TECHNIQUES FOR THE PROTECTION AND REPAIR OF REINFORCED CONCRETE STRUCTURES

1. INTRODUCTION
Many of the recent structures existing in Portugal are made of reinforced concrete. For example, 45%
of the residential buildings are made with it. Initially, in the 60s to 80s, when this material started to be
extensively used, people thought it was eternal, so durability was not an issue to be considered in
design and construction.
Now it is understood that structures made of reinforced concrete get old and have a limited lifetime,
usually of 50 years. Without durability criterion that lifetime can short to only 20 or 30 years, if subjected
to severe aggressive environments. To achieve the 50 years without any big repair intervention new
regulation, namely the EC2, is very strict in terms of durability, specifying minimum reinforcement cover
and concrete class in accordance with environmental exposure.
This summary refers to this theme, studying the new Standard EN 1504 Products and Systems for the
Protection and Repair of Concrete Structures, summing up the information exposed in it and
explaining it, constituting a state-of-art of this subject.

2. STANDARD EN 1504
The European Standard EN 1504 was elaborated by the Technical Committee CEN/TC 104 and it
defines the principles that shall rule the protection and repair of concrete structures. This standard
covers the following aspects [1]:

Assessment of the condition of the structure.

Identification of the causes of deterioration.

Determining the objectives of protection and repair.

Selection of the appropriate principle(s) of protection and repair.

Selection of methods.

Definition of properties of products and systems.

Specification of maintenance requirements following protection and repair.

The Standard is organised in different parts, in accordance with the following:

Part 1: General scope and definitions.

Part 2 to 7: Specifications related with various kinds of interventions.

Part 8: Quality control and evaluation of conformity.

Part 9: General principles for the use of products and systems.

Part 10: Site application of products and systems and quality control of the works.

One important issue that this standard introduces is the classification, in accordance with the damage,
of all the causes for reinforced concrete structures deterioration, as it is exposed in the next chapter.

3. REINFORCED CONCRETE DETERIORATION

In this chapter the various causes of reinforced concrete deterioration are exposed, with a proposal of
the methods suitable for an intervention of prevention or repairing of the respective damage. Those
methods are named and explained in a further chapter of this summary.
1. Deterioration due to concrete defects
1.1. Mechanical actions
1.1.1.

Impact Methods for repairing: M1.3, M1.4, M3.1, M3.2, M3.3, M5.1

1.1.2.

Overload Methods for repairing: M1.3, M1.4, M3.1, M3.2, M3.3, M3.4, M4.1, M4.2,
M4.3, M4.4, M4.5, M4.6, M4.7

1.1.3.

Movement Methods for repairing: M1.3, M1.4, M3.1, M3.2, M3.3, M3.4, M4.1, M4.2,
M4.3, M4.4, M4.5, M4.6, M4.7

1.1.4.

Explosion Methods for repairing: M1.3, M1.4, M3.1, M3.2, M3.3, M5.1

1.2. Chemical reasons

1.2.1.

Alkali-aggregate reaction Methods for repairing: M1.3, M1.4, M2.1, M2.2, M2.2,
M2.4, M3.1, M3.2, M3.3, M3.4, M5.1

Fig. 1 Mapped cracking due to alkali-aggregate reaction (left), gel formed near the aggregate (right)

1.2.2.

Aggressive agents Methods for repairing: M1.1, M1.2, M1.3, M1.4, M1.5, M1.6,
M1.7, M2.1, M2.2, M2.3, M2.4, M6.1, M6.2

1.2.3.

Biological activities Methods for repairing: M5.1, M5.2, M6.1, M6.2

1.3. Physical actions

1.3.1.

Freeze / thaw Methods for repairing: M2.1, M2.2, M2.2, M2.4

1.3.2.

Thermal Methods for repairing: M1.3, M1.4, M1.5, M3.4, M5.1

1.3.3.

Salt crystallization Methods for repairing: M1.1, M1.2, M1.3, M1.4, M1.5, M1.6, M1.7,
M2.1, M2.2, M2.3, M2.4, M6.1, M6.2

1.3.4.

Shrinkage Methods for repairing: M1.3, M1.4, M1.5, M3.4, M5.1

1.3.5.

Erosion Methods for repairing: M1.6, M3.1, M3.2, M3.3, M3.4, M5.1, M5.2

1.3.6.

Wear Methods for repairing: M1.6, M3.1, M3.2, M3.3, M3.4, M5.1, M5.2

2. Deterioration due to reinforcement corrosion

Fig. 2 Crack due to corrosion (left), spalling due to rebar corrosion (right)

2.1. Carbonation Methods for repairing: M1.1, M1.2, M1.3, M1.4, M1.5, M1.6, M1.7, M2.1, M2.2,
M2.3, M2.4, M7.1, M7.2, M7.3, M7.4, M8.1, M9.1, M10.1, M11.1, M11.2, M11.3
2.2. Stray currents Methods for repairing: M2.1, M2.2, M2.3, M2.4, M8.1, M9.1, M10.1, M11.1,
M11.2, M11.3
2.3. Corrosive contaminants
2.3.1.

At mixing (chlorides) Methods for repairing: M2.1, M2.2, M2.3, M2.4, M7.2, M7.5,
M8.1, M9.1, M10.1, M11.1, M11.2, M11.3

2.3.2.

From external environment (chlorides) Methods for repairing: M1.1, M1.2, M1.3,
M1.4, M1.5, M1.6, M1.7, M2.1, M2.2, M2.3, M2.4, M7.5, M8.1, M9.1, M10.1, M11.1,
M11.2, M11.3

2.3.3.

Other contaminants

4. INTERVENTION
The Standard helps defining the kind of intervention to adopt, exposing the various options possible. It
also specifies numerous aspects to consider in the design and execution of the intervention. The
methods defined in the Standard for protection and repairing of concrete structures are organised in
accordance with the principles to achieve. In the next table those principles and methods are exposed
[1]:

Principle

Methods

M1.1 Impregnation
M1.2 Surface coating with and without crack bridging ability
M1.3 Locally bandaged cracks
P1 [PI] Protection against
M1.4 Filling cracks
ingress
M1.5 Transferring cracks into joints
M1.6 Erecting external panels
M1.7 Applying membranes
M2.1 Hydrophobic impregnation
M2.2 Surface coating
P2 [MC] Moisture control
M2.3 Sheltering or overcladding
M2.4 Electrochemical treatment
M3.1 Applying mortar by hand
M3.2 Recasting with concrete
P3 [CR] Concrete
restoration
M3.3 Spraying concrete or mortar
M3.4 Replacing elements
M4.1 Adding or replacing embedded or external reinforcing steel bars
M4.2 Installing bonded rebars in performed or drilled holes in the concrete
M4.3 Plate bonding
P4 [SS] Structural
M4.4 Adding mortar or concrete
strengthening
M4.5 Injecting cracks, voids or interstices
M4.6 Filling cracks, voids or interstices
M4.7 Prestressing (post tensioning)
M5.1 Overlays or coatings
P5 [PR] Physical resistance
M5.2 Impregnation
M6.1 Overlays or coatings
P6 [RC] Resistance to
chemicals
M6.2 Impregnations
M7.1 Increasing cover to reinforcement with additional cementitious mortar concrete
M7.2 Replacing contaminated or carbonated concrete
P7 [RP] Preserving or
M7.3 Electrochemical realkalisation of carbonated concrete
restoring passivity
M7.4 Realkalisation of carbonated concrete by diffusion
M7.5 Electrochemical chloride extraction
P8 [IR] Increasing resistivity M8.1 Limiting moisture content by treatments, coatings or sheltering
P9 [CC] Cathodic control
P10 [CP] Cathodic
protection
P11 [CA] Control of anodic
areas

M9.1 Limiting oxygen content (at the cathode) by saturation or surface coating
M10.1 Applying electrical potential
M11.1 Painting reinforcement with coatings containing active pigments
M11.2 Painting reinforcement with barrier coatings
M11.3 Applying inhibitors to the concrete

Before the execution, planning must be accomplished to achieve good results. The Standard refers
which preparation works must be done in accordance with the method adopted. The most important
works are:

Preparation of the concrete surface (cleaning, roughening, concrete removal).

Preparation of reinforcement surface (cleaning).

5. TECHNIQUES FOR THE PROTECTION AND REPAIR OF REINFORCED CONCRETE

The Standard EN1504 names the methods to be used in accordance with the principle to achieve with
the intervention. Those methods are based on techniques. The same technique is repeated in various
methods depending on the aimed principle. In this summary we will explore those techniques.
1. Superficial protection
1.1. Impregnation
This technique is used to limit the access of aggressive elements without interfering with the structure
aspect. There are simple impregnations, made of low density resins, that penetrate and fill the pores of
the surface of the concrete, diminishing its superficial permeability and increasing resistance. There is
also the hydrophobic impregnation, that uses silans and siloxans. In this case the pores are not filled.
Simply, inside of them, a hydrophobic compound repeals moisture and, so, low pressure water is not
absorbed. In the use of this technique the risk of evaporation of the product during application must be
considered and, also, it shall penetrate at least 2mm.
Methods in which the impregnation is used: M1.1, M2.1, M5.2, M6.2, M8.1

Fig. 3 Impregnation of a surface (left), surface protection with paint (right)

1.2. Surface coating

This technique provides superficial protection, since it consists on a layer put on top of the substrate
surface. There are two kinds of coating. One is painting, consisting on a thin layer (0.1 to 1.0mm) that
control carbonation, chloride penetration, chemical attack. There is also the mineral or mixed mineral
and polymers coating, usually a layer with 1 to 5mm thick, that provide physical resistance to the
surface, lowers its permeability and covers low width cracks. In this coatings a minimum permeability
should be specified so that moisture wont accumulate near the surface, deteriorating it.
Methods in which the surface coating is used: M1.2, M2.2, M5.1, M6.1, M8.1, M9.1

1.3. Membranes
This is a special type of surface coating, whose main feature is being very flexible and totally
impermeable. Their use should consider the risk of moisture accumulation near the surface, if any
exists within the concrete.
Methods in which the surface coating is used: M1.3, M1.7, M6.1, M9.1

1.4. Overcladding mortar or shotcrete

This technique consists on providing extra cover to reinforcement and protection to surface, with
collocation of new layer over the surface with a thickness from 5mm to 60mm or more. If it is a very
thick layer (over 60mm) it should be used small diameter debris to reduce the effect of shrinkage. Also
some admixtures can be used to diminish the chemical vulnerability, increase elasticity and
workability such as fly ash or polymers. The use of overcladding should be preceded by a prehumidification of the surface of the substrate. Also the adhesion guaranteed between new and old
materials should be superior to 1.0MPa.
Methods in which the overcladding is used: M2.3, M5.1, M6.1, M7.1

1.5. Physical external protection

This kind of protection consists on installing, externally to the structure, material such as, for example,
precast concrete panels or composite plates. Depending on the chosen material, it can provide great
protection against penetration of aggressive elements or physical degradation due to use, erosion or
impacts.
Methods in which the physical external protection is used: M1.6, M2.3

Fig. 4 Membrane application (left), physical external protection with fibre glass pates (right)

2. Prevention against corrosion

2.1. Steel protection against corrosion
There are two kinds of steel protection: rebar coatings or the use of corrosion inhibitors. The first either
contains active pigments with anticorrosive properties or acts as a barrier isolating the steel from water,
which is, for example, the case of resins. In the other hand, the inhibitors are used in the concrete and
they act in the anode reconstructing the protective layer of steel or they act in the cathode. Their
effectiveness is still questioned nowadays.
Methods in which the steel protection against corrosion is used: M11.1, M11.2, M11.3
2.2. Cathodic protection
The cathodic protection consists on installing a system that forces the rebars to act as cathodes. It can
be passive if it consists on the installation of sacrificial anodes with lower electric potential than the
steel, in electric contact with the rebars. Otherwise, it can be active if electric current originated in a
external font is imposed to a system that is formed by the rebars and a neutral anode that is collocated
on the surface of the element. This is a very effective way of protecting the steel against corrosion due
to chloride penetration.
Methods in which the steel protection against corrosion is used: M10.1

Fig. 5 Steel protection coating (left), cathodic protection of a bridge pier (right)

3. Techniques of repairing deteriorated concrete

3.1. Treatment of cracks
In general, if a crack width is greater than 0.3mm, it must be injected with a material that can, in
accordance with the Standard, be either able of transmitting forces, or be flexible enough to keep up
with crack movements or, else, be hidroexpansive, absorbing water and filling the crack. A mineral
product can be used, such as cemment grout or a polymer, such as epoxy resin. Cracks can also be
superficially sealed or reinforced with steel. The selection of the correct technique and product
depends upon knowing the reason for its existence and if it is expected further movements in it.
Methods in which the treatment of cracks is used: M1.4, 1.5, M4.5, M4.6
3.2. Patching repair of deteriorated surface with mortar or concrete
Due to spalling or extensive deterioration of the surface, it can exist superficial zones that leave the
steel unprotected against corrosion. So these areas must be filled and, to do it, it can be used mortar
or concrete made with small aggregates, after deteriorated concrete removal and surface preparation.
The material used should have admixtures to reduce shrinkage and increase workability, so that the
patch area wont crack or result too much permeable. For that, polymers and fly ash can be added.
Sometimes the steel is very corroded and with significative section lost. In those cases new steel
should be added and forces must be transmitted between old and new rebars.
Methods in which patching of deteriorated surface is used: M3.1, M3.2, M3.3, M4.4, M7.2
4. Electrochemical treatment of contaminated concrete
If the carbonation depth if already very significant, there is the possibility of electrochemical
realkalisation, that provides new alkalis to the area surrounding the steel, increasing pH and so helping
to create a new protective layer. Also, if thats the case, chloride can be removed from inside concrete.
Both techniques make use of simple installation, generically, consisting on a metal mesh outside
concrete, electrically connected to reinforcement, with imposed current. These must be kept for a few
days, but they are of simple installation, non intrusive and quite effective and durable.
Methods in which electrochemical treatment is used: M7.3, M7.4, M7.5
5. Strengthening of the structure
The Standard refers to the strengthening if structures safety is affected due to deterioration. In
particular, it refers to adding or replacing steel bars, to bonding external plats (steel or composite
material) or to the use of internal or external prestress.
Methods in which strengthening of the structure is used: M4.1, M4.2, M4.3, M4.7

6. Other techniques referred in the standard

Finally, some other techniques for intervention are possible and named in the Standard. This is the
case of electrochemical moisture control (M2.4), replacing of deteriorated elements (M3.4) and limiting
the oxygen content at the cathode by saturation or surface coating (M9.1).

6. CASE STUDY REPAIRING AND PROTECTING OF A DETERIORATED CONCRETE FAADE

The faade repaired and protected belongs to a 10 storey building, in Lisbon, built in 1976. The faade
is composed of reinforced concrete elements. Those elements showed general signs of deterioration,
such as, spalling of surface concrete due to steel corrosion. Executed tests and visual observation led
to the conclusion that the concrete carbonation caused reinforcement corrosion and that element
geometrical conception led to accumulation of rain water.
It was decided a typical intervention with concrete patching repair of the deteriorated areas followed by
a superficial protection. The methodology adopted was:
a) Mapping of spalling areas or with exposed reinforcement.
b) Concrete removal with cutting disk or jackhammer, 20mm deeper than the reinforcement.

Fig. 6 Reinforced concret element deteriorated (left), deteriorated concrete removed (right)

c) Mechanical surface preparation to create surface roughness.

d) Steel cleaning to remove rust and detect the need of replacement if section loss was significative.
e) Steel protection with cement base barrier, from the brand SikaMonotop 610.
f)

Patching with tixotropic monocomponent mortar, made of cement, fly ash and resin, reinforced
with fibres (brand SikaMonotop 612). This mortar was applied by hand, in layers with a thickness
less than 20mm.

g) The adopted surface protection was a system that act as a membrane (Sikagarg Aquaprimer
552W (80m), Sikagard 570 (110 m) and Sikagard 550W (160 m)).

During intervention a continuous scheme of quality control was implemented to guarantee the
effectiveness of protection.

Fig. 7 Area being patched, in the first mortar layer (left), surface after repairing (right)

Fig. 8 Products used for surface protection (left), quality control of surface protection (right)

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