CONCRETE DAMAGE REPAIRS OF EXISTING MARINE TERMINALS
CONCRETE DAMAGE REPAIRS OF EXISTINGMARINE TERMINALSBERNARDO WAISMAN, P.E.PREVENTION FIRST 2018LONG BEACH, CALIFORNIASEPTEMBER 25-26, 20181PREVENTION FIRST 2018
TOPICS TYPES OF CONCRETE DAMAGEREINFORCING STEEL CORROSION DAMAGEREPAIR METHODS AND MATERIALSTYPICAL REPAIR COSTSRECOMMENDATIONS FOR NEW TERMINALSLESSONS LEARNED2PREVENTION FIRST 2018
TYPES OF CONCRETE DAMAGE REINFORCING STEEL CORROSIONCauses cracking, closed spalls, open spalls & delaminationSTRUCTURAL DAMAGECaused by large object impact, abnormal accidentalberthing or seismic loadsDENTING & PITTINGCaused by floating debris, abrasion and concrete ageSLOPE PROTECTION CRACKINGCaused by saturated soil movement and undermining ofconcrete slab3PREVENTION FIRST 2018
TYPES OF CONCRETE DAMAGEConcrete Beam with Cracks& Rust Stains4PREVENTION FIRST 2018Concrete Beam with Open Spall &Exposed Corroded Rebar
TYPES OF CONCRETE DAMAGEConcrete Beam with Open Soffit Spall& Exposed Corroded Rebar5PREVENTION FIRST 2018Concrete Beam with Corner Open Spall& Exposed Corroded Rebar
TYPES OF CONCRETE DAMAGEConcrete Beam with Cracks& Open Spall6PREVENTION FIRST 2018Utility Vault with Soffit & Wall DamageBeing Repaired
TYPES OF CONCRETE DAMAGEConcrete Column with Open Spall& Corroded Rebar7PREVENTION FIRST 2018Concrete Column with Open/ClosedSpall & Corroded Rebar
TYPES OF CONCRETE DAMAGEReinforced Concrete Pile withVertical Crack8PREVENTION FIRST 2018Prestressed Concrete Pile withVertical Crack & Rust Stains
TYPES OF CONCRETE DAMAGEPrestressed Concrete Pile withHorizontal Structural Crack9PREVENTION FIRST 2018Reinforced Concrete Pile withBreakage from Object Impact
TYPES OF CONCRETE DAMAGEPrestressed Concrete Pile with Pitting10PREVENTION FIRST 2018Slope Protection Cracks
REINFORCING STEEL CORROSION DAMAGEPASSIVATION LAYERThe high alkalinity provided by freshconcrete results in the formation of thepassivation layer on the surface of thereinforcing. This is a thin film of rust thatprotects the steel from further corrosion.Chloride ions present in the marineenvironment penetrate the concretecover and break down the passivationlayer, initiating the progressive corrosionprocess.11PREVENTION FIRST 2018
REINFORCING STEEL CORROSION DAMAGEEffect of Concrete Alkalinity on Corrosion Fresh concrete provides a high-alkalinityenvironment (pH 12) that protectsthe reinforcing from corrosion. The intrusion of chloride reduces thealkalinity of the concrete. Corrosion mayoccur when the pH reaches a value of 9or less.12PREVENTION FIRST 2018
REINFORCING STEEL CORROSION DAMAGECorrosion LevelService Life1st Phase2nd Phase3rd PhaseChloride r Corrosion Progression13PREVENTION FIRST 2018Stress SpallingBeam Corroded Rebars
REPAIR METHODS AND MATERIALSREPAIR PROCEDUREREPAIR MORTAR1. CHIP-OFF LOOSE CONCRETE AND CLEAN SURFACE OF ALLBOND INHIBITING MATERIALS.2. GRIND PERIMETER OF REPAIR AREA TO 1/2" MINIMUMDEPTH TO AVOID FEATHERED EDGES.3. CLEAN REBARS MECHANICALY TO REMOVE ALL RUST.REPLACE CORRODED REBAR WITH MORE THAN 30%SECTION LOSS.4. USING A STIFF BRUSH APPLY SIKA ARMATEC 110 EPOCEMCORROSION INHIBITING & BONDING AGENT AT 20 MILSMINIMUM THICKNESS COVERING ALL EXPOSED STEEL ANDALLOW TO DRY. APPLY A SECOND COAT AT 20 MILSMINIMUM THICKNESS AND ALLOW TO DRY.5. PRE-WET SURFACE TO SATURATED SURFACE DRY.6. PREPARE AREA WITH SIKA ARMATEC 110 EPOCEM.7. PLACE REPAIR MATERIAL SIKAREPAIR 223, OR SIKATOP 123PLUS.8. CURING WITH WET BURLAP AND POLYETHYLENE SHEETING.Beam Corner Repair14PREVENTION FIRST 2018FORMREPAIRMORTARFORM
REPAIR METHODS AND MATERIALSREPAIR PROCEDURE1. DEMOLISH BEAM SOFFIT ALONG DAMAGED AREA.2. CLEAN EXPOSED SURFACE OF LOOSE CONCRETE ANDALL BOND INHIBITING MATERIALS.3. CLEAN REBARS MECHANICALLY TO REMOVE ALL RUST.REPLACE CORRODED REBAR WITH MORE THAN 30%SECTION LOSS.4. USING A STIFF BRUSH APPLY SIKA ARMATEC 110EPOCEM CORROSION INHIBITING & BONDING AGENT AT20 MILS MINIMUM THICKNESS COVERING ALL EXPOSEDSTEEL AND ALLOW TO DRY. APPLY A SECOND COAT AT20 MILS MINIMUM THICKNESS AND ALLOW TO DRY.5. SET FORM. PRE-WET SURFACE TO SATURATED SURFACEDRY.6. PLACE 5,000 PSI, 3/8" MAXIMUM AGGREGATE SIZECONCRETE INTO FORM, VIBRATE FORM WHILE POURING.7. CURING WITH WET BURLAP OR CURING COMPOUND.Beam Full Soffit Repair15PREVENTION FIRST 2018REPAIRCONCRETEFORM
REPAIR METHODS AND MATERIALSREPAIR PROCEDUREMORTAR BEVEL1. MECHANICALLY REMOVE GREASE, RUST,MARINE GROWTH, UNSOUND CONCRETE, ANDOTHER BOND INHIBITING MATERIALS.FIBERGLASS SLEEVE2. PLACE FX-70-1 COMPRESSIVE SEALING STRIPAT BOTTOM.1" MIN VOID3. POSITION FX-70 FIBERGLASS SLEEVE.4. MIX AND PUMP FX-70-6MP EPOXY GROUT INTOBOTTOM 6" OF ANNULAR VOID AND ALLOW TOEPOXY GROUT SEALCURE.5. MIX AND PUMP FX-225 UNDERWATER GROUTFIBERGLASS SLEEVEUP TO 4" FROM TOP OF SLEEVE.6. MIX AND POUR FX-70-6MP EPOXY GROUT INTOTOP 4" OF SLEEVE.BOTTOM SEAL7. CONSTRUCT A BEVEL AT TOP OF GROUT USINGFX-763 TROWEL GRADE EPOXY MORTAR.Pile Grouted Sleeve Repair16PREVENTION FIRST 2018CONCRETE PILEEPOXY GROUTCRACKSSPALLUNDERWATERGROUT IN ANNULARVOIDEPOXY GROUT SEALBOTTOM SEAL
REPAIR METHODS AND MATERIALSREPAIR PROCEDURE1. CLEAN CRACK VACUMMING OR BLOWING WITHCOMPRESSED AIR.2. MAKE "V" GROOVE AROUND PERIMETER WITH 1/4"MINIMUM WIDTH.3. DRILL AND INSTALL INJECTION ENTRY AND VENTINGPORTS WITH SIKADUR 31 OR SIKADUR 33 ADHESIVE.4. SEAL CRACK WITH SIKADUR 31 HIGH-MODULUSEPOXY GEL ADHESIVE OR SIKADUR 33 HIGHMODULUS EPOXY PASTE ADHESIVE. ALLOW TO CURE.5. FILL CRACK INJECTING SIKADUR 35 HIGH-MODULUS,LOW VISCOSITY, EPOXY ADHESIVE. MAXIMUMINJECTION PRESSURE 40 PSI. ALLOW TO CURE.6. CUT-OFF ENTRY AND VENTING PORTS.Pile Epoxy Injection Repair17PREVENTION FIRST 2018
REPAIR METHODS AND MATERIALSSacrificial Anode Protection18PREVENTION FIRST 2018
REPAIR METHODS AND MATERIALSReinforcing SteelJunction BoxCementitious GroutZinc Anode MeshGlass ReinforcedPolymer SleeveConcrete Pile Galvanic Protection19PREVENTION FIRST 2018
REPAIR METHODS AND MATERIALSBeam Full Soffit Repair20PREVENTION FIRST 2018Completed RepairsBeam and Column Repair
REPAIR METHODS AND MATERIALSPile Grouted Sleeve RepairPile Epoxy Injection RepairCompleted Repairs21PREVENTION FIRST 2018
REPAIR METHODS AND MATERIALSPile Epoxy Injection Repair22PREVENTION FIRST 2018Completed RepairsUtility Vault Repair
TYPICAL REPAIRS COSTConcrete repairs of marine terminals are expensive. Following is a list ofthe main reasons: Use of heavy marine equipment like crane barges, material bargesand tugs.Skilled and experienced labor is required.Work over water is more difficult and time consuming. Debriscontainment is required to prevent it from falling into the ocean.Strict security and safety measures required by government,operators and contractors increase labor time.High repair quantities escalation factor that may vary from 1.25 to2.50, depending on the condition of the damaged concrete.Occasional crew and equipment standby time due to weatherconditions and vessel schedule changes.23PREVENTION FIRST 2018
TYPICAL REPAIRS COSTTypical concrete repairs unit cost: Beam one corner repairBeam full soffit repairColumn repairPile grouted sleeve repairPile epoxy injection repairscaffolding required24PREVENTION FIRST 2018 1,500/LF 2,500 - 3,000/LF 2,500 - 3,000/LF 4,000/LF 200/LF 3,000 per location if
RECOMMENDATIONS FOR NEW TERMINALS Specify 5,000 psi, 9 sack cement, low water-cement ratio (w/c 0.35) concrete for superstructure. Substitute part of cement withpozzolans. Include in concrete mix water-reducing, corrosioninhibiting admixtures. Prestressed concrete piles have shown goodperformance in marine terminals.Consider increasing the minimum concrete cover prescribed inAmerican Concrete Institute ACI-318. This will reduce the intrusionof corrosion producing elements and increase the service life of thestructure.Consider using sacrificial anode protection. Manufacturers claim itcan retard the initiation of the rebar corrosion process by 10 to 15years.25PREVENTION FIRST 2018
RECOMMENDATIONS FOR NEW TERMINALS Design the lowest beam with the soffit elevation above the maximumpredicted water elevation for the service life of the structure.Example:Soffit elevation MHHW 0.6 x significant wave height (Hs) sealevel rise (SLR) 2' 6.2' 0.6 x 4' 1.9' 2' 12.5' (MLLW datum).Implement a comprehensive construction quality control program. Usethe assistance of the engineer of record to resolve unpredicted issuesencountered during construction.Good communication between the owner, engineering consultants,regulatory agencies, and contractors is essential for the successfuldevelopment and completion of the project.26PREVENTION FIRST 2018
LESSONS LEARNED During field inspections of concrete marine structures, it is beneficialto spend extra time on the observation and recording of the damage.What seems very obvious at the time of observing the damage, itbecomes not so obvious days or weeks later when processing thefield notes and preparing the inspection drawings. The extra timespent in the field will save time and effort during the followingphases of the repair project.During the planning, bidding, and execution of the concrete repairsproject, consideration should be given to the repair quantitiesescalation. The escalation factor may vary from 1.25 to 2.50,depending on the condition of the damaged concrete.27PREVENTION FIRST 2018
3. drill and install injection entry and venting ports with sikadur 31 or sikadur 33 adhesive. 4. seal crack with sikadur 31 high-modulus epoxy gel adhesive or sikadur 33 high-modulus epoxy paste adhesive. allow to cure. 5. fill crack injecting sikadur 35 high-modulus, low viscosity, epoxy adhesive. maximum
(A) REINFORCED LARGE TIRE BIAS REPAIRS - RT Bias Repairs are extra strong molded permanent repairs for bias ply tires which offer both strength and flexibility. These chemically self vulcanizing repairs are shaped for the best fit making repairs faster and easier and eliminating the need for separ
The Essential Guide to Cargo Damage 3 Table of Contents Preface 4 Chapter 1 – Introduction 6 Chapter 2 –Types of damages 8 2.1 – Physical Damage 10 2.2 – Reasons for Physical Damage 11 2.3 – Wet Damage 16 2.4 – Reasons for Wet Damage 17 2.5 – Contamination Damage 19 2.6 – Reasons for Contamination Damage 20 2.7 – Reefer related Damage 21
Surgical repairs can be classified as anatomic or non-anatomic repairs. Anatomic repairs, such as the one described by Brostrom, use endogenous ligamentous structures to restore the lateral ankle ligaments [15]. Non-anatomic repairs use additional tissue to stabilize the lateral ankle ligamen
All other equipment repairs may be charged to Function 8100 (Maintenance of Plant). 0354 Vehicle Repairs/Maintenance 0355 Technology‐Related Repairs and Maintenance (Formerly Computer Repairs) Expenditures for technology‐related repairs and maintenance. 0356 Inspect/Repair Fire Extinguisher
Elbow Drop 6 Grapple Upper, Head Damage Elbow Drop 11 Grapple Side, Chest Damage Side, Chest Damage Knee Slam Grapple Lower, Leg Damage Mo V eC oNTR LS D TAILS Head Scissors Elbow Grapple Upper, Head Damage Armcrusher Grapple Side, Arm Damage Leg Stomps Grapple Lower, Leg Damage Lower, Leg Damage Mo Ve CoNTR oLS DeTAILS
OFFICE OF STRUCTURES STRUCTURAL DETAIL MANUAL . Chapter 11 - Structural Repairs. SECTION 02 . CONCRETE REPAIRS (SR-CR) DATE: . Pier detail shown, abutment detail similar. Anchor edge of remaining SIP form with 5/8 '' dia. galvanized concrete anchors @ 2'-0'' c/c, 4'' embedment. Refer to Sections 423 and 423.03.03. APPROVAL DIRECTOR
Concrete Beams 9 Lecture 21 Elements of Architectural Structures ARCH 614 S2007abn Reinforced Concrete - stress/strain Concrete Beams 10 Lecture 21 Elements of Architectural Structures ARCH 614 S2007abn Reinforced Concrete Analysis for stress calculations steel is transformed to concrete concrete is in compression above n.a. and
Redi-Mix Concrete, LLC 10K11521 . While EPDs can be used to compare concrete mixtures, the data cannot be used to compare between construction products or concrete mixtures used in different concrete products unless the data is integrated into a comprehensive LCA. For example, precast concrete, concrete masonry units and site cast concrete all .
