Hi ngh khoa hc tan quc ln th hai v S c v h hng cng trnh xy dng

STRUCTURAL CONCRETE REPAIR BY MEANS OF MACHINES SIKA CONCEPTS AND TECHNOLOGY

Philippe Doriot Civil Engineer HES-UTS. STM Manager Sika Limited (Vietnam)

Introduction More and more often old concrete structures need either maintenance work or even sometimes replacement of the existing structural concrete. Indeed, nowadays, concrete structures are exposed to various external or internal aggressions that would lead to the deterioration of the concrete structure. The purpose of this presentation is to introduce an efficient and economical concrete repairs system using machines for the application of the repair materials. The Sika Concepts would give guidance on the correct procedure and on the appropriate repairs systems selection, while the Sika Technology would present in which manner the application of the repairs system should be performed. In addition, several International case studies will support this paper proving that nowadays such concrete repairs system should be used when economical and high quality repairs are required. 1. CONCRETE DAMAGES The successful repair and protection of concrete structures that have been damage or have been deteriorated require professional assessment, then design, supervision and execution of a technically correct strategy. Prior to see how to conduct a proper assessment of the conditions of the structure, it seems important for us to remind that concrete damage occurs under different conditions. Concrete, damage and defects Basically in this category we can summarize 3 main causes leading to the deterioration of the concrete structures. Concrete structures can be Mechanical, Chemical or Physical attacked.

The Mechanical damages are the results of solicitations provoked by impact, vibration or even explosion. Abrasion or wears solicitations might lead as well as to mechanical damage. This section would be not complete if overloading solicitations are not mentioned. The Chemical damages can be the results of the action of bacterial, direct chemical exposure or even the too well know alkali aggregate reaction (AAR/ASR or AAR/ACR). The third common damage, that is Physical damage, would be the results of thermal movement on the structures, erosion or even efflorescence/leaching. In countries where cold winter seasons is part of the normal weather conditions, salt crystal expansion and freeze thaw action would be as well as a kind physical damage to concrete structures. Concrete damage due to steel reinforcement corrosion Most of the concrete structures are steel reinforced structures. In reinforced concrete, the steel is normally protected against corrosion by the passivating alkalinity of the cement matrix. However, under certain circumstances this protection might disappear and corrosion of the steel would be developed. The development of steel corrosion would lead to the spalling of the concrete, rust staining for instance. Damage by Carbonation. The carbon dioxide ingress causes carbonation of the cement matrix. Another damage is the results of metals of different electropotential that are connected to each other in the concrete and corrosion would occur. Such damage is commonly calling Stray/Electrical current damage. The Contamination by corrosives like Chlorides is carried into the concrete in solution in water. At the steel surface, even in alkaline concrete, they attach and break down the passivating layer and then accelerate the steel corrosion process. 2. MANAGEMENT IN CONCRETE REPAIRS In order to conduct a proper and correct repair work, it is required to process systematically a certain strategy by observing the following rules. Assessment Survey of the existing structures: This process should always include investigations on the current conditions of the visible and non-visible defects. It is as well as interesting to be able to know the history of the use of the structure in order to be able to appreciate the past, current and/or future exposures. Diagnostic of the Causes of the Deteriorations. Following the review of the assessment survey in terms of original design and construction methods, it is required to determine the root of cause. The questions that we need to answer are: does the identified damage is the result of mechanical, chemical, physical damage or does it the results of reinforcement corrosion damage? Determination of the Objective regarding the Repairs and Protection.

The Owner has obviously a number of options that will effectively decide the appropriate repair and protection system meeting his further requirements. We can mention: Do nothing; Demolish the existing structure; Downgrade the structure; Prevent or reduce further damage without repairs; Improve, refurbish or strengthen all or part of the structure. If the last option is retained, at that stage the Selection of the Repairs system can take place. The Selection of the Repair products system will have an influence on the application system. This part would be detailed in the part No 4 of this paper. Implementation, methodology. The last part of the management in concrete repairs is its implementation, typically how the repair system would take form. It must be understood that in some cases it is the repair product that would dictate the application method, while in others cases, the application method can be chosen disregarding the type of repair products. This demonstrates once again, that there is really a need of managing the repair work. This management can be efficient only if clear communication and information exchanges between all parties are efficiently implemented. This part is exposed on the part No 5 Repair System application selections 3. SIKA REPAIR PRINCIPLES In this Part, we are going to see, what are the principles of our repair system. By order we can summarize the following: Remove damage concrete to exposed steel. By mechanical means, all defected concrete must be removed up to the steel. Protect exposed steel. Once the steels are exposed and cleaned, it is required to protect them against further corrosion development Replacement of the damaged concrete. Prior to place the repair material, suitable surface preparation and cleaning would be performed. Then by hand or by means of machine the removed concrete volume would be replaced by a repair product that meets the requirements particularly in terms of durability, stresses, exposures, appearance, curing time and cost. Protection against development of latent damage. Once the steel has been protected against corrosion and the damaged concrete replaced, it is possible to even add additional protection in order to prevent the development of latent damage typically like carbonation attacks. Leveling of the surface and pores sealing on the surface.

Depending on the repair system choice, it might be required if the system includes a protective coating to seal or level the material that replaced the damage concrete. Sealing and protective coating application preventing direct aggressive influence Typically hydrophobic impregnations or anti-carbonation coating complete the latest part of the Sika Repair Principles. 4. SELECTION OF THE SIKA CONCRETE REPAIR PRODUCTS Prior to decide on the application method, it is rather advisable to determine the system of products for the repair. We would see in the part No 5 Repair System application selection. Here below are stated the parameters allowing the selection of the Sika Concrete Repair Products: Nature and conditions of the structures. It is required to identify the type of the substrate, supports. The dimensions and positions of the repair are parameters that need to be known. Exposures and stresses on the structures. Typically parameters that need to be confirmed are: mechanical strength requirement such as compressive, tensile, bonding and shear strength. Does the repair material would be subject to special chemical, physical, dynamic or even mechanical solicitations? Durability and maintenance. To select appropriate repairs system products, it is required to know what is the life expectancy of the repair in terms of durability. Does the strategy consider possible future maintenance? These parameters and consequently the resulting products choice would have an impact on the over all cost of the repair. Application timing, curing and environmental constraints. A typical requirement would be that the repair work requires to be conducted as quick as possible, without or with minimum disturbance. We can see from this aspect that curing and the achievement of the mechanical properties of the repair material take their importance. Appearance of the finishing surface. What kind of aspect and/or quality of the finishing surface is required are some of the parameters that need to be known in order to determine the suitable repair products. In place cost. At the end of they day, as cost matter nowadays is always one of the most influencing parameter, we would have to take it into consideration. However, cost related matters should not be the first and the parameter that would dictate the repair choice. Indeed, it would be rather judicious to establish various repair systems corresponding to certain designated properties for a certain cost in order to let the Owner decide.

5. REPAIRS SYSTEM APPLICATION SELECTION As mentioned earlier, depending of the final mechanical properties of the repair material in some cases the product would be either hand or machine applied. By machine applied we consider in this paper the following systems: Shotcrete rotor type spraying machine Dry sprayed applied repair mortar Aliva AL 246: Dry rotor spraying machine. Out-put:0,4 4,0 m3/h Maximal aggregate size: 16 mm Conveying distance: H= 300 m, V= 80m Suitable for: Sikacrete-Gunite 103 and SikaCem-Gunite 133

Mortar pump Wet applied cementitious repair mortar Aliva AL 2000: Screw pump type machine. Out-put:0,3 2,4 m3/h Maximal aggregate size: 8 mm Conveying distance: H= 60 m, V= 20m Suitable for: Sika MonoTopR and Sika MonoTop 615 HB Pneumatic roughcast applicator Wet applied sprayed of fine or coating repair.

Aliva AL 1150: Pneumatic gun spray. Out-put:1- 3 l/min Nozzle plate: 5-9,5 mm Conveying distance: H= 300 m, V= 80m Suitable for: Sika MonoTop 610 and SikaTop Armatec 110 EpoCem

Here below a chart guiding in which conditions the application of the repair should be performed for a designated product allowing both types of application. However, based on the criteria, this chart would as well as give guidance, if the repair should be hand or machine applied. In that case, the product to be chosen must be of the related application type. The product would be either a hand or machine applied product. Criteria (*) Repair Volume
- Daily application volume > 6 man hand applied

Machine applied +++

Hand application

Repair Profile
Thick, overhead Small, individual patches

++ ++ ++ ++ +++ ++ +++ + + +

Environmental - Dust, noise (*) High Density (*) High early Strength (*) Compaction (*) Bond strength

+++ = Most suitable in terms of quality and cost. ++ = Suitable. + = Applicable possible under certain circumstances. (*) Typically when looking for such properties, a sprayed applied cementitious repair material would be the best solution, understanding that the volume to be applied is large and allow considering an application by means of machine. 6. SIKA CONCRETE REPAIR SYSTEMS - PRODUCTS

As we have previously seen, when considering the repair of a concrete structure, we have to deal with more than one single product. Actually, the repair work would consist of a Repair system consisting of various products. The type, their chemical base of products would depend and vary according the following:

Sika Repair Principles Suitable products as per the type of application in term of Nature of the repair.

 Sika Concrete Repair Systems Suitable products as per the requirement dictated by the Objectives. Selection of the Application System Suitable products as per the Application method.

Sika Concrete Repair Systems Summary as per Sika Repair Principle Action Protect Exposed Steel Material Base EpoCem Product SikaTop-Armatec EpoCem Application 110 Gun Spray Or Brush Spraying Dry Spraying Dry Hand Hand Hand Roller

Polymers modified + Sika MonoTop 610 Silicafume Cementitious Polymers modified + Sikacrete- Gunite 103 Silicafume Cementitious SikaCem -Gunite 133 Sika MonoTop (***) SikaGrout (***) Modified Amino Alcohol Sika FerroGard 903 (ACCI) EpoCem Sikagard (***) EpoCem Sika Refit- 2000 Polymers modified + SikaTop -Seal 107 Silicafume Cementitious

Replace Damage Concrete

Protect Latent Damage Pore filling

Gun Spray Or Spraying Wet

Prevent Siloxane Aggressive Ingress

Sika Aquastop S Sikagard (***) W

Hand Roller

SikaTop-Armatec 110 EpoCem: Cement based epoxy modified 3 components anti-corrosion coating and bonding agent. Sika MonoTop 610: 1 components Cementitious polymers modified containing silicafume for Bonding Slurry and reinforcement Corrosion Protection. Sikacrete- Gunite 103: 1 component cementitious repair gunite containing silicafume for dry spraying repairs. Can be trowelled once applied. SikaCem -Gunite 133: 1 component polymers modified cementitious repair gunite containing silicafume for dry spraying repairs. Can be trowelled once applied.

Sika MonoTop (***): 1 component polymers modified repair mortar for hand of wet spraying applied. SikaGrout (***): Non shrink cementitious grout for pourable repair. Sika FerroGard 903: 1 component corrosion inhibitors for reinforced concrete. Sikagard (***) EpoCem: 3 components cement based epoxy modified pore sealer Sika Refit 2000 : 1 component polymers modified containing silicafume pores sealer SikaTop -Seal 107: 1 component flexible protective and waterproofing coating. Sika Aquastop S / Sikagard (***) W: Siloxane base water Repellent Impregnation. 7. REPAIR SYSTEM PRODUCTS APPLIED BY MACHINE: PRINCIPLES OF WORKING In this part, we would see how sprayable repair products could be efficiently applied insuring perfect bonding, compaction and consequently meeting the Objectives requirements. a) Dry spraying applied method.

Principle: The Dry mix mortar is transported by means of air under pressure. Closed to the nozzle the water is manually added according to the consistency wished. The mortar being sprayed with a minimum of 2 bars pressure, would be compacted efficiently onto the prepared substrate. The dry spray method is particularly suitable for major repair projects where dust and rebound can be effectively confined or protected against and where the environment and appearance are not unduly sensitive. b) Wet spraying applied method.

Principle: The repair mortar is first mixed as per the recommended water dosage and fed in softplastic consistency into the pumps hopper. By dense stream, the pump will transport the material to the point of use. Air is added at the nozzle, which then dissipates and compacts the mortar onto the prepared surface. The Wet mix mortar is suitable for most types of concrete repair, particularly in confined spaces and where appearance is important. All the wet sprayed applied repair mortar would allow the possibility to be trowelled after being applied. It must be stated that general rules and practices regarding repair work remain valid and must be performed prior spraying any mortar. Indeed, the application of the mortar required a proper surface preparation in order to get perfect bonding properties between old concrete (the substrate) and the new applied mortar. Here below guidance chart, showing suitable application choice when the Application principle of the repair work is decided. For instance when large volume of repairs products would need to be applied. In relation with the Objectives of the repair (in terms of durability, exposure, chemical attack, etc.), we can chose different kind of repair products that can be either dry applied or wet applied. However the choice between a wet or a dry machine application would depend on the additional criteria stated below: Wet mortar application Low Dust generation Mortar consistency Aesthetic (Trowel) In confined spaces Minimum rebound Dynamic load Hand applied possible Dry mortar application Long transport No premixing Thick layer High out-put No primer required Easy cleaning Start/stop easy

8. CONCLUSION AND INTERNATIONAL REFERENCE PROJECT LIST

Nowadays, the constant improvement and development of new construction repair materials and the efficiency of the spraying equipment allows the application of repair material by means of machines meeting Owners expectations. It is even more interesting to consider the implementation of them due to the constant increase of constraints regarding quality, durability, timing, and cost. Such techniques, already implemented for more than 10 years in certain countries prove that when large repair volumes need to be applied with high quality requirements, this solution remain the most suitable solution. International reference project list of Sprayed applied repairs (Extract) Project name Requirement / Problem Products used

South Australia, Port Large sections of spalling SikaTop Armatec-110EC August Rail bridge on concrete piers Sikacrete-Gunite-103 Australia, aqueduct, Annandale Carbonation affected steel SikaMonoTop-610 corrosion SikaCem-Gunite-103 Sikagard-680S Australia St Columbians Complete restoration College restoration, deteriorating building Australia, Woomera External concrete repair water tanks, S.A Australia, Miria Island Chloride attack repair water tank repair, Tas of SikaCem-Gunite-103 SikaCem-Gunite-133 SikaTop Armatec-110EC Sikacrete Gunite-103 Sika MonoTop-615HB Malaysia, TNB, Prai Concrete Jetty For Tenega spalling Nasinal Berhad erosion and Sikacrete Gunite-103

Malaysia, LRT Transfer Large Honeycomb Tunnel Sikacrete Gunite-103 Tunnel lining repair China, Xiaolandgi Dam Switzerland, plant, Zurich Spalling concrete due to Sikacrete Gunite-103 fire quality, SikaMonoTop-610 and R Sikagard-720 EpoCem Sikagard 701 W, 670 W Switzerland (Zurich) & Concrete damage by SikaMonoTop-610 and R France (nice, Monaco) erosion and bacterial attack SikaGrout 212/214-11 Waste water drainage SikaCem Gunite 133

Heating Poor concrete carbonation

Germany, sewage Chemical attack, thermal SikaMonoTop-610 and R treatment plant movements Sikagard-720 EpoCem USA, Kingdom Seattle Carbonation, concrete spalling SikaTop Armatec-110EC Sikacrete -Gunite-103

England, Silvertown Concrete spalling due to SikaTop Armatec-110EC Viaduct, London carbonation and Chlorides Sikacrete Gunite-103