REPAIR MANUAL

Dr. Mohammed Maslehuddin

Research Institute
King Fahd University of Petroleum and
Minerals
 Purpose of the Manual
Assist engineers in diagnosing concrete
deterioration problems and planning repair
and rehabilitation of deteriorating
structures.
 Contents of Repair Manual
Chapter 1: Guide to mechanisms of
concrete deterioration
Chapter 2: Assessment of the extent of
concrete deterioration
Chapter 3: Strategy for repair of
deteriorated concrete
structures
Chapter 4: Repair materials and their
evaluation
 Contents (contd.)
Chapter 5: Repair procedures
Chapter 6: Repair systems
Chapter 7: Long-term monitoring
strategies
 Chapter 1
A guide to forms of concrete deterioration

Reinforcement corrosion
Carbonation
Sulfate attack
Salt weathering
Alkali-aggregate reactivity
Cracking of concrete
Acid attack
Damage due to fire
Attack due to micro-organisms
 Chapter 2
Assessment of Concrete Deterioration
Preparation (preparatory desk work)
Preliminary investigation (visual inspection
and appraisal)
Detailed investigation (data collection, field
measurements, condition survey, sample
collection, testing of samples, analysis and
evaluation)
Conclusion and recommendations
 Chapter 2 (contd.)
Preparation prior to inspection
Design information
Plans/drawings, as-built drawings,
specifications and other related information
Location of the structure and topology and
accessibility
Structural drawings for reinforcement details
Service history
 Chapter 2 (contd.)
Preliminary investigation
Structural condition, extent of cracking,
damage
Safety of the structure
Need for commissioning a detailed
inspection
Accessories needed for detailed
inspection
Traffic control requirements
Any unusual problems facing the structure
 Chapter 2 (contd.)
Detailed investigation
Data collection
Field measurements and condition survey
Sample collection
Testing and field samples
Analysis and evaluation
Report
Conclusions
Recommendations
 Chapter 2 (contd.)
Commonly used test methods
Methods for estimating in-situ concrete
strength
Methods for determining properties other
than strength
Methods for the physical evaluation of
structures
 Chapter 3
Strategy for repair of deteriorated concrete
structures
Cause and extent of damage
Consequence of the damage
Time for intervention
Economics
Operational constraints
 Chapter 3
Repair options
No repair
Repair
Cosmetic
Partial
Total
Partial repair or total replacement
Factors influencing the selection of
repair strategy (No repair)
Minimal damage
No chance of re-occurrence of damage
due to overload etc.
Expected service life is more than the
design life
Appearance is not a problem
Factors influencing the selection of
repair strategy (Repair)

Cosmetic repair
Limited deterioration
Rate of deterioration is too low as in the no
repair option
Improve the appearance
Factors influencing the selection of
repair strategy (Repair)

Partial repair (patch repair)

Rectify apparent defects
Structural safety is not affected
Factors influencing the selection of
repair strategy (Repair)

Total repair
Advanced deterioration
Structurally unsafe
Operational constraints for total replacement
Factors influencing the selection of repair
strategy for corrosion (No repair)

Active corrosion but corrosion rate is low

Low chloride concentration
Structural integrity is not compromised
Factors influencing the selection of repair
strategy for corrosion (Repair)

Cosmetic repair
Active corrosion but corrosion rate is low
Chloride concentration is high
No spalling, localized delamination
Structural integrity is not affected
Factors influencing the selection of repair
strategy for corrosion (Repair)

Partial repair (patch repair)

Active corrosion
Localized delamination or spalling
Structural safety is not affected
Factors influencing the selection of repair
strategy for corrosion (Repair)

Total repair
Active corrosion
Uniform spalling or delamination
Excessive loss of cross section of bars at
many locations
Factors influencing the selection of repair
strategy for corrosion (Partial or total
replacement)

Repair is economically not feasible

No operational constraints
Structure is structurally unsound
 Chapter 4
Repair Materials and their Evaluation
Repair mortars
Cementitious repair mortars
Polymer modified cementitious mortars
Resin-based repair mortars
Sprayed concrete
Injection grout
Flowing micro concrete
Bond coat materials
Steel primers
Surface coatings
 Chapter 4
Repair Materials and their Evaluation
Test methods
Compliance criteria
 Chapter 5
Repair Procedures
Repair of cracked and deteriorated
concrete
Shrinkage cracks
Settlement cracks
Thermal cracks
Dormant or dead cracks
Live cracks
 Chapter 5
Repair Procedures (contd.)
Vacuum impregnation
Resin injection
Repair of surface defects
Repair of inadequate cover
Repair of deteriorated and cracked concrete due to
sulfate attack and salt scaling
Repair of cracks caused by alkali-silica reaction
Repair of deterioration due to exposure to chemicals
Repair of deterioration and cracking due to exposure
to high temperature and fire
Repair of spalled concrete
 Chapter 6
Repair systems
Marine environments
System 7 or 1
Below ground structures
System 1 or 6
Sulfur fumes
System 6, 5 or 8
Acid exposure
System 6, 5 or
Sweet or saline water
System 9 or 10
Fire damage
System 7 or 8
 Chapter 7
Long-term Monitoring Strategies
Visual inspection
Debonding
Monitoring chloride and moisture content
Measurement of carbonation depth
Assessing reinforcement corrosion
Resistivity
Corrosion potentials
Corrosion rate