Repair of Concrete

Superstructure and Substructure

April 11-13,2016
 BRIDGE
IS AN IMPORTANT ELEMENT IN A HIGHWAY TRANSPORT
SYSTEM.
PLAN
PARTS OF A CONCRETE BRIDGE:

Deck Slab Railing/

Railing/
Girder
2
8
9
6 1
10

3 7
4
5

Pier

TWO MAIN PARTS OF A STANDARD BRIDGE:

A.) SUPERSTRUCTURES (1,2)

B.) SUBSTRUCTURES (3,4,5)

 REPAIR OF CONCRETE STRUCTURES :
A. REPAIR OF CONCRETE DECK SLAB/GIRDER/
ABUTMENT/PIER:
1. EPOXY INJECTION ON CRACKS:

Epoxy injection is used to

restore structural soundness
of structures exhibiting
inactive cracks. Cracks with
more than 0.3 mm up to 3.0
mm widths can be bonded
and sealed by injecting low-
viscosity epoxy.
(After Injection)
Required Materials and Tools/Equipment:

Required Materials
Epoxy Resin (Compatible with host concrete/sealant)
Sealant (Compatible with host concrete/epoxy resin)
Injection port

Required Equipment/Tools
Epoxy Injection Pump or Gun
Power Disc Grinder/Cutter
Portable Generator
Brush etc.
 Specifications of Epoxy Resin for Injection

Specifications of Sealant (Putty) for Epoxy Injection

 Work Sequence:

Clean the Cracks Adhesion of Pipe Fitting Seal Cracks at the Surface

Fitting of Injector and Curing of Injected Material

Inject the Epoxy
2. CAULKING:
Crack widths of more than 3.0 mm
with depth of less than 300 mm.
The top surface edges should be
chipped or sawn to form ditch of V-
type or U-type, in order to provide
a caulking for inlet of resin flow into
the crack by injection pump.

Approx. 10mm Approx. 10mm

Sealant Sealant
Crack Crack

Caulking (V-Type) (U-Type)

Required Materials and Tools/Equipment:

Required Materials
Epoxy Grout (Compatible with host concrete/sealant)
Sealant (Compatible with host concrete/epoxy grout)
Set of Injection Tools

Required Equipment/Tools
Epoxy Injection Pump or Gun
Power Disc Grinder/Cutter
Portable Generator
Brush etc.
Specifications of Epoxy Based Injection Material

Specifications of Epoxy Based Sealant

 Work Sequence:

Drilling Holes and

Clean the cracks Preparation of Caulking Fixed Injection Pipe

Injecting the Epoxy Grout Curing of Injected Material

3. PATCHING: Patch repair is performed to restore small
TYPEAA
TYPE
areas where sound concrete is damaged by
spalling, scaling and impact. The patch
thickness is limited to a maximum of 100
mm depth of hollow surface.
1.) Type-A
- without exposed rebars,
EPOXYBONDING
EPOXY BONDING
- defective widths of up to 300mm and
depths of up to 50 mm.
TYPEBB
TYPE - Portland cement mortar
2.) Type-B
- with exposed rebars,
- defective widths between 300 mm and
600 mm, and up to 100 mm depths.
EPOXYBONDING
EPOXY BONDING
- Polymer cement mortar
Required Materials and Tools/Equipment:

Required Material

Type-A Type-B
Portland Cement Polymer Cement
Epoxy Bonding Coat Epoxy Bonding Coat
Sand Zinc Rich Primer
Required Equipment
Power Disc Grinder
Light Mechanical Breaker or Hammer
Chisel
Portable Generator
Brush
/Concrete
 Work Sequence:
W
Section
W
Loss
Damaged
Area
Removed
Line
H
W H

30D 30D
Damaged
Removed
H should be at least 20mm Length
W and H should be
at least 20mm
Line D means diameter of the Rebar
Cleaning of Concrete/Rebar
Removal of Defective Concrete

Bonding Coating to Placing Mortar Curing

Concrete / Rebar
4. CARBON FIBER SHEET BONDING TO DECK SLAB
Carbon Fiber Sheet Bonding is
intended to enhance the
capacity of the concrete deck
slab and extend its service life.
And shall be designed to
Continuous Arrangement strengthen and stiffen concrete
bridge deck slab.
Carbon Fiber Sheet and Plate Placement on Girders

150mm
15.00 m
A1
Side 250mm

150mm
1.84 m
4 pcs of
250mm 250mm
wide CFS
A2
Grid Arrangement 0.26 m
7.11 m; 17 pcs of
0.26 m Side
250mm 250mm
250mm wide
CFS
Required Materials and Tools/Equipment:
Required Material:
Carbon Fiber Products Epoxy Materials
CFS (Strap Type) Epoxy Primer
Epoxy Putty
Epoxy resin adhesive

Required Equipment :
Abrasive Sandblaster
Air Compressor
Disc Grinder
Portable Generator
Paint Roller/Brush
 WORK SEQUENCE

Adjustment of Application of
Preparation Application of Unevenness Epoxy Resin for
of Concrete Primer with Putty Undercoat

Installation of Installation of Squeezing of Surface Protection

Longitudinal Transversal Strip to
Layer CFS Layer CFS Entrapped Air
5. STEEL PLATE BONDING
The bonding of steel plates to concrete
deck slab using epoxy adhesives is to
enhance the bridge load carrying capacity.
The effect of bonding a plate to the tension
face of a reinforced concrete section is to
increase the depth from the compression
face to the neutral axis and the area of
Wide Plate Type effective reinforcement, thus, increasing
the moment of resistance of the section.
Two types of Steel Plate Bonding:
a.)Wide plates - used for strengthening
the slab in both the main reinforcing bar
and distribution bar directions.
b.)Narrow plates - used for
strengthening the slab in one direction
Narrow Plate Type only.
Required Materials and Tools/Equipment:
Required Materials
Injection Method Pressure Attaching Method
Steel Plate Steel Plate
Primer (Epoxy Base) Primer (Epoxy Base)
Epoxy Resin Adhesive Epoxy Resin Adhesive
for Injection Epoxy Sealant
Epoxy Sealant Anchor Bolts
Anchor Bolts Wood and Angle Bar for Fitting

Required Tools/Equipment
Injection Method/Pressure attaching Method
Disc Grinder
Welder
Electric Drill
Epoxy Injection Pump with Accessories
Wire Brush
Two Methods of Bonding Steel Plate to Concrete Surface:
1. Injection Method - applied for wide plate type
Concrete Slab
Anchor Bolt
Epoxy Grout

Air Pipe
Injection Pipe
Steel Plate
Sealed with Epoxy Resin

2. Pressure Attaching Method - applied for narrow plate type

Anchor Bolt

Concrete Slab

Epoxy Adhesive
Pressing Wood Steel Plate to be Bonded

Foam Rubber

Angle Bar

Round Washer
 Work Sequence
1. Injection Method:

Surface Preparation Setting the Steel Plate Sealing the Steel Plate
on the Slab

Injection of Epoxy Resin Curing and Painting

 Work Sequence
2. Pressure Attaching Method:

Surface Preparation Application of Epoxy Resin

Pressure Attachment of Steel Plate Curing and Painting

6. PARTIAL/TOTAL DECK SLAB REPLACEMENT

Partial/Total replacement of
slab is carried out to replace
portion/whole of the concrete that
has been severely damaged. If
damaged portion is not removed,
further deterioration is expected,
which could impair the strength,
stability and serviceability of the
Severely Damaged and
structure.
Water Leaking Deck Slab
Required Materials and Tools/Equipment:
Required Materials
Portland Cement, Sand, Gravel, Fast Setting Mortar
Rebar (Reinforcing bar, Grade 60)
Epoxy Resin (Bonding Coat to Concrete)
Zinc Rich Primer (Bonding Coat to Rebar)
Required Tools/Equipment
Sawing Equipment
High Pressure Water Blasting
Handy Concrete Breaker or Jackhammer
Handy Power Chisel
Concrete Mixer/Transit Mixer
Vibrator
Troweling tools
 WORK SEQUENCE

Removal of Damaged Preparation of Old Setting Formworks

Deck Slab Concrete Concrete and Rebar

Placing Concrete Curing and Removal of

Formworks
Placing Signage
7. WATERPROOFING ON DECK SLAB
The application of waterproofing
membrane on the deck slab is
primarily to protect the concrete
surface from the damaging effect on
contact with water and corrosive
materials.
Types of Waterproofing Membrane System:

1.) Rubberized Membrane Type mainly 2.) Asphalt Compound Membrane Type
consists of chloroprene rubber consists of asphalt mixed with special
rubber
Required Materials and Tools/Equipment:
Required Material
Rubberized Membrane Asphalt Compound Membrane
Primer Primer
Rubberized Membrane Asphalt Compound Membrane
(1st layer ~ 4th layer) Silica sand
Tack Coat (Finish Coat) Tack Coat (Finish Coat)

Required Equipment/Tools
Rubberized Membrane Asphalt Compound Membrane
Paint Roller Kettle with Heater
Roller Brush or Hair brush
Rubber Brush
 WORK SEQUENCE
1.) Rubberized Membrane Type
Asphalt Pavement
5th Layer (Finish Coat)
Waterproof Applied 4th Layer (Top Coat)
Asphalt Pavement
Slab 3rd Layer (Intercoat)
2nd Layer (Base Coat)

1st Layer (Primer)

Composition of Layer for Rubberized Membrane

Preparation of Deck Surface 1st Layer (Primer) 2nd Layer (Base Coat)
3rd Layer (Intercoat) 4th Layer (Top Coat)

5th Layer (Tack Coat) Asphalt Pavement

 WORK SEQUENCE
2.) Asphalt Compound Membrane Type

Tack Coat

Composition of Layer for Asphalt Compound Membrane

Preparation of Surface Primer Coating Melting Asphalt Compound

Application of Asphalt Application of Silica Sand Curing
Compound for Protection

Tack Coat Asphalt Pavement

Required Materials and Tools/Equipment:
WORK SEQUENCE
Mix the materials with water of
minimum mixing time of 2
minutes.
the
8. RECASTING CONCRETE GIRDER

Recasting of concrete
girder is carried out to
repair portion of the
concrete that has been
severely damaged. If
damaged portion is not
removed, further
deterioration is expected,
which could impair the
strength, stability and
serviceability of the
structure.
Required Materials and Tools/Equipment:
Required Materials
Non Shrink Grout Cement (Fast Setting Mortar)
Water
Rebar (Reinforcing bar, Grade 60)
Bonding Coat to Concrete (Epoxy Resin Adhesive)
Anti-corrosion Primer to Rebar (Zinc Rich Primer)
Required Tools/Equipment
High Pressure Water Blasting
Handy Concrete Breaker or jackhammer
Handy power Chisel
Mortar Mixer with Pump
Handy Power Grinder
 WORK SEQUENCE

Removal of defective Preparation of old concrete Application of zinc rich

concrete and rebars primer and epoxy adhesion

Installation of forms Pouring of non shrink grout Removal of forms

cement
9. CARBON FIBER SHEET/PLATE BONDING TO
CONCRETE GIRDER
Carbon fiber sheet/plate bonding
for reinforced repair and
strengthening systems is installed to
enhance the capacity and extend the
life of concrete structures Carbon Fiber Sheet/Plate Bonding

Arrangement of Carbon Fiber Sheet/Plate

Required Materials and Tools/Equipment:
Required Material
Carbon Fiber Products Epoxy Materials
Carbon Fiber sheet Epoxy primer
Carbon Fiber Plate Epoxy putty
Epoxy resin

Required Equipment
Abrasive Sandblaster
Air Compressor
Disc Grinder
Portable Generator
Paint Roller/Brush
 WORK SEQUENCE
a.) For CFS

Preparation of Concrete Application of Primer Adjustment of Unevenness

with Putty

Application of Epoxy Resin Installation of CFS (1st layer) Squeezing of Strip to

for Undercoat Entrapped Air
Over Coating Resin
Application

Installation of CFS (2nd layer)

Surface Protection
 b.) For CFP

Preparation of Concrete Application of Primer Adjustment of Unevenness

with Putty

Application of Epoxy Installation of CFP Squeezing of Strip to

Resin on CFP Entrapped Air

Pressure Attachment of CFP

10. STEEL PLATE BONDING TO CONCRETE GIRDER
Steel Plate Bonding is
adopted for strengthening the
girder against bending
moment as well as shear.

The method involves use

of narrow steel plates
installed in the
longitudinal direction of
the concrete girder and is
achieved by using
pressure attaching
Detail of Pressure Attaching Method
method. by Anchor Bolts
Required Materials and Tools/Equipment:
Required Materials
Steel Plate
Primer (Epoxy Base)
Epoxy Resin Adhesive
Epoxy Sealant
Anchor Bolts
Wood and Angle Bar for Fitting
Required Equipment/Tools
Disc Grinder
Welder
Electric Drill
Epoxy Injection Pump with Accessories
Wire Brush
 WORK SEQUENCE

Surface Preparation Application of Epoxy Resin

Pressure Attachment of Steel Plate Curing and Painting

11. JACKETING WITH CONCRETE AT PIER
Chipping Surface Existing Pier

Concrete jacket is
applied to protect the Vertical Re-bar
Re-bar

deteriorated concrete Stirrup

due to corrosion of

New Concrete

rebars, damaged due

Footing
to rapid water flow or
broken due to
continuous impact from
materials flowing in the
channel such as drift
woods.

Concrete Jacket for Repair of Pier

Required Materials and Tools/Equipment:
Required Materials
Portland cement Polymer Cement Mortar with
Crushed Aggregate Lithium Nitrite Hydrate (optional)
Sand, Rebars Water, Formworks

Required Equipment/Tools
Drilling Machine to Concrete
Concrete Vibrator
Concrete Mixer/Mortar Mixer
Handy Concrete Breaker
 WORK SEQUENCE

Add rebars

Removal of Deteriorated Concrete Adding Rebar Setting Formwork

Concrete Placing Curing Concrete

Required Materials and Tools/Equipment:
WORK SEQUENCE

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