August 2020

Repair and Rehabilitation

Constrofacilitator
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construction and infrastructure www.constrofacilitator.com
 Repair and Rehabilitation

Concrete structures are always externally exposed to the natural environment like the rain, beating hot sun
and wind. These natural elements cause the structure to be weathered over a certain period. Maintaining
the structure prevents the building from deteriorating easily and makes it durable in the long run Proper
maintenance includes regular inspection of buildings which helps to identify the deteriorated elements so
that they can be timely xed on time. Consequently, the need for repair and rehabilitation has grown
considerably in recent years.

This edition of eMag-Lounge on different services of repair and rehabilitation, post-tensioning, steel
fabrication and structural strengthening for repair and rehabilitation. Before nalizing any scheme for
repairs and rehabilitation of a distressed concrete structure, the concerned expert has to be fully aware of
the causes of distress, the extent of damage to the structure and the present condition of the concrete in the
structure.

August 2020 • Constrofacilitator 2

 Post Tensioning system for repair and
04
rehabilitation

Structural steel fabrication - application,

08
benefits and equipments for retrofitting

Retrofitting of structures - Design and

12
Techniques

Different types of services for repair and

17
rehabilitation

4 8
12 17

3 Constrofacilitator • August 2020

 POST TENSIONING SYSTEM FOR REPAIR AND REHABILITATION
Post Tensioning system for repair and
rehabilitation
P
ost-tensioning can be
explained as the method
of reinforcing concrete
or other materials with
high-strength steel
strands or bars, typically
referred to as tendons.
Their applications
include commercial buildings, residential
buildings, parking structures, slabs-on-
ground, bridges, sports stadiums, rock and
soil anchors, and water-tanks. Post-
tensioning tendons, which are prestressing
steel cables inside plastic ducts or sleeves,
are positioned in the forms before the con-
crete is placed. Afterward, once the con-
crete has gained strength but before the ser-
vice loads are applied, the cables are pulled
tight, or tensioned, and anchored against
the outer edges of the concrete.
August 2020 • Constrofacilitator
Elements of the post-tensioning system
for repair and rehabilitation
The basic element of a post-tensioning sys-
tem is called a tendon. A post-tensioning
tendon is made up of one or more pieces of
prestressing steel, coated with a protective
coating, and housed inside of a duct or
sheathing. A tendon will have anchors on
each end to transmit the forces into the
structure. Long tendons may also have
intermediate anchors along their length.
Anchorages are another critical element.
Anchor Head is an important part of the
post-tensioning system. It works in tandem
with the Wedge that holds the individual ten-
sile element. The prestressing load is then
transferred to the Bearing Plate. For some
small tendon sizes, this prestressing force
04
can be transferred directly to the structure
without the need for Bearing Plate. In the
case of some mono anchorage system, the
Wedge will hold an individual tensile ele-
ment directly to the Bearing Plate.
Internal bonded tendons – where one or
more strands are inserted into a metal or
plastic duct that is embedded in the con-
crete. By filling the duct with special grout,
the tendon is 'bonded' with the surrounding
concrete. Internal bonded tendons are
installed before concrete is poured and
become locked in concrete. This approach
is often used for bridges and heavily loaded
beams in buildings – flat internal systems
are also an excellent choice for thin slabs.
Internal unbonded tendons – where the
prestressing steel is not bonded to the con-

crete that surrounds it, except at the anchor-
ages. They are used in slabs and slabs-on-
ground for buildings and parking structures
but also more and more in infrastructure pro-
jects.
External unbonded tendons – these are
installed on the outer surface of concrete
structures. This type of post-tensioning
allows access for maintenance and
replacement, this is therefore the solution of
choice for bridge enhancements and
refurbishments.
Another important element is the hydraulic
tension jack. Tension is applied to
prestressing steel by using a hydraulic
stressing jack. The jack bears against one
of the anchors that are embedded in the
concrete and pulls the steel to a predeter-
mined force. As the tensioning is occurring,
the steel is being elongated, and the con-
crete or masonry element is being com-
pressed.
In unbonded construction, the plastic
sheathing acts as a bond breaker between
the concrete and the prestressing strands.
It also protects against damage by
mechanical handling and serves as a bar-
rier that prevents moisture and chemicals
from reaching the strand.
Bearing Plate is a very important element in
a post-tensioning system. It serves the pur-
pose of transferring prestressing force
derived from the tendon to the concrete.
And it is precisely in this, that explains what
Shallow foundations
POST TENSIONING SYSTEM FOR REPAIR AND REHABILITATION
External unbonded tendons
we want to achieve in prestressed concrete
structures, and thus we take special interest
in the Bearing Plate.
Advantages of the post-tensioning system
for repair and rehabilitation
There are post-tensioning applications in
almost all facets of construction. In building
construction, post-tensioning allows longer
clear spans, thinner slabs, fewer beams
and more slender, dramatic elements. Thin-
05
ner slabs mean less concrete is required.
Also, it means a lower overall building
height for the same floor-to-floor height.
Post Tensioning can thus allow a significant
reduction in building weight versus a con-
ventional concrete building with the same
number of floors. This reduces the founda-
tion load and can be a major advantage in
seismic areas.
Lower building height can also translate to
considerable savings in mechanical sys-
tems and façade costs. Another advantage
of post-tensioning is that beams and slabs
can be continuous, i.e. a single beam can
run continuously from one end of the build-
ing to the other. Structurally, this is much
more efficient than having a beam that just
goes from one column to the next.
Post-tensioning is the system of choice for
parking structures since it allows a high
degree of flexibility in the column layout,
span lengths and ramp configurations.
Post-tensioned parking garages can be
either stand-alone structures or one or more
floors in an office or residential building. In
areas where there are expansive clays or
soils with low bearing capacity, post-
tensioned slabs-on-ground and mat foun-
dations reduce problems with cracking and
differential settlement.
Post-tensioning allows bridges to be built to
very demanding geometry requirements,
Constrofacilitator • August 2020
 POST TENSIONING SYSTEM FOR REPAIR AND REHABILITATION
including complex curves, variable
superelevation and significant grade
changes. Post-tensioning also allows
extremely long-span bridges to be con-
structed without the use of temporary inter-
mediate supports.
In stadiums, post-tensioning allows long
clear spans and very creative architecture.
Post-tensioned rock and soil anchors are
used in tunneling and slope stabilization
and as tie-backs for excavations. Post-
tensioning can also be used to produce vir-
tually crack-free concrete for water-tanks.
Installation of a post-tension system for
repair and rehabilitation
Expert advice and supervision are impor-
tant for post-tensioning works. The
sequence of work also plays a key role.
Ÿ Designing the shape of the PT layout
and specifying the right system is a
vital stage in the process
Ÿ Work on applying the post-tensioning
system can begin after any formwork
or bottom reinforcement has been
installed.
Ÿ Typically, for a bonded system, ducting
will be laid out first, then strands will be
installed with the help of a strand-
pushing machine and end anchorages
will be placed
Ÿ Cables are arranged as indicated by
the engineer and chaired to run
through the center of the slab.
Ÿ Commercial foundations will have
much more steel. Tendons can be eas-
ily routed around obstructions.
Ÿ The concrete placement follows next.
When the concrete has attained its min-
imum strength, the strands are
PT Anchorages
August 2020 • Constrofacilitator
anchored in a common anchorage
device.
Ÿ The duct is then filled with a
cementitious grout that provides cor-
rosion protection to the strand and
bonds the tendon to the concrete sur-
rounding the duct.
Ÿ PT tendon placement and stressing is
usually done by companies with certi-
fied workers who specialize in this
work.
Different products of post-tension for
repair and rehabilitation
There are several products of post-tension
for repair and rehabilitation. We will discuss
the most important ones.
PT Anchorages
Anchorages are used to fix the ends of the
tendons in post-tensioning systems. Vari-
ous designs are available, depending on
the system supplier, but basically, they are
steel blocks through which single or multi-
ple strands pass and are anchored by
wedges. The strands may be tensioned indi-
vidually or as a group.
The anchorages are cast into the concrete
and transfer the entire load from the strands
into the concrete. This causes high local
bursting forces. To prevent the concrete
splitting additional reinforcement is
required close to the anchorage. Where
high tensile strength bars used for
prestressing, the bars are threaded (either
just at the ends or over their whole length)
and anchored after tensioning using nuts
that bear against steel plates set in the con-
crete. Again additional reinforcement is
needed to prevent bursting of the concrete.
06
Strands
Strands
Strands are made from 7 individual cold-
drawn wires, 6 helically wound outer wires
and one center wire (king-wire). The
mechanical properties of the strand as well
as corrosion protection properties are most
important to DSI. For a maximum in corro-
sion protection, we offer electrically isolated
systems using polyethylene (PE) or poly-
propylene (PP) ducts.
PT Duct & Grouting Systems
The purpose of grouting is to provide per-
manent protection to the post-tensioned
steel against corrosion and to develop a
bond between the Prestressing cables and
the surrounding structural concrete. Grout-
ing shall be carried out as early as possible,
but generally not later than two weeks of
stressing. Whenever this stipulation cannot
be completed with for unavoidable reasons
adequate temporary protection of the
cables against corrosion by methods or
products, which will not impair the ultimate
adherence of the injected grout shall be
ensured till grouting. Different equipment
includes- Grout Mixer Mechanical type,
Grout Pump, Grout Screen, Connection
and air vents, Generator etc.
PT Duct
Monostrand PT systems
Monostrand PT systems can be used as an
economical method in non-corrosive envi-
ronments. Some applications include
indoor residential or office areas. To provide
a cost-effective system, the anchorage
devices are not encased in an extruded
 POST TENSIONING SYSTEM FOR REPAIR AND REHABILITATION

jacket and plastic sleeves/grease caps are

not included. However, our regular system
still includes steel tendons with the special
corrosion-inhibitor inside our distinctive
green plastic sheathing.

Multi-Strand system

Multistrand system comprises three to fifty-

five strands (either 12.7 or 15.2mm diame-
ter), round duct and anchorages.
Prestressing force is applied to the tendons
after the casting and curing of the surround-
ing concrete. All strands are stressed simul-
taneously using a hydraulic jack and are fas-
tened at the live end by wedge grips. The
free space inside the duct is then pressure-
filled with cement grout.

Vacuum-assisted grouting for bonded PT

repair

Before grouting, a vacuum chest is used to

pump the air in the prestressed channel to
make the vacuum in the channel more than Monostrand PT systems
80%. Then the squeegee is used at the
other end of the channel. A positive pres-
sure greater than 0.7 MPa presses the
cement slurry into the prestressed tunnel.
Because there are only a few air holes in the
channel, it is difficult to form bubbles; at the
same time, due to the positive and negative
pressure difference between the channel
and the squeegee, the plumpness and den-
sity of the hole paddle are greatly improved.
Vacuum-assisted grouting for bonded PT
repair.

Conclusion

It is important to take the opinion of expert Vacuum-assisted grouting

guidance for post-tensioning. It is a very

important and complicated process. There
are various services offered by different
companies such as External PT for Bridge
girders & Slabs, Floor System and Suitable
Arrangement for Slab and many more oth-
ers. So choose the com[pny that fits your
requirement.

Source

Tmgglobals, reaerchgate, bbrnetwork,

dsiamerica, dywidag-systems,
p o s t t e n s i o n i n g . c o . n z , v e c t o r-
construction.com, gemengserv.com,
dsicivil.com.au, en.vsl.cz, fwmetals.com,
galathermo.com, dywidag-systems.com,
tmgglobals.com,structuraltechnologies.co
Multi-Strand system m

07 Constrofacilitator • August 2020

 STRUCTURAL STEEL FABRICATION
Structural steel fabrication - application,
benefits and equipments for retrofitting
S
tructural steel fabrication is
the process of cutting, bend-
ing, shaping, and assem-
bling steel to create different
products. Structural steel fab-
ricators produce various
steel sections and assemble them to create
mega structures like buildings, industrial
equipment, tools, stairs etc. Structural
steel fabrication is a multifaceted process
that requires specialized knowledge,
skills, and resources to complete success-
fully. To create structural steel beams,
components, or equipment, a good metal
fabricator follows a specific process. The
process includes cutting, bending and
assembling.
Cutting is done by sawing, shearing, or
chiseling; torching with handheld torches
08
(such as oxy-fuel torches or plasma
torches); and via numerical control
(CNC) cutters (using a laser, mill bits,
torch, or water jet).
Bending is done by hammering or via
press brakes, tube benders and similar
tools. Modern metal fabricators use press
brakes to coin or air-bend metal sheet into
form. CNC-controlled backpages use
hard stops to position cut parts to place
bend lines in specific positions.
Assembling is done by welding, binding
with adhesives, riveting, threaded fasten-
ers, or further bending in the form of
crimped seams. Structural steel and sheet
metal are the usual materials for fabrica-
tion; welding wire, flux and/or fasteners
are used to join the cut pieces.
Most modern steelwork fabrication facto-
ries have computer aided design and
detailing (CAD) which is linked directly
to factory floor computer numerically con-
trolled (CNC) machinery creating a genu-
ine CAD/CAM environment. The accu-
racy of the computer generated details
being transmitted directly to the computer
aided manufacturing (CAM) machinery
increases the quality standards of produc-
tion
The fact that machinery has taken over
from the tape measure means that the
frame is produced to high quality stan-
dards which are reflected in the speed and
accuracy of steel erection on site. This
results in significant benefits both to the
client and main contractor.
Constrofacilitator • August 2020

Steps for Structural steel fabrication
Structural steel fabrication can be carried
out in shops or at the construction site. Fab-
rication of steel work carried out in shops
is precise and of assured quality, whereas
field fabrication is comparatively of infe-
rior quality. In India construction site fab-
rication is most common even in large pro-
jects due to inexpensive field labour, high
cost of transportation, difficulty in the
transportation of large members, higher
excise duty on products from shops. Bene-
ficial taxation for site work is a major
financial incentive for site fabrication.
The methods followed in site fabrication
are similar but the level of sophistication
of equipment at site and environmental
control would be usually less. The skill of
personnel at site also tends to be inferior
and hence the quality of finished product
tends to be relatively inferior. However,
shop fabrication is efficient in terms of
cost, time and quality.
Ÿ Specifying size as per custom need
Ÿ Blueprint creation
Ÿ Converting blueprint into shop draw-
ings
Ÿ Cut and Drill Steel Beams
Ÿ Piece Etching
Ÿ Component Assembly
Ÿ Complete Assembly
Ÿ Component Finishing
Ÿ Erection of Final Project
Structural steel fabrication
August 2020 • Constrofacilitator
Structural steel fabrication - Applica-
tions and Benefits
Structural steel is a beneficial material for
a wide range of applications. The material
weighs far less when compared to many
other metals, and it is more economical
than many of them as well. Utilizing it can
lend products a great deal of strength. For
this reason, it is a very popular material
for large-scale construction projects.
Steel is also quite malleable, allowing it to
be customized to fit your specifications if
you hire a fabricator/welder with the skill
and experience necessary to make these
transformations possible. Structural steel
is an alloy, and as such, it can be adapted
to give it different properties. This makes
it useful for a tremendous array of pro-
jects.
Structural steel fabrication has applica-
tions across various industrial sectors
such as aerospace industry, construction
industry, manufacturing industry, mining
industry, energy sector, transport, auto-
motive, and shipbuilding. Following are
some of the structural steel products used
industry-wise.
Ÿ Manufacturing: Steel ladders, plat-
forms, industrial stairs, steel hand-
rails and mezzanines
Ÿ Construction: Steel beams, girders,
steel plates, and H-shaped steel sec-
STRUCTURAL STEEL FABRICATION
tions
Ÿ Energy: Oil and gas well platforms,
transmission towers, wind turbines,
and pipelines
Ÿ Mining: Rails, beams, rods, grating,
pipes, and fittings
Ÿ Shipbuilding: Steel flooring and grat-
ing, ladders, steel sheets and stairs
Ÿ Aerospace: Various parts of aircraft.
Ÿ Automotive: Safety features and vari-
ous parts of the automobile engine.
Types of structural steel fabrication’
Ÿ Custom Shapes
Ÿ Tee beam
Ÿ Channel beams
Ÿ Bearing Pile
Ÿ Angel beams
Ÿ I-Beam
Ÿ Pipe
Ÿ Hollow Steel Section
Different methods for structural steel
fabrication for retrofitting
Cutting and burning for retrofitting
A variety of tools are used to cut raw mate-
rial. The most common cutting method is
shearing. Special band saws for cutting
metal have hardened blades and feed
mechanisms for even cutting. Abrasive
cut-off saws, also known as chop saws,
are similar to miter saws but have steel-
cutting abrasive disks. Cutting torches
can cut large sections of steel with little
effort. Burn tables are CNC (computer-
operated) cutting torches, usually pow-
ered by natural gas. Plasma and laser cut-
ting tables, and water jet cutters, are also
common. Plate steel is loaded on the table
and the parts are cut out as programmed.
The support table consists of a grid of bars
that can be replaced when worn. Higher-
end burn tables may include CNC punch
capability using a carousel of punches and
09
 STRUCTURAL STEEL FABRICATION
taps. In fabrication of structural steel by
plasma and laser cutting, robots move the
cutting head in three dimensions around
the cut material.
Forming for retrofitting
Forming converts flat sheet metal into 3-
D parts by applying force without adding
or removing material. The force must be
great enough to change the metal's initial
shape. Forming can be controlled with
tools such as punches and dies. Machin-
ery can regulate force magnitude and
direction. Machine-based forming can
combine forming and welding to produce
lengths of fabricated sheeting (e.g. linear
grating for water drainage). Proper design
and use of tools with machinery creates a
repeatable form that can be used to create
products for many industries, including
jewelry, aerospace, automotive, construc-
tion, civil and architectural.
Machining for retrofitting
Machining is a specialized trade of
removing material from a block of metal
to make it a desired shape. Fab shops gen-
erally have some machining capability,
using metal lathes, mills, drills, and other
portable machining tools. Most solid com-
ponents, such as gears, bolts, screws and
nuts, are machined.
Welding for retrofitting
Steel is a naturally strong material, but
proper welding and fabrication tech-
10
niques can heighten this trait. Steel would
not be as reliable for high-pressure appli-
cations like columns and I-beams in com-
mercially designed buildings if not for the
intervention of welding and fabrication.
Not every welding team can use steel to its
full potential, but here at Swanton Weld-
ing we have the experience necessary to
create steel products which are ideal for
construction and design projects. We will
tailor our steel to meet your specifica-
tions, giving you a final product you will
be able to depend on for a very long time.
Refinements in welding techniques have
allowed architectural designs to be more
complex and stylized than ever before.
Not only that, the steel used in these
designs is even more dependable than it
once was. The many processes that
Swanton Welding uses are designed to
strengthen and complete the building pro-
jects of our clients not matter how com-
plex their application may be.
Plasma cutting for retrofitting
Plasma cutting is a process that cuts
through electrically conductive materials
by means of an accelerated jet of hot
plasma. Typical materials cut with a
plasma torch include steel, stainless steel,
aluminum, brass and copper, although
other conductive metals may be cut as
well. Plasma cutting is often used in fabri-
cation shops, automotive repair and resto-
ration, industrial construction, and sal-
vage and scrapping operations. Due to the
high speed and precision cuts combined
with low cost, plasma cutting sees wide-
spread use from large-scale industrial
CNC applications down to small hobbyist
shops.
Equipments used for Structural steel
fabrication for retrofitting
Plate Processor for retrofitting
Plate Processor is a machine that is used to
process printing plates. The emulsion on
a printing plate is water-soluble before it's
exposed. When it's exposed, whether to
ultraviolet light, purple light or heat (de-
pending on the kind of plate you're using),
the exposed areas become insoluble. You
put the exposed plate in the entry. There is
first a spray bar--a tube with lots of holes
in it--that applies a soap & water solution
to the plate. Next, a rotating brush with
soft bristles removes the unexposed parts
of the emulsion. Following that are a
series of spray bars that wash the plate
with water. Next comes a squeegee and
warm air to dry the plate. A final spray bar
applies gum arabic to the plate to preserve
it, and a final blast of warm air dries the
gum. When the plate emerges from the
machine, it's processed, gummed, dried
and ready to print with.
Beam Drill Lines for retrofitting
A Beam Drill Line is an important tool in
medium sized to larger structural fabrica-
tion shops. Used to drill holes accurately
in a beam, angle or section of bar stock,
these machines can make short work of
laying out the largest of structural mem-
bers. Prior to the introduction of the Beam
Drill Line the method to produce holes
Constrofacilitator • August 2020

down the length of a beam, bar or angle
was to manually layout the beam, and
using a manually positioned and operated
magnetic based drill, individually drill
each hole. This manual method, which is
still used today in many start up shops,
leaves a large possibility for errors in lay-
out or manual interpretation of prints and
drawings.
Thermal cutting machine for retrofitting
Thermal cutting machines use the pro-
cesses in which heat of an electric arc, radi-
ation energy or an exothermic reaction is
utilised to melt or oxidise a metal at an
accelerated rate to achieve a cut. There are
a number of processes which utilise the
heat of the arc to cut metals and they
include shielded metal arc, air carbon arc,
plasma arc, gas tungsten arc and gas metal
arc. Electron beam and laser beam use the
radiation energy to achieve cutting of met-
als. Oxy-fuel gas flame in conjunction
with oxygen jet is utilised to initiate and
sustain an exothermic oxidising reaction
which generates enough heat and affects
August 2020 • Constrofacilitator
parting of metals particularly low carbon
ferrous alloys. Out of these processes
oxy- acetylene, air carbon arc and plasma
arc are the three major thermal cutting pro-
cesses used in the industry.
Bandsaw for retrofitting
A bandsaw is a power saw with a long,
sharp blade consisting of a continuous
band of toothed metal stretched between
two or more wheels to cut material. They
are used principally in woodworking, met-
alworking, and lumbering, but may cut a
variety of materials. Advantages include
uniform cutting action as a result of an
evenly distributed tooth load, and the abil-
ity to cut irregular or curved shapes like a
jigsaw. The minimum radius of a curve is
determined by the width of the band and
its kerf. Most bandsaws have two wheels
rotating in the same plane, one of which is
powered, although some may have three
STRUCTURAL STEEL FABRICATION
or four to distribute the load. The blade
itself can come in a variety of sizes and
tooth pitches (teeth per inch, or TPI),
which enables the machine to be highly
versatile and able to cut a wide variety of
materials including wood, metal and plas-
tic.
Conclusion
Given above is an overview of the total
process of structural steel fabrication.
Most commercial and industrial struc-
tures are primarily constructed using
either structural steel or reinforced con-
crete. When designing a structure, an engi-
neer must decide which, if not both, the
material is most suitable for the design.
There are many factors considered when
choosing a construction material. Cost is
commonly the controlling element; how-
ever, other considerations such as weight,
strength, constructability, availability,
sustainability, and fire resistance will be
taken into account before a final decision
is made.
Info-
northern-weldarc.com
swantonweld
slpepress.com
southernfabsales.com
beautyharmonylife.com
aspireenergy.com
lovemansteel.com
secondcitymetalfab.com
steubenedc.com
kssl.ie
cuttingmaster.com
ficepcorp.com
oceanmachinery.com
thomasnet.com
budsmachinetools.com
11
 RETROFITTING OF STRUCTURES

Retrofitting of structures -
Design and Techniques

Constrofacilitator • August 2020 12


R
etrofitting means providing
something with a compo-
nent or feature not fitted dur-
ing manufacture or adding
something that it did not
have when first constructed. It is often
used in relation to the installation of
new building systems, such as heating
systems, but it might also refer to the
fabric of a building, for example, retro-
fitting insulation or double glazing. For
more information see: Definitions of
retrofitting.
The process of retrofitting involves the
careful balancing of different elements
and their effects on the overall perfor-
mance of a building. A change in one
part of a building can affect another,
and sometimes this is only apparent
after irreversible defects have occurred.
For example:
Ÿ Sealing buildings to improve their
air-tightness can cause condensa-
tion problems.
Ÿ Insulating a roof without also ven-
tilating it can cause decay of timber
structure.
Ÿ Internal wall insulation will remove
the benefits of thermal mass which
may have a detrimental effect on
Retrofitting work
fuel usage.
Ÿ External wall insulation will pre-
vent the thermal store of heat from
solar gain to be utilised within the
building.
Ÿ Poorly installed cavity wall insula-
tion can create cold spots that then
have damp problems that are
extremely difficult to rectify.
Ÿ Pre-existing problems can be cov-
ered up, and so more difficult to
diagnose and rectify.
Retrofitting design estimation
Before making what may amount to a
major investment in the retrofit of exist-
ing buildings for energy and
sustainability improvements, it is
important to determine if the invest-
ment is worthwhile in perspective with
other building conditions. Is the build-
ing structurally sound? Are seismic
upgrades needed to meet current stan-
dards and local building code require-
ments? Do hazardous material like
asbestos, polychlorinated biphenyls
(PCB) and lead paint have to be con-
tained and removed? Can the work be
done in phases to minimize disruption
to the occupants? Relocating occu-
pants to other facilities can be a signifi-
13
RETROFITTING OF STRUCTURES
cant expense.
Once you have determined that other
building conditions are not impedi-
ments to upgrading for sustainability
and improved energy performance, you
should have a plan and follow a
sequence of activities in order to deter-
mine the best options for energy and
sustainability improvements
Ÿ First, determine if the existing sys-
tems are operating at optimum lev-
els before considering replacing
existing equipment with new
higher efficiency equipment. This
can be accomplished by perform-
ing an energy audit. Sometimes,
considerable savings in utility costs
can be gained by evaluating the
performance of the building enve-
lope and existing systems: leaks,
clogged/dirty filters, stuck damp-
ers, disabled sensors, faulty or
incorrect wiring, or even lack of
knowledge on how to properly
operate and maintain equipment
can all contribute to inefficiencies
and increased costs. Audit the per-
formance of the building's water
systems as well; since leaking and
inefficient systems not only waste
water, they also use energy by need-
lessly running pumps and other
electrical equipment.
Ÿ Then, if the building is metered,
review utility bills from the last two
years to determine if consumption
(not cost) has risen.
Ÿ For existing federal buildings, per-
forming an energy audit (assessing
existing condition and operational
procedures of the building and
major building systems and identi-
fying areas for improvement) is
one of the Guiding Principles for
Sustainable Existing Buildings.
Ÿ Next, determine air tightness of the
building envelope by examining
the building envelope, looking for
leaky windows, gaps around vents
and pipe penetrations, and mois-
ture intrusion. Upgrading heating
and air-conditioning systems with-
out addressing problems with the
Constrofacilitator • August 2020
 RETROFITTING OF STRUCTURES
building envelope will result in less
than optimum performance of
those systems.
RETROFITTING TECHNIQUES
Concrete Jacketing
One way of retrofitting the beams is by
concrete jacketing. This involves plac-
ing an additional layer of concrete
around the existing beam, together
with additional longitudinal bars and
stirrups, to enhance the flexural and/or
shear capacities. The present paper
reports an investigation into the
strengthening of beams with bottom
bars discontinuous at the joints. Con-
crete jacketing is needed to increase
bearing load capacity following a modi-
fication of the structural design or to
restore structural design integrity due
to a failure in the structural member.
This technique is used on vertical sur-
faces such as walls, columns and other
combinations such as beam sides and
bottoms.
Glass and carbon wrapping system
Carbon fiber has very high tensile
strength and is also very lightweight.
When bonded to the exterior of a con-
Concrete Jacketing
Jacketing columns
Constrofacilitator • August 2020 14
crete column, beam, or slab, it can add
significant strength without adding
weight that would increase the load on
foundations and other structural mem-
bers. The composite material is called
fiber-reinforced plastic (FRP). FRP wraps
are easy to apply and can be used on
any size or shape of structural member.
Traditional techniques for strengthen-
ing, such as adding concrete and rein-
forcing steel around the outside of a
structural member (often with
shotcrete), external post-tensioning, or
adding structural steel supports (shor-
ing) often are more expensive due to
the extra work to get everything into
place. The primary reason to use this
technique is to add strength to an exist-
ing structure. In some cases, it might be
used on new construction, although at
this time that is usually only in response
to some sort of design or construction
error. In appropriate applications.
Jacketing columns
Jacketing is a technique used to
increase the strength of existing struc-
tural members (e.g. Columns, Beams
etc.) by providing a “Jacket” of addi-
tional material around the existing
member. Columns are designed to
transfer loads from top to bottom. Now
Glass and carbon wrapping system
Jacketing of beam - column joints
due to long age or non calculated
excessive loadings or or change of func-
tions, there might be different loading
than designed for on the columns in
order to support this extra loadings, the
sizes of columns will have to be
increased. This extra layer of reinforce-
ment and concrete over and above the
completed column is known as
jacketing of column. It is generally used
in case of buildings after earthquakes or
very old buildings to increase its life.
Jacketing of beam- column joints
According to Indian Standard codal pro-
visions for earthquake considerations it
has been found that many structures
located in seismically active zones are
not capable of withstanding seismic
waves. Moreover the seismic behaviour
of the existing buildings is affected due
to design deficiency, construction defi-
ciency, additional loads, additional per-
formance demand, etc. During recent
Earthquakes it is observed that the prin-
cipal cause of collapse of many
moment-resisting frame buildings is
because of the Shear failure of beam –
column joints. In a view of improving
the seismic performance of existing
structures, enormous number of
research works have been carried out to
develop various strengthening and
rehabilitation techniques. During
future seismic activities Retrofitting pro-
cess reduces the vulnerability of dam-
age of an existing structure. It aims to
strengthen a structure to satisfy the
necessities of the current codal provi-
sions for seismic design. In recent years
it has been found that among various
retrofitting methods, seismic retrofit
with FRP materials has gained notable
acceptance. Retrofitting with FRP mate-
rials is now extensively being used as a
seismic retrofitting method and it is a
technically sound and cost effective
repairing technology. In this paper, it
has been reviewed the possibilities and
methods in practice for wrapping the
beam column joints. This paper also
summarizes the scope and uses of FRP
materials such as carbon Fibre Rein-
forced Polymer (CFRP) and Glass Fibre

Reinforced Polymer(GFRP).
Strengthening of individual footings
Generally, strengthening of the founda-
tions might be needed due to the alter-
ations in serviceability of the buildings.
One method of strengthening can be
carried out by constructing a concrete
jacket to the existing footings.
Strengthening foundations by install-
ing jackets can be achieved either with-
out increase in bearing area at the base
or increasing it, whenever the soil has
inadequate bearing capacity. Below
mentioned procedure is for soil with
adequate bearing capacity.
Steps to be followed are-
Ÿ Step1 - Excavate the surcharge soil
around the footing.
Ÿ Step2 - Roughen the top surface of
the base slab for proper bond
between the poured concrete and
existing one.
Ÿ Step3 - Drilling holes in the existing
concrete of footing to install dow-
els.
Ÿ Step4 - Fastening the new steel
bars with the dowels using steel
wires. The diameter and number of
steel bars should be according to
the design.
Strengthening of individual footings
Tuned mass damper
Ÿ Step5 - Coating the external foot-
ing surface for proper bond
between new concrete and old con-
crete.
Ÿ Step6 - Completing the Jacketing
of the footing by pouring new con-
crete in the steel cage.
Base Isolation
Base isolation is one of the most popu-
lar means of protecting a structure
against earthquake forces. It is a collec-
tion of structural elements which
should substantially decouple a super-
structure from its substructure that is in
turn resting on the shaking ground,
thus protecting a building or non-
building structure's integrity. Base isola-
tion is one of the most powerful tools of
earthquake engineering pertaining to
the passive structural vibration control
technologies. The isolation can be
obtained by the use of various tech-
niques like rubber bearings, friction
bearings, ball bearings, spring systems
and other means. It is meant to enable
a building or non-building structure to
survive a potentially devastating seismic
impact through a proper initial design
or subsequent modifications. In some
cases, application of base isolation can
raise both a structure's seismic perfor-
mance and its seismic sustainability con-
Base Isolation
Wall Thickening
15
RETROFITTING OF STRUCTURES
siderably.
Tuned mass damper
A tuned mass damper (TMD), also
known as a harmonic absorber or seis-
mic damper, is a device mounted in
structures to reduce the amplitude of
mechanical vibrations. Their applica-
tion can prevent discomfort, damage,
or outright structural failure. They are
frequently used in power transmission,
automobiles, and buildings. A tuned
mass damper (TMD) is a device consist-
ing of a mass, a spring, and a damper
that is attached to a structure in order
to reduce the dynamic response of the
structure. The frequency of the damper
is tuned to a particular structural fre-
quency so that when that frequency is
excited, the damper will resonate out of
phase with the structural motion.
Energy is dissipated by the damper iner-
tia force acting on the structure.
Wall Thickening
The existing walls of a building are
added certain thickness by adding
bricks, concrete and steel aligned at cer-
tain places as reinforcement, such that
the weight of the wall increases and it
can bear more vertical and horizontal
loads, and also its designed under spe-
cial conditions that the transverse loads
does not cause sudden failure of the
wall
Seismic retrofitting
Seismic retrofitting is the modification
of existing structures to make them
more resistant to seismic activity,
ground motion, or soil failure due to
earthquakes. With better understand-
ing of seismic demand on structures.
Retrofitting of existing structures with
insufficient seismic resistance accounts
for a major portion of the total cost of
hazard mitigation. Thus, it is of critical
importance that the structures that
need seismic retrofitting are identified
correctly, and an optimal retrofitting is
conducted in a cost effective fashion.
Once the decision is made, seismic
Constrofacilitator • August 2020
 RETROFITTING OF STRUCTURES
retrofitting can be performed through
several methods with various objectives
such as increasing the load, deforma-
tion, and/or energy dissipation capacity
of the structure Conventional as well as
emerging retrofit methods are briefly
presented in the following subsections.
Seismic Retrofitting Techniques are
required for concrete constructions
which are vulnerable to damage and
failures by seismic forces. In the past
thirty years, moderate to severe earth-
quakes occur around the world every
year. Such events lead to damage to the
concrete structures as well as failures.
Composite Wraps
Composite wraps or carbon fiber jack-
ets are used to strengthen and add duc-
tility to reinforced concrete and
masonry components without requir-
ing any penetration. Composite wraps
are most effective on reinforced con-
crete columns by providing additional
confinement.
Post Tensioning
Post tensioning is considered one of the
potentially efficient retrofit options for
reinforced concrete or masonry build-
Seismic retrofitting
Composite Wraps Post Tensioning
Constrofacilitator • August 2020
ings. Masonry has a relatively large com-
pressive strength but only a low tensile
strength. Hence, it is most effective in
carrying gravity loads. Commonly,
induced tensile stresses exceed the com-
pressive stresses and reinforcing must
be added to provide the necessary
strength and ductility.
Addition of shear walls
Shear wall is a structural member used
to resist lateral forces i.e. parallel to the
plane of the wall. For slender walls
where the bending deformation is
more, Shear wall resists the loads due
to Cantilever Action. In other words,
Shear walls are vertical elements of the
horizontal force resisting system.
A shear wall is stiffer in its principal axis
than it is in the other axis. It is consid-
ered as a primary structure which pro-
vides relatively stiff resistance to vertical
and horizontal forces acting in its
plane. Under this combined loading
condition, a shear wall develops com-
patible axial, shear, torsional and flex-
ural strains, resulting in a complicated
internal stress distribution. In this way,
loads are transferred vertically to the
building's foundation. Therefore, there
Addition of shear walls
16
are four critical failure mechanisms. The
factors determining the failure mecha-
nism include geometry, loading, mate-
rial properties, restraint, and construc-
tion.
Conclusion
There are developments of new tech-
niques for the search of better sustain-
able retrofitting methods. These tech-
niques mentioned above are the most
used ones. The architect, engineer, or
code official must recognize that retro-
fitting a structure influences how that
structure reacts to hazards other than
those associated with floodwaters,
such as wind hazards. A holistic
approach should be taken with regards
to hazards when possible. Flood-
related hazards such as water-borne ice
and debris impact forces, erosion
forces, and mudslide impacts, as well as
non-flood-related hazards such as
earthquake and wind forces, should
also be considered in the retrofitting
process. Retrofitting a structure to with-
stand only floodwater-generated forces
may impair the structure's ability to
withstand the multiple hazards men-
tioned above. Thus, it is important to
approach the retrofitting method selec-
tion and design process with a multi-
hazard perspective.
Image Source:
Sciencedirect
wbdg.org
iitk.ac.in
ijcrt.org
ijirset.com
fema.in
holmesstructures.com
pvora.in
devaz-eg.com
en.vsl.cz
kenway.com
mocivilengineering.com
mdpi.com
blowick.co.uk
taylordevices.com
wikimedia.org
lmpconcreting.com.au
depta.com.tr

T
he deterioration of
Reinforced Con-
crete structures is
recognized as a
major problem
worldwide. Apart
from requiring reg-
ular maintenance,
many structures
require extensive
Repair and Rehabilitation. Over a while,
as these structures become older, we
find in them certain degradation or dete-
rioration with resultant distress mani-
fested in the form of cracking, splitting,
delaminating, corrosion, etc.
Consequently, the need for repair and
rehabilitation has grown considerably
in recent years. Repair and Rehabilita-
tion methods need to be designed with
consideration for the anticipated or
desired remaining service life of the
Constrofacilitator • August 2020 17
SERVICES FOR REPAIR AND REHABILITATION
Different types
of services for
repair and
rehabilitation
structure. A distinction must be made
between repairs and rehabilitation
intended to stop deterioration fully and
those merely aimed at slowing down
deterioration processes for a limited
period. Specialization and a deep
understanding are needed in Repair
and Rehabilitation works.
There are various types of services
available for repair and rehabilitation,
which are discussed below.
Structural repairs
Structural Repairs refer to repairs to the
structural members of the roof, founda-
tion, floor slabs and permanent exterior
walls and support columns of the
Building. Unwanted movement in
buildings can cause a good deal of dis-
tress and worry for building owners.
Subsidence, physical disturbance and
failure of building materials are just
some of the factors that can impact the
structural integrity of a property. Fortu-
nately, while there are many reasons
why a building can move, modern
repair technology and advances in
application techniques mean that
effective solutions are on hand to
tackle the problem.
It is always better to appoint a specialist
structural surveyor to monitor the situa-
tion before any works are deemed nec-
essary. This surveillance can take a
while, but the right diagnosis is always
worth waiting for. In short, structural
repair and stabilization offer a cost-
effective, low impact and environmen-
tally sound alternative to demolition
and rebuilding. It is essential, therefore,
that contractors with the necessary
competencies and experience are
selected for the long term success of
 SERVICES FOR REPAIR AND REHABILITATION
any structural repair program.
advanced technology, techniques and
expertise were once the preserve of his-
torical buildings, but now these meth-
ods are finding a place in the restora-
tion and preservation of more modern
domestic properties.
Cathodic protection
Cathodic protection (CP) is a tech-
nique used to control the corrosion of a
metal surface by making it the cathode
of an electrochemical cell. A simple
method of protection connects the
metal to be protected to a more easily
corroded "sacrificial metal" to act as the
anode. The sacrificial metal then cor-
rodes instead of the protected metal.
For structures such as long pipelines,
where passive galvanic cathodic pro-
tection is not adequate, an external DC
electrical power source is used to pro-
vide sufficient current. Cathodic pro-
tection systems protect a wide range of
metallic structures in various environ-
ments. Common applications are:
steel water or fuel pipelines and steel
storage tanks such as home water heat-
ers; steel pier piles; ship and boat hulls;
offshore oil platforms and onshore oil
well casings; offshore wind farm foun-
dations and metal reinforcement bars
in concrete buildings and structures.
Another common application is in gal-
vanized steel, in which a sacrificial coat-
ing of zinc on steel parts protects them
from rust. Cathodic protection can, in
some cases, prevent stress corrosion
cracking.
Column and micro jacketing
Column and micro jacketing
Column Jacketing is one of the tech-
niques used to improve or restore the
capacity of reinforced concrete col-
umns. Micro concrete Jacketing is a
technique used to increase the
strength of beam-columns of existing
structures. The important objective of
column and beam jacketing is to
increase the seismic capacity of the
moment-resisting framed structures.
Jacketing is particularly used for the
repair of deteriorated columns, piers,
and piles and may easily be employed
in underwater applications. The
method is applicable for protecting con-
crete, steel, and timber sections
against further deterioration and for
strengthening. Repair of damages of
Structural Repairs
reinforced concrete like column, beam,
wall etc. To use repair mortar. Jacking
of RCC columns to increase load tak-
ing capacity.
Patch repair
A patch repair is the most common
technique to repair corrosion damage
in RC structures. For a patch repair, the
concrete cover is typically removed to
approximately 25 mm past the steel
bars (which are then cleaned of corro-
sion products) and a repair material is
installed. For a structure under repairs
steel is usually affected by corrosion;
loose rust scales are removed prefera-
bly all around the bar using abrasive
tools or sandblasting and stabilized for
rust formed with suitable rust conver-
tors; then a protective coating is
applied over the rebars such as alka-
line cement polymeric coat, epoxy phe-
nolic coat or zinc-rich paint, etc. Con-
siderably lost rebar sections are
replaced with new bars with sufficient
lap on both ends.
Corrosion protection of steel struc-
tures
Structural steel will not corrode until it is
immersed/wetted by an electrolytic
solution and gets electrically con-
nected to another metal or alloy having
18 Constrofacilitator • August 2020

a more positive electric potential. Thus
elimination of electrolyte itself can be
effective for corrosion prevention. The
durability of the steel-concrete slab is
adversely affected by the corrosion of
the reinforcements. In a sound con-
crete, the pH value of the cement paste
is about 12-13, offering protection to
steel by the formation of a thin layer of
bonded and insoluble oxide, which
stops the reaction of oxidation. The cor-
rosion is possible with a lower pH of
cement paste, in the range of 8 to 9.
The pH lowering is often created by the
carbonation, the ingression carbon
dioxide from the atmosphere into the
concrete. Also, the ingression of chlo-
rides and Nacl existing in a marine envi-
ronment greatly accelerates the corro-
sion rate. TMT bars, as well as CRS
grades containing small percentages
of Cu and Cr and these bars, have 1.5 –
1.9 times better corrosion resistance
than that of CTD bars. Similarly, Stain-
less steel bars/galvanized bars have
also been developed for use in hostile
environments. It can be used in combi-
nation with carbon steel, for example,
in the repair/renovation of structures,
where it will provide enhanced durabil-
ity over repair using carbon steel. The
use of all these grades will enhance the
durability of reinforced concrete struc-
tures.
Ground-penetrating radar
Ground-penetrating radar (GPR) is a
geophysical method that uses radar
pulses to image the subsurface. This
nondestructive method uses electro-
magnetic radiation in the microwave
band (UHF/VHF frequencies) of the
Constrofacilitator • August 2020 19
SERVICES FOR REPAIR AND REHABILITATION
Corrosion protection of steel structures
radio spectrum and detects the
reflected signals from subsurface
structures. GPR can have applications
in a variety of media, including rock,
soil, ice, freshwater, pavements and
structures. In the right conditions, prac-
titioners can use GPR to detect
subsurface objects, changes in mate-
rial properties, and voids and cracks
GPR has many applications in several
fields. Engineering applications
include nondestructive testing (NDT) of
structures and pavements, locating
buried structures and utility lines, and
studying soils and bedrock. In environ-
mental remediation, GPR is used to
define landfills, contaminant plumes,
and other remediation sites, while in
archaeology it is used for mapping
archaeological features and cemeter-
ies. GPR is used in law enforcement for
locating clandestine graves and buried
evidence. Military uses include detec-
tion of mines, unexploded ordnance,
and tunnels. Borehole radars utilizing
GPR are used to map the structures
from a borehole in underground mining
applications. Modern directional bore-
hole radar systems can produce three-
dimensional images from measure-
ments in a single borehole.
Ground-penetrating radar
External PT for Bridge girders & Slabs
The principle of external post-
tensioning is the same as that of
prestressing, 'ie, the application of an
axial load combined with a hogging
bending moment to increase the flex-
ural capacity of a beam and improves
the cracking performance. It can also
have a beneficial effect on shear
capacity. Precise evaluation of flexural
and shear capacity of beams with
unbonded tendons, either internal or
external to the section, is difficult. This
is because the load in the tendons is a
function of the overall behaviour of the
beam, rather than just depending on
the strain distribution in a particularly
critical section.
External post-tensioning has been
applied most generally to beam-type
bridges. The tendons can be straight or
draped using deviators depending on
the particular requirements. Various
profiles can be adapted to suit the
required combination of axial load and
bending. Additional compressive mem-
bers can be introduced if the additional
compression stresses imposed on the
bearn are not desirable. External post-
tensioning can be used to improve the
performance of any kind of beam
bridge, be it timber, reinforced con-
crete, prestressed concrete, steel or
composite. The main reason for its use
has been to provide increased flexural
strength required because of under-
design, increased traffic loading, loss
of structural strength due to deteriora-
tion or to correct serviceability prob-
lems. A truss bridge can be strength-
ened by applying a polygon tendon to
the truss as a unit. The cable is fixed to
 SERVICES FOR REPAIR AND REHABILITATION
the top of the truss at the supports, slop-
ing, down to the bottom of the truss at
mid-span.
Corrosion Monitoring
Corrosion monitoring techniques can
be classified into different groups
according to various criteria, for exam-
ple, direct or indirect, intrusive or non-
intrusive, on-line or off-line, etc. If the
monitoring technique measures a
direct result of corrosion, it is direct, oth-
erwise, it is indirect. Corrosion cou-
pons, electrical resistance (ER), and lin-
ear polarization resistance (LPR) are
typical examples of direct techniques.
Indirect techniques measure an out-
come of the corrosion process, exam-
ples including ultrasonics and radiog-
raphy. If a monitoring technique
requires entry into the process stream,
it is intrusive, otherwise, it is non-
intrusive. Corrosion coupons, ER, and
LPR can be classified as intrusive since
access to the process stream is
required for these probes. External
hydrogen flux probes, handheld ultra-
sonic probes, magnetic flux leakage
probes, etc. can be classified into non-
intrusive techniques.
Selective demolition
Selective demolition uses carefully
planned sequenced activities that sep-
arate and sort the materials within a
building. Rather than knock a building
down, an Oregon demolition company
deconstructs it using special equip-
ment. The solution reduces waste, max-
imizes efficiency and reduces a pro-
ject's carbon footprint. Building owners
often seek this option when they want
to update a structure's interior, convert
a space, improve the building's health,
or add an extension.
Non-destructive testing (NDT)
Non-destructive testing (NDT) is a test-
ing and analysis technique used by
industry to evaluate the properties of a
material, component, structure, or sys-
tem for characteristic differences or
welding defects and discontinuities
without causing damage to the original
part. NDT also is known as non-
destructive examination (NDE), nonde-
structive inspection (NDI) and non-
destructive evaluation (NDE). Non-
destructive testing can be applied to
each stage of an item's construction.
The materials and welds can be exam-
ined using NDT and either accepted,
rejected or repaired. NDT techniques
can then be used to monitor the integ-
rity of the item or structure throughout
its design life.
Corrosion Monitoring
Selective demolition
Expansion joint repair
Expansion joints allow for expansion
and shrinkage of blocks of concrete.
These are caused by internal expan-
sion, caused by thermal variations,
load fluctuations, or movements of the
concrete mass. Expansion Joints are
to permit the separate segments of the
structural frame to expand and con-
tract in response to temperature
changes without adversely affecting
the structural integrity or serviceability.
But with the use and deterioration of the
structure, these joints at times become
clogged and damaged areas become
a source of leakage.
Conclusion
These are the most used services for
repair and rehabilitation services, with
time more and more customized ser-
vices are evolving as per requirements.
The success of repair activity depends
on the identification of the root cause of
the deterioration of the concrete struc-
tures. If this cause is properly identified,
satisfactory repairs can be done for the
improvement of strength and durability,
thus extending the life of the structure,
is not difficult to achieve.
Image Source:
sciencedirect, steel.insmag.org,
s a n r a c h n a , s e m a n t i c s s c h o l a r,
seledemo.co, twi global, world spike,
prooftech.com.sg, primefeed.in,
shayonaengineers.com, archaeologi
t h e e n g i n e e r i n g c o m m u n i t y. o r g ,
grantmackaydemolition.com, cal-
surveys.co.uk
20 Constrofacilitator • August 2020
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