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Indian Civil Engineer

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Friday, June 13, 2008

Rehabilitation of Corrosion Damages in Columns by Jacketing
(This article is intended to present the technology and materials of construction, as practiced for a G+4 building in
Chennai. This is not intended to be of diagnostic or design significance.)
Minor Damages
Jacketing with micro-concrete was adopted for columns in initial stage of corrosion with minor damages such as
narrow cracks and discolouration, without appreciable damage to existing steel. The brief specifications and
methodology for the same are as follows:

1. Existing structure shall be propped to ensure support during rehabilitation work

2. Plaster/concrete on distress areas shall be removed and steel exposed. The entire surface is cleaned
preferably with sandblasting.

3. Zinc based epoxy primer shall be applied on exposed surface of reinforcement in one or two coats to ensure
complete protection.

4. Packaged cement-based micro-concrete shall be provided to sufficient thickness all round existing columns.
It is only needed to add water to packaged micro-concrete.

5. If after cleaning, fresh concrete area is larger than 100mm, concrete shall be provided with larger aggregate
instead of micro-concrete. In this case, graded aggregates are to be mixed with packaged micro-concrete.

6. Before concrete, the column surface shall be soaked in water for few hours. Concrete surface may be
provided with slow setting epoxy adhesive primer film to ensure composite action of old and fresh
concrete.

7. Curing shall be done for 7 days.

8. A polyurethane outer coating may also be provided, if necessary
9. All chemical application shall be done by skilled contractors and shall be in accordance with manufacturers
specifications.
Moderate Damages

Jacketing with carbon-fibre-composite micro-concrete was adopted on columns with later stage of corrosion and
moderate damages such as cracks, spalling and some damage to existing steel.
The brief specifications and methodology for the same are as follows:

1. Existing structure shall be propped to ensure support during rehabilitation work

2. Plaster on distress areas shall be removed and steel exposed. The entire surface is cleaned preferably with
sandblasting.

3. Zinc based epoxy primer shall be applied on exposed surface of reinforcement in one or two coats to ensure
complete protection.

4. Depressions on surface may be filled with epoxy putty and/or cement-based micro-concrete. Large
depressions shall be filled using micro-concrete with graded aggregates.

5. One or more layer of carbon fibre fabric shall be applied onto the surface sandwiched between two layers
of suitable saturant polymers.

6. Before concrete, the column surface shall be soaked in water for few hours. Concrete surface may be
provided with slow setting epoxy adhesive primer film to ensure composite action of old and fresh concrete
24 hours prior to application of jacketing.

7. Curing shall be done for 7 days

8. A polyurethane outer coating may also be provided, if necessary
9. All chemical application shall be done by skilled contractors and shall be in accordance with
manufacturers specifications.
Severe Damages
Where columns are badly spalled and column steel is considerably eaten away, structural repair was done with RC
Jacketing. The brief specifications and methodology for the same are as follows:

1. Existing structure shall be propped to ensure support during rehabilitation work

2. Excavation shall be done to expose footing top below.
3. Plaster on distress areas shall be removed and steel exposed. The entire surface is cleaned preferably with
sandblasting.

4. Zinc based epoxy primer shall be applied on exposed surface of reinforcement in one or two coats to ensure
complete protection.

5. Depressions on surface may be filled with epoxy putty and/or cement-based micro-concrete. Large
depressions shall be filled using micro-concrete with graded aggregates.

6. The column size is proposed to be increased all round using M20 micro-concrete with graded aggregates.
New main steel and lateral steel are to be provided. Steel shall be HYSD TMT bars. Clear cover of 50mm
may be provided. Steel for use shall be clean and free from dust, rust or oily material.

7. Holes shall be drilled into overhead soffit and footing beneath. The depth of hole should accommodate load
transfer. Rotary percussive drills may be used with air or water flushing. Diamond drilling is not considered
suitable.

8. Pumpable grade polyester resin grout (paste/capsule) shall be used for filling overhead and vertical drill
holes.

9. The bars are now pushed into the drill holes and positioned. Butt welding of bars may be permitted in case
of lap splices. After the respective curing period of the grout, steel ties shall be tied round the steel and
formwork for concrete may be made ready.

10. Before concrete, the column surface shall be soaked in water for few hours. Concrete surface may be
provided with slow setting epoxy adhesive primer film to ensure composite action of old and fresh concrete
24 hours prior to application of jacketing.

11. M20 cement based micro-concrete shall be applied in the formwork to jacket the column
12. Curing shall be done for 7 days
13. A polyurethane outer coating may also be provided, if necessary
14. All chemical application shall be done by skilled contractors and shall be in accordance with
manufacturers specifications.
Summary of Chemicals for Rehabilitation
Zinc based epoxy primer (for corrosion protection of steel)
Cement-based Micro-concrete (with/without graded aggregates)
Epoxy putty
Carbon fibre fabric with saturant
Pumpable grade polyester resin grout (paste/capsule)
Slow setting epoxy adhesive primer (for bond between new & old concrete)
Aliphatic polyurethane coating (optional over finished surface)
Wax based Concrete curing compound

Labels: Maintenance Technology

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