacturer's recommendations.
dry out the manufad urer's stated proce
dures should be followed. These proce
dures are often along the /ines of:
i) Roughen the surface of the previous
layer
ii) Thoroughly soak the surface
iii) Apply bonding aid or priming coat
iv) Proceed with next layer
8.13 The final build-up layer within a repair shaH not be
less than 10mm thick and shaH be levelled off or profiled
usi ng trowelling techniques to produce a finish as specified
below.
8.14 Curing to retain moi sture shaH be implemented im
mediately on completion of the repair. The surface of the
mortar shaH be protected from strong sunligh t and drying
winds.
8.15 The repair shaH be cured by the method and for the The Working Party was of the opinion
period recommended by the manufacturer of the repair that there is a good case for specifying
system. During this period the temperature of the ma terial curing by sealed polythene sheets over the
shaH not be allowed to drop below SoC and the repair shaH
repairs for 72 hours as a minimum
be shaded from direct sunlight. Curing membranes shall
notwithstanding the manufacturer's
not be permitted.
stated recommcndations. The curin.g
period will have ta be adjusted according
to elimate. hl winter there will be a
necessity to protect from frost. Good pro
tection and curing in exposed windy con
ditions is particularly important.
26
; iIiiiiif ? +PW*kM' et "t5tkfH*iHEw; '" j Mi
.: ,.raI' !
The specification prohibi/s the ux,' "::
ing membranes because they -.' .
the adhesion of any applied coa:-:'.: f
coating is not 10 be applied this .:-.: ..:
_ "1
tian may be removed. Sorne eur!r.: ' .
branes may be specifically fonm .
receive a subsequent coatirlg.
The importance of effective curin:, :.,",-.d
be overemphasized. Inadequal.c." "'S
can lead to cracking or delJondir.;:.' .1e
repair.
Filling - Resin M ortar
8.16 Surfaces shall be c\ean ar.d sound prior to the use of
resin repair mortar. Surfaces be dry unless a primer
specifically designed for damF surfaces is used.
8.17 Primer shaH be applied te the substrate ensuring that
If the primer is absorbed b"j the
within say 30 minutes theYi a
it is weIl brushed into the prepared surface taking care to
should be applied in accor::lan ;..:::.1e
avoid "puddIing" in depressk-,ns. Where, due to the na
manufacturer'5 instruct ir.. YI s.
ture of the substrate, the primer is absorbed by the con
crete, a second application of :-1rimer shaH be made. The
second coat shaH be applied ' ..:ithin 16 hours of the first
coat.
8.18 The resin mortar shaH applied whilst the primer
has adequate surface tack.
8.19 The mixed material be applied to the primed
surface in layers not the manufacturer's recom
mended thickness using a tech:lique to prevent entrapped
air.
8.20 If subsequent layers are t0 be applied the surface shaH
be thoroughly scratched to pr0\'ide a good mechanical key.
The time between layers shaH be in accordance with the
manufacturer's recommendations. Primer shall be ap
plied between each layer as required in the manufacturer' s
. : ..
instructions.
8.21 Intermediate stages and the completed repair shaIl be Resins de-oelop full strer :tth Il "-- _ ,:::
protected From rain until at ](>,lst 24 hours after the repair
characteristics within 48 ".ours ,;.. '
theperioJ will belongera: :O'Wer
has been completed. The temperature of the repair shaH
not be allowed to drop belo\\' SoC and the repair shaH be
tures.
shaded from direct sunlight during reinstatement and
until at least 48 hours after completion of the repair.
Surface Finish
8.22 The final layer of aIl repairs shaH be finished to
provide a close textured accurate level surface which mat
ches theappearance of the surrounding concrete including
arrises and which accords with the standard achieved in
the successful trial sample repairs.
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9. SURFACE PREPARATION FOR PROTECTIVETREATMENT
General Notes
Fairing coats are supplied as a part of sorne repair systems. They will also be required on rough areas to provide a suitable base
for coating. However fairing coats can only be applied to limited thickness typically 2or 3 mm. Where the surface profile requires
a layer thicker than this a repair mor/ar or other suitable material will have to be used.
There may be an option be/ween using a fairing coat with a low-build coating system and no fairing coat with a high-build
coating system. A surface fil/er would still be required with the high-build coating system. The high-build coating option may
be cheaper but may not achieve comparable Ilesthetic results as cracks and repairs may show through.
9.1 The surface shaH be prepared by blast cleaning, steam Equiprnent used for surface preparation
cleaning, water jettingor needle gunning to remove alldirt,
should reflect constraints existing al sile
salt deposits, grease, paint or other contaminants and any
when the work is being carried out e.g.
surface scaling, weak surface layers or lai tance and to open
problems of ingress of water and dust,
nuisance ta the generai public.
up blowholes. Unless otherwise directed or approved the
final cleaning down operation or treatment to the whole
Surface texture of prepared concrete
. surface shall be carried out as a single continuous oper
shciuld be that specified by the manufac
ation.
turer of the subsequent treatment.
9.2 Items such as glazing and door and window frames
shaH be adequately protected during the preparation pro
cess and the application of protective treatment.
9.3 Nibs or ridges on the surface or within repairs or at the
joints between repa ir and original concrete shaH be ground
smooth prior to the application of protective treatment.
9.4 Surface filler shall be applied to blowholes and other The use of surface fillers is important
isolated surface blemishes or defects in order to provide a
where a coating system is ta be used ta
surface suitable to receive subsequent treatment.
reduce carbonation. Pinholes in coating
over pores can leati to rapid local carbo
nation.
9.5 The fairing coat shaH be applied to the whole of the Delete if no fairing coat is required. If this
exposed concrete element or structure, unless otherwise clause is included the thickness shouid be
directed by the Engineer.
stated in the Bill of Quantitles. Any re
quirement for re-profiling members
should be stated.
9.6 For cementitious fairing coats and surface fillers the
substrate shaH be treated as required by the application
instructions of the manufacturer of the fairing coat.
9.7 Fairing coats and surface fillers shall be mixed, applied
and cured strictly in accordance with the manufacturers
recommenda tions.
9.8 Before applica tion of fairing coa t or surface filler begins
the Contractor shaH satisfy himself that the condition of the
surface to which the materials are to be applied and the
weather are such as to allow the work to proceed. Fairing
coa t or surface filler shall not be a pplied if the air tempera
ture or concrete substrate temperature is SOC or less and
shaH cease if the air temperature reaches SoC on a falling
thermometer unless the planned procedures specified in
Clause 8.2 are implemented. A higher temperature than
SoC shaH be substituted above if required by the instruc
tions of the manufacturer of the fairing coat or pore filler.
78
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9.9 Fairing coats and surface fillers shaH be fini shed to give
a smooth level surface. Arrises shall be formed as necess
ary.
9.10 Trial sample panels of fairing coat shaH be prepared
in the works forapproval. No other fairingcoat application
shall be carried out until a trial sample panel has been
approved. The trial sample panel shaH be used as a stand
ard against which the rest of the work will be judged.
; :..
i;
Deiete if no fairing coat is required.
:29
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10. PROTECTIVE TREA TMENT FOR CONCRETE SURFACES
General Notes
The owner of the building should be made aware of the ongoing maintenance implications of using protee/ive coatings.
Required temperatures, relative humidifies and surface moisture condition should be clearly specified and facilities should be
provided on site ta check these parameters.
ln generaJ it is difficu/t ta measure wet or dry film thickness on concrete. The application rates can be used as a guide ta the
film thickness likely to have been achieved providing temperature and melhod of application remain constant.
The selection of application equipment requires care in lhat it should take account of the r.ature of the tt!,ea to be trealed and
should be compatible with the products ta be employed. Operating pressures, output etc. need ta be considered and the
manufacturer consulted.
Mixing limes, working life and overcoating times should be checked with the manufacturer taking into account the temperature
al the time of use.
Where exlernal application is ta take place the imminent weather conditions should be checked by reference ta the local weather
office and by local observation. Arrangements should be made to protect the surface [rom water or contaminants [rom other
sources.
Trials of material compatibility should reflect the true site circumstances of use i.e. the method of application of the coating.
Records of application rates should incorporate temperatures and details of site circumstanees such as weather conditions.
The Specification or drawings should state colour requirements for surface treatmenl. The use of different coloured primer/lst
coatj2nd coat makes is easier ta check that ail coats have been applied.
Useful information on protective treatmenfs for concrete surfaces is given in CIRIA Technical Report 130, "Protection of
reinforced concrete by surface treatments
N

,
10.1' Protective treatment shaH be applied to the whole of The words "as described in the con tract "
the exposed concrete surface and repairs as described in should be deleted if ail of the exposed
the mntract. concrete is ta be trealed. Otherwisedraw
ings which indicate the locations to be
treated should be included.
10.2 Protective treatments shall be mixed and applied
strictlyin accordancewith the manufacturer' s instructions.
,- Thinning.ordiluting in excess of the manufacturer's rec
ommendtions shaH not be permitted.
10.3 AB surfaces shaH be dry before and during the appli Instruments which indicatesurface mois
cation of protective treatment. Ambient and surface tem lure condition, though not on an abso
peratures/ ambient relative humidity and the surface
lu!e seale, are available and values are
moisture condition shaH be measured and recorded by the
quo!ed in sorne coating manufacturer's
specifications.
Contractor on each day before coating commences and
during coating. No coating shaH be applied unless the
conditions meet the coating manufacturer' 5 specification.
10.4 Where repair mortars or fairing mats or surface fillers
and mating systems are supplied by different manufac
turers, the repair mortar shaH be subjected to trials by the
coating manufacturer and repar material manufacturer to
ensure compatibility between the various elements and
eviden shall be provided of acceptable performanceelse
where on simiJar structures under similar conditions.
10.5 Records of application rates shall be submitted by the
Contractor to the Engineer on a daily basis indca ting batch
numbers, the area covered by each coat and the amount of
coating material used.
30
w Mff'GRDMh a
10.6 Items or areaS which are not to be coated shall be
suitably protected or masked before application of the
protective treatment.
10.7 Trial sample panels of protective treatment shaH be
prepared in the works for approval by the Engineer. Pro
tective treatment application shaH not be carried out until
a trial sample panel has been approved by the Engineer.
The trial sample shan be used as a standard against which
the rest of the work will be judged.
.: :-.
MHE Q%& F PMM' <,.tiW_lWif'f
11. TRIAL SAMPLEREPAIRS
General Notes
The need for sample repairs will depend ta a certain extent on the size of the contract and the avallable time. If possible the size
and location should be shown on the drawings or described in the Specification.
Pull-off testing could be specified for the cores and used as a basis for assessing pull off values achieved in the works.
11.1 Trial sample repairs for approval shaH be undertaken
for each type ofdesigna ted repair not less than three weeks
before the related work is scheduled to start. Trial sample
repairs shaH be carried out using materials of the same
formulation as that to be used in the works. If the formu
lation of materials is changed during the course of the
works, additional trial sample repairs shan be carried out.
11.2 Trial repairs shaH be assessed by the Engineer to check
that the required standard will be achieved by the materi
aIs and methods proposed by the Contractor. Trial repair
areas shall be used asa standard against which subsequent
work shaH be judged.
11.3 Trial sample repairs shaH be chosen, as far as it 1S
reasonably possible to encompass the majority of the posi
tions and orientations of the surfaces to be repaired.
11.4 During the trial repairs six cubes for each type of
mortar shaH be made and three tested at 7 and three at 28
days. Cubes shaH be made cured and tested. generally in
accordance with BS 6319 Part 2 andlor the manufacturer' s
recommendations.
11.5 After reinstatement six number 50mm diameter cores Coring should not be undertaken until 3
shaH be cut through each trial repair area to a depth such days after repair for resin mor/arS and 14
that each core penetra tes the substrate by approximately days after repar for cementitious mor
25mm. The cores shaH be visuaHy examined by the Engin fars. These periods may have ta be ex
eer to determine the degree of compaction and
tended in periods of cold weather.
adhesion achieved. '. :..
The cores could be used used for pull-oft
tests as described in Clause 12.8.
11.6 On completion of the coring a section of the trial
samplerepairs shaH becarefully broken out in the presence
of the Engineer to demonstrate that adequate compaction
and adhesion have been achieved.
11.7 Approval for trial repairs shaH be based on the fol Acceptance criteria may have ta be ad
lowing: justed in the light ofexperience.
i)
Cube results shaH demonstrate an average If necessary add ta 11.7:
strength which exceeds 90% of the
iv) Colour match and surface texture
manufacturer's stated strength with no single
match with adjacent concrete.
result less th an 75% of the manufacturer' s
Where the repair material is required to
reach aparticular strength for structural
stated strength.
ii)
reasons il will be necessary to use this
Visual inspection of the trial area shaH indicate
strength as the acceptance criterion
that the area is free from excess voidage and has
rather than the manufacturer's quoted
good bond to the substrate/reinforcement.
strength.
Iii)
Cores are weIl compacted and free from entrapped
If a characteristic strength has been spe
air with good inter-layer adhesiDn.
cified in 13.3add ta 11.7a reference to the
characteristic strength and the amount
by which the result shall exceed the spe
cified characteristic strength.
32
12 MMMM 1N,., ,aa' Ahfi
12. TESTING
General Notes
Clauses 12.8. la 12.12 ta be omitted if pull-off testing is not specified. Also amend sequence of operations in Clause 1.4.
Alternative forms of testing could be substituled or added.
A European Standard on testing of repair mate rials is in the early course of preparation but may not be available for several
years.
12.1 One sample of mortar for repairs shaH be taken for
every three days on which repair mortar is used unless
otherwise specified by the Engineer. The strength result
from the sample shaH represent mortar placed on the pre
vious day, the day on which the sample was taken and the
following day. Three cubes shall be made and tested from
each sample. For cement based mortar, the cubes shaH be
tested at 28 days. The average of the three 28 day values
shall be taken as a strength result. For resin based mortar
the cubes shaH be tested at an age agreed by the Engineer
and the average value for those cubes shaH be taken as a
strength result.
12.2 Sampling and testing of repair mortars shall be in
accordance with BS 6319 Part 2 unless otherwise specified
by the Engineer
12.3 AlI testing shan be carried out by a NAMAS ac
credited labo ra tory.
12.4 Test cubes sha1l be stored and cured in a manner Cubes oJ pa/ymer modified morlar should
appropria te ta the materials under test in accordance with be placed in sealed polylhene bags imme
the manufacturer's instructions but generally in accord
diately after making and struckfrom Iheir
ance with BS6319. They shalI be delivered properly ident
mould at an age ofl day. Thereafter they
should he air cured al a temperature of
ified to the approved laboratory.
approximately 2fYC until they are tested.
12.5 Cube results shaH be judged for compliance against Where the repair material is required ta
the manufacturer's quoted strength. Each strength result comply with a "char.acteristic" slrength
shall exceed 80% of the manufacturer's stated typical
for slructural reasqns it will be necessary
strength.
la use Ihis strerigth as the acceptance

12.6 The repairs at risk due to non compliance shaH in Adjust this clause ta clearly identify
dude aIl repairs executed on days represented by any which repairs are at risk if a "charac
strength result which fails to achieve compIiance.
leristic" strength luis been specified in
13.3. The repairs at risk will depend an
the form af the acceptance criteria speci
fied in 12.5.
12.7 As a consequence of non-compliance in the tenns of
the above, the Contractor shaH be directed to take such
remedial action as the Engineer may consider necessary.
This action may include removal of material in repairs at
risk as described above and/or further testing required to
establish the acceptability or otherwise of the repair mor
tar. The Contractor shall.bear: the cast of any such addi
tional testing and removal and reinstatement of repirs.
33
H H ~ W i'ri*ee
-
12.8 During the course of the works the Engineer will carry
out approximately x No pull-off tests on repaired areas.
The tests wiII be carried out fourteen days after reinstate
ment of the area under test. The Contractor shaH cu t 50mm
diameter cores through the repair and 50mm into the
original concrete at locations directed by the Engineer. The
Contractor shaH make good the core hoIes after completion
of the test using the repair methods and materials de
scribed in this specification.
12.9 Three No. pull-off tests shaH be carried out on each
selected area. The average of the three values shaIl be taken
as a pull-off strength result.
12.10 Each pull-off strength result on an area shaH be at
least 0.8 N/mm
2
unless failure occurs within the parent
concrete at a lower value.
12.11 The mode of failure shaH be recorded i.e. within
substrate, within repair material.
12.12 As a consequence of non-compliance with the puII
off strength requirement, the Contractor shaH be directed
to take such remedial action as the Engineer may consider
necessary.
Add number of pull-off tests. Pull-off test
locations have to avoid reinforeement.
Sorne authorities advocale using a disc
cutler to cut a 50mm square rather than
co ring prior to the pu/l-off test. The ac
cep/ance value ofO.8Nfmm
2
may have to
be revised (upwards or downwards) in
the light of experience.
34
J'
Aseem_
13. MATERIALS
General Notes
Alternative clauses could be drafled to allaw site batching of repar mortar using po/ymer latex or the use of flowng concrete.
These are felt to be applicable only ta larger contracts. The clauses shauld inc/ude requirements for strict quality cantrol and the
Engineer should consider modifications to the testing regime. The Contractor should be required ta demonstrate that he can
exert effective co.ntrol over the sile batching operation.
The properties of repaiT materials need to match those of the concrete in the structure under repar. Hgh shrinkage valuesl
differenees in elastic modulus and thermal coefficient can lead ta high stresses in the patch and the surrounding concrete which
could cause debonding and premature failure.
At present there are few national standards which are directly applicable ta repar materiais. Many manufacturers have carried
out comprehensive test programmes but il is nol possible ta compare materials because different test methods may have been
used. Work is at present being undertaken by CEN ta produce European Standards for test rnethods and eventually repair
materiais. At present it is considered that the best approach is ta include the narnes ofl say, three repair system manufacturers
based on Experience of past sa tisfact ory performance in similar conditions.
A schedule of proposed repair materials, ta be completed by tenderers, is given in Appendix C.
13.1 AlI materials for repair and protection of concrete Add narnes and addresses of manufac
structures shaH be obtained from a single manufacturer turers.
from the list given below. Alternative manufacturers may
be proposed by the Contractor prior to commencement of
Repair systems are available from a large
work at site but their materials shaH not be used without
number of manufacturers of widely va
rying resourees and track record. Mem
the prior approval of the Engineer.
bers of the Working Party were strongly
a)
of the opinion that where circumstanees
b)
permit this Clause should be amended ta
c)
inc/ude referenee ta FeRFA or other such
. etc)
body. Sorne materials have British Board
of Agrment Certification.
ft is recommended that aIl elements of a
repair and protection system (reinforee
ment protective system, bonding aid or
primer, repair mortar, surface filler, fair
ing coat and protection system) are ob
tained from a single manufacturer.
O/herwise there can be divided responsi
: :..
bilities ifproblemsarise. Ifuseof products
from more than one manufacturer is un
avoidable then the combination should be
the subject of trials by bath manufac
turers ta check compatibility. Evidence
of previous successful use ofthe materials
in combination would also be useful.
13.2 AlI materials shaH be used strictly in accordance with
the manufacturers' instructions and this Specification.
Manufacturers' instructions shall be available to ail opera
tives at site.
13.3 Repair mortars, fairing coats and pore fillers shaH be Add any strength or other requirements
factory pre-batched materials. The chloride ion content of for the repair mortar. If the term "charac
cement based materials shaH not exceed 0.1 % by weight of tenstic strength" is used this would have
cement. The ingredients and their proportioning shan be
ta be defined as say "that strength below
such that disruptive alkali aggregate reaction does not
which only 5% ofsamples are expected ta
occur.
fall". Add ta the clause if colaur and
surface lex/ure match VJith tlu::: existing
concrete are required.
25
13.4 Mixing and application of repair and protection ma
terials shaH be carried out strictly in accordance with the
manufacturer's instructions. Mixing of part bags or other
containers of components shall be allowed only with the
prior permission of the Engineer and the manufacturer.
13.5 Ail materials and the manner in which they are used
shaH conform to the relevant Health and Safety and Con
trol of Substances Hazardous to Health Regulations.
13.6 Materials shall be stored in an environment which
conforms with the requirements of the manufacturer. Ma
terials shaH not be removed from store until immediately
prior to mixing or use. Matenal from damaged containers
shaH be discarded.
Storage facilities are required ta be stated
in the information provided by the Con
Iractor with his tender.
* MG HM ....?
APPENDIXA
SURVEY AND LOCATION OF DEFECTS
(ALTERNA TIVE FORM WHERE SURVEY 15 CARRIED OUT BY THE ENG1NEER
DURING THE CONTRACT)
: ;.
1. ..
37