1980/1 [1980.1] 4310] No. RW/PL-17 (14)/76-Vol. II Dated the 31st March, 1981 To All the Chief Engineers/Addl. Chief Engineers of litoral States, Union Territories PWDs dealing with Highways ‘Sub: Guidelines for maintenance repair of existing concrete bridges susceptible to being affected by corrosion ‘Your kind attention had already been drawn in this Ministry's circular letter No. PL-67 (29)/76-NHVI dated 22.9.78 to the need for conducting periodic inspection of highway structures on National Highways, in accordance with the provisions contained in LRC. Special Publication No. 18—“Manual for Highway Bridge Maintenance Inspection.” 2. _ The problem of corrosion and corrosion protection of concrete bridges exposed to marine environment has been engaging since some time the attention of this Ministry which has launched a research on this subject. Until findings of research are available, it has been decided that the maintenance and repairs to the concrete highway bridges/structures located in coastal areas and affected by corrosion, shall be carried out in accordance with the provisions in the enclosed guidelines. 3. In order to ensure the safety and efficient functioning of the bridge structures,the Chief Engineers are requested to attach utmost importance to such inspections for“preventive” maintenance ofthese structures and to bring it to the notice of their officers and staff the above guidelines to be followed. 4. Suggestions to improve/augment the above guidelines based on experiences are welcome, Enclosure to letter No. RW/PL-17 (14)/76-VolH dt 31.3.81 GUIDELINES FOR MAINTENANCE AND REPAIRS OF EXISTING CONCRETE BRIDGES SUSCEPTIBLE TO BEING ‘AFFECTED BY CORROSION Concrete bridges mainly in the coastal areas are vulnerable to corrosion due tothe aggressiveness ofthe environment Repairs the 1s soon as deterioration is noticed, and this requires a regular and timely inspection ofthe existing 2 __Iisessential that records are maintained to provide a complete upto—date history of structure right from construction stage with a ‘mention of any special ant-corrosve treatments adopted atthe time of design and construction stage itself 3. Inspection 3A. _Allbridgesshallbe inspected once a year to ascertain ifthere ae any signs of distress such as appearance of strains, cracks, spalling ‘tc and action taken to remedy such defects. Such bridges be kept under constant observation by resorting to frequeat inspections and further remedial measures undertaken as considered necessary. 32. The inspection report should cover the items listed in the proforma—Annexure-A. The items requiring special attention during inspection ae briefly elucidated in notes at the end of Annexure-A. 33. The reports shall be compared with previous reports o get an idea ofthe rae of deterioration. Ifthe rate of deterioration is alarming, further detailed investigations to ascertain causes of deterioration etc. shall be undertaken. Thereafter the desired adequate remedial measures suggested 4 Ldentifiation of Corrosion and Damage of Concrete 4.,_Thedurabilityofthe structure varies considerably in various zones of exposure which could be delimited forthe purpote of applying ‘ese specifications as under 42) Submerged zone : that part ofthe structure which falls below the splash zone In this area the primary concern is to prevent chemical deterioration of concrete, corosion of embedded steel and abrasion. ) Splash zone: sreaof the structure subjected to repeated wetting and drying by sa wate, viz. the difference between the highest and thelowest water levels reached by the waves with a statistical tun period ofé months super imposed on the highest and lowest evel of spring tides plus one metre above highest tide level. nth are, atention has to be paid to chemical deterioration of concrete and corrosion of embedded steel In very cold climate the aspect of freezing and thawing has also to be considered though the same isnot generally applicable to India. Atmospheric zone: that part of the structure above the splash zone exposed tothe atmosphere. Jn this area attention has to be paid tothe prevention of corrosion of embedded steel due to wind action carrying salVsand particles. 42. The causes leading o corrosion of reinforcement and/or damage of concrete such as inadequate cover, poor concrete quality. ype ‘and qualty of aggregates and cement used, quality ofwater used etc. shall be investigated 1 ascertain, whether they have been responsible1980/2 forthe deterioration of concrete and steel 43. _Forbridgesmore than yearsold and exposed to adverse atmospheric conditions detailed inspection usingtechniques mentioned in ‘para 6 may be undertaken. 5. Remedial Measures: Si. Based on the detailed inspection and afer identification ofthe causes leading tothe defects inthe structure the remedial measures ‘could be classified as follows: |) Tnadequate cover : For components baving inadequate cover, surface treatment by way of providing additional good quality dense concrete cover with 20 mm size of aggregates v0 as to have a minimum cover of 50 mm shall be considered. 4) Repairs toecracks; Where corrosion bas just setin and cracks appear bu palling has not started, itisfeltubatitmay beadequate tosealthe narrow cracks against ingress of moisture etc For this purpose where rigid type sealant is required, it may be sufficient to cement ‘gosto junit or inject into the cracks epoxy mortar with adequate bonding and tasie strength, For exible sealants achase should be cut slong the ine of crack and then sealed with an elastic material such as poly-sulpide rubber orby the insertion ofa prepared neoprene ot ‘rubber bitumen sealing strip. Even aftersuch a treatment itwllbe necessary to keep aconstant watch onits performance so astoundertake further step as and when required. (Gi) Repatso damaged spalledconerte: For repairs to damaged/spalled concrete, where exieasive damage has already occurred due to corrosion, the defective concrete should be cut out othe fll depth but not less than 50 mm beyond the loose concrete layer and all loose ‘materials removed. The exposed reinforcement shouldbe thoroughly cleaned up tothe root ofthe rust with brushes sand basting. chemical solution, etc Iffelt necessary the bar could alsobe removed and replacedby another new bar duly welded in postion. Ontheeplaced aswell 1s remaining stel surface either a thin coat of neat cement grout or epoxy coating as per specifications enclosed (Annexure-B) with ade~ {quate bonding and tensile strengths should be applied before any further treatment. The repairs can ether be done by reconcreting with saaller chips of 20 mm size preferably and good quality dense concrete, or guniting with cement mortar or epoxy mortar. The guniting for ‘cement mortar shal satisfy the following specifications : (@ Water cement ratio 0.35 100.50 by weight wet enough to reduce rebound, (Mortar mix of part of cement: 3 104 parts of sand. (©) Drying shrinkages 0.06 0 0.1 per cent (4 Cement used shall be with inhibitors such as calcium nitrite of approved specifications. (©) Thickness of guniting 0 1065 mm. (Test panels should be gunned under field conditions to check or reduce rebound (@ Conventional 150/300 mm cylinder moulds shot creted shall give strength of about M 300 at 28 days. Where epoxy mortar guniting is tobe preferred, the specifications in respect ofthe same will have tobe drawn in consultation with ‘expers in the fleldas this ia specialised job, However, not much experience has been gained to draw the specifications and report on per- formance of such treatment for bridges in this country. (jv) For exposed components of expansion joint, the sume shall be protected by a suitable covering of proven specification. 6 Theperformance ofthe remedial measures undertaken shall be carefully watched and monitored For monitoring use of copper sul- ‘phate half cell for measuring the potential difference over atime period in the alfected portion and comparing such values with previous records, use of nondestructive tests such as SCHMIDT Hammer, Ulirasonic Pulse: Transmission Techniques etc. covld be considered. ANNEXURE A PROFORMA FOR INSPECTION A HISTORY OF BRIDGE 1, Name of Bridge 2 Location of Bridge (with map showing predominant direction of wind) 3 Age of rider onthe dat of Inspection. distance from sea, Whether located in back waters 5 eterna chemical industy inet or arf alueat psi 6 ‘Type of bridge along with GAD-RCC. Prestressed. 7. Grade of concrete with cement content 8 W/C ratio used (if availabe). 9. Chemical analysis of all the materials (if available). 10. Minimum cover to steel reinforcement used. LL. Whether any anticorrosive treatment adopted at the time of construction. 12 Position of Construction Joints (if available) a INSPECTION REPORT Bridge component affected 1), Superstructure fi) Substructure iil, Foundations the ver.1980/3 i) Bearings ¥) Any other 2. NATURE OF DISTRESS OBSERVED {) Rusting or staining of concrete ) Bulging and/or cracking of concrete Ail) Spalling of concrete iy) Rosting of metallic bearings 3, Extent of increase in deterioration sinoe previous inspection 4 Repair measures proposed to be taken, c ANY OTHER OBSERVATION NOTE: The items of inspection, as listed in proforma (item B 1) are briefly elucidated here 1 ‘Bearings : While inspecting the bearings, following shall be kept in mind: ') The general condition like cleanlines, rusting and greasing of metallicplate bearings ‘Condition of rubber bearings, deterioration due to oxidation, Mattening, bulging & splitting Condition of grease/ol (if provided) incase of metallic bearings. ‘Whether any structural cracks in supporting members like abutment cap, pier cap, pedestal, ec. 2 Superstructure: The inspection officer shall inspect the superstructure and report in respect of the following: (0 Reinforced concrete members: The following aspects shal specially be looked for spotting (rusting, cracking leaching spalling and other signs of deterioration in critical areas of the structure viz, splash zone, waterline at low tide level and portions exposed 10 ‘atmospheric attack on the windward side. For the latter the web of concrete girder and box girder articulations underside of decks, etc, shall particularly be inspected. (Gi) Prestressed Concrete Members: For prestressed concrete members aspect like loss of camber, excessive deflection, cracking, deterioration in concrete vz, spalling ec. shall be looked for. The critical areas being end anchorage zones, junction of diaphragms, underside atthe centre of span for longitudinal cracking et. 3. Expansion Joints: Besides inspection for proper fonctioning of the expansion joint, any deterioration in the material such as rust- ing ete, shall be looked for along with remedial measures required. 4. Wearing Coat: The surface condition ie. whether there are any crack, spalling of concrete, disintegration et. need tobe reported. along wit remedial measures 5. Mand rails and Footpaths: Hand rails, being slender members, are susceptible to corrosive distress Appearance of rust stains, ‘racks, sealing deterioration in concrete, spalling ct. need to be reported along with remedial measures. ANNEXURE B ‘CONCRETE CLASSES PSD, PSG, AND XYP ‘Concrete lasses PSD, PSG, and XYP shall meet allof the requirements of concrete Class AX except the materi shall be proportioned to produce aconcrete which shall havea minimum compressive strength of not less than 5000, 7000 and 6500 pounds per square inch, respec tively. atthe age of 28 days. ‘The Contractor shall design a mix that meets the specified strength requirements in conformance with ASTM C685. A coefficient of varia- ‘ion 20 percent shall be assumed unless the supplieran demonstrate a record of sufficient tests to justify theuse of a lower coefficient in ‘conformance with ASTM C 685. ‘The mix shall be reviewed by the Engineer and verified by tests of cylinders made rom the mix prior to commencing workon the portion of the bridge using this concrete. The use of calcium chloride as an admixture to the concrete will nt be allowed. EPOXY-COATED STEEL REINFORCING BAR ‘This item of work shall consis of furnishing fabricating coating and placing epoxy-coated steel reinforcing bars in accordance wih the plans the standard specifications and these special provisions. The coating material shall be applied by the electrostatic spray method or the electrostatic fludized-bed method. COATING MATERIAL ‘The coating material shall be one of the following or an approval equal (a) SCOTCHKOTE 202 by the Minnesota Mining and Manufacturing Company, Inc. (©) FLINTFLEX 531-6080 by the E1. Dupont de Nemours Company, Ine (©) EPOXY POWDER 720-09 by the Cook Paiat and Varnish Company. (6) CORVEL ECA-140-5-Green-2779 by the Polymer Corporation. (©) EPOXIPLATE-Mé, 347, 48 and 349 by the Armstrong Products Company. (0) MOBILOX 1004-R-2 by Mobil Chemical Company. (® SCOTCHKOTE 213 by the Minnesota Mining and Manufacturing Company Inc. (h) NAP-GARD 7-2000 by the Napco Corporation. (@) OXY-PLAST EL-704P4 by the FullesO'Briea Corporation. ( SCOTCHKOTE 214 by the Minaesots Mining and Manufacturing Compnay Inc. (®) HYSOL Dx 23-0602 by the Dexter Corporation.1980/4 Manufacturers information on the proper use and application requirements ofthe resia to be uted shall be submitted tothe Engincer by ‘the Contractor. ‘The Contractor shal furnish a written certification thatthe material furnished fr the coating ofthe reinforcing steel is the same forrmula- tion as previously approved by the National Bureau of Standards, or the Materials Laboratory of the Washington State Department of ‘Transportation. The Contractor shall supply tothe Engineer a representative sample of 8 ounces ofthe powdered epony resin used to.coat ‘each given lot of bars. The sample shall be packaged in an airtight container wih identification by lot numbers. SURFACE PREPARATION ‘The surface ofthe stee reinforcing bars which are to be coated shall be biased toxcar white metal in accordance with the see structure Painting Council Surface Preparation Specification SSPC-SPIO-G3T, amended January I, 1971. ‘All races of grit and dust from the blasting shall be removed. The surface shall be clean and fre of any oil grease or other surface con- ‘taminants at time of coating, ‘The coating shal be applied tothe cleaned surface as soon as possible after blast cleaning The time between blast cleaning and coat ‘the bars shall not be more than approximately eight hours without specific approval ofthe Engineer. COATING PROCESS Bars shall be costed in acordance wih the resin manufacturers recommendations and these specifications. The coated bars shall meet, the requirements specified and may be inspected for approval at the coating plant Samples of costed bars ofeach size for testing shall be submited to the Engineer for plant and proceas approval. A certification statement tating that all bars have been coated in accordance With the resin manufacturers recommendations and these specifications shall be furnished with each shipment This certification shall Jnchade foreach bar size the preheat temperatures, cure times thickness check, holidays detected and bend test results. Two copies of these certifications shall be forwarded to the Engineer. ‘The coating applicator shall submit certifications ofcompliance withthe above requirements In addition, the Contractor shall submit to the Engineer six camples of each size ofepory coatedbars shown inthe plans The samples shall be four fectlong and the Contractor shall ensure that samples fr this testing sall not short the bar lengts specified in the project plans HANDLING Toprotectthe coated reinforcement from damage, he Coutractr sti use padded or nonmetallic slingsand padded siraps Bundled bars shall be handte i a manner which wil pvent excessive sagging of burs which wll damage the coating The Bundled bars shal not be ‘dropped or dragged and canst be stored om wooden cribbing I inthe opinion ofthe Engineer. the coated burs have been extensively damaged the material will be rejected. The Contraster may propose, for approval of the Engineer. alternate precautionary measures FABRICATION AND PLACEMENT ‘The bars shall be fabricated as specified in sation 907 ofl standard specifications before or after applying the epoxy coating ‘Metal chairs and supports shall be coated with an epoxy or tar inet coating approved the Engineer. The Contractor may proposethe te ofother device for approval ofthe Engncer Pasicoatetic wires approved by the Enginecrshal be used o protec the coated bars ftom physical damage during placement. ‘Thebans shall be accurately placed inthe pottiomshown in the-plans anfimaly he Idin place during placing and setingo he concrete ‘All epory costed basin the top mat of the roadway slab shall betied stall ints: sions All other epoxy-coated bars shall be ted at all fntertetions except where the spacing is less than I foot 0 incilesin citer dre ction, in which case alteate intersections shall be tied ‘Afer placement ofthe coated bars and before pouring the bridge dbo omeret te coated bars willbe inspected and, ection, the Contactor shall patch damaged areas as specified cluewtere i hs specification. ‘COATING THICKNESS ‘Afiim with thickness afer curing of8 mils + 2mils shall be applica aunifor:n, sooth coat Thickness ofthe film willbe measuredon {representative number of bars from each production lt bythe sammemcthod_ as outlined in ASTM Designation B 499, Now-magnctic Coutings on Magnetic Basis Meta. CONTINUITY OF COATING “The coating shall be checked afer ore a the contin plantforomatinsy of costing and thll be fre frm holes, ods contamination, cracks and damaged ares In addition, here shall nt bearonedian to Loi aya poles not visually discernible) in each linea foot ot Contd ber A blidy detector shal be used in sczordancrwishie maaufact ners instructions to check the coating Pr holidays AGT-/2 oll, AC. powered, onlin, holiday detector shall be waa FLEXIBILITY AND BONDING OF COATING ‘The coated reinforcing bars shall be capable of being Bent 20 degrees over a mandrel ofthe following dlamete without and visible ‘evidence of cracking or disbondingof the costing The ameter ofthe matadel for aumber4,$,6,78,9, 10and 11 bas shall bed, 5, 6.7.8.9 {Oand{ inches respectively. Therateof bending shallbe one minute plusor minus 15 seconds The coating applicator shall testone sam: ple each ber sae as prescribed above fr each day's proczsing I there any evidence of racking o disbonding of the coating. to TWaltional eat samples from different bars shal be secured and tested from the bars previously costed that day. Any evidence of cracking ‘Or dsbonding will be considered caute for rejection ofthe coated bars presented by these samples. PATCHING MATERIAL Patching or repair material, compatible withthe coating and inert in oyncrete, shall supplied by the epoxy resin manufacturer and shall have approval ofthe Enginecr. The material shall be suitable for repairs of azeas of coating that have been damaged. ot the Engineer1980/5 PATCHING Patching material shall be appliedo damaged areas at the points of occurrence, suchas at the initial application, fabrication, destination ‘or installation points, ‘Areas tobe patched shall be clean and fee of surface contaiminants. Tey shall be promptly treatedin accordance with the resin manufac turer's recommendations and before detrimental oxidation occurs. ‘Unless otherwise shown inthe plans, all bars shall be epory-costed. ‘All costs fr furnishing and installing epoxy-coated reinforcing bars shall be incidental to and included inthe unit contract price ofthe various contract items containing epoxy-coated reinforcing see 1980.2. No. RW/PL-17 (14)/76-Vol. II Dated the 4th January, 1982 To Alll the C.Es/Addl. C. Es of Littoral States, Union Territories, PWDs dealing with Highways ‘Sub: Interim specifications for new concrete bridges to be constructed in marine environments and susceptible to corrosion Your kind atntion isinvitedo this Minity’s circular leterofeven number dated the 31st March, 1981 forwarding”Guideline for maintenance and repairs of eristing concrete bridges susceptible to/being affecied by corrosion”. It is equally important that specifications adopted for the construction of new concrete bridges in such environments are adequate for inhibiting corrosion, so as to ‘and long term safety, and serviceability of our bridge structure. The Ministry has undertaken a research programme in ‘which a detailed study ofthe problems of corrosion has been sponsored in the Ceatral Electro Chemical Institue at Karaikudl, with a view to drawing up suitable specifications for concrete bridges tobe constructed in marine environments susceptible to corrosion. However, till ‘such time final results ofthis stady are made available, it has been decided tat for ll centrally financed new concrete bridges located in ‘marine environment susceptible to corrosion the interim specifications, herewith enclosed, may be adopted. 2 __Iisalso recommended thatamongst concrete superstructures preference shouldbe given oa structural arrangement whichis fully prestressed both longitudinally and crass-wise. A svstem with gap slabs should be avoided as not only the joints permit ingress of moisture ino cable dicts however effectively sealed and promote chances of corrosion but also holes in some cases are not i the same vertical and horizontal alignments causing difficulties for threading cables. Comparatively speaking easy accessibility of steel structures for inspection and periodic protective painting. combined with feasibility of convenient repairs and replacement of members made them for the bridge ‘superstructures an equally viable alternative and in certain locations even a preferable solution. These must also be considered inspite of ‘the inital higher coat of sel structures. Conventional normal practice of using fully galvanised secions and painting wth special anti- ‘corrosive paints should be continued at regular intervals for protection against corrosion. 3. __Itis, however, imperative that corrosion protection of concrete bridges special attention is pad tothe requirements of quality con- ‘wol, ensuring strict compliance of the prescribed standatds for materials, concrete production and placement laid down in the “Specifications for Road and Bridge Works"and the enclosed interim specifications, the latter superseding the former, wherever ‘confit occurs 4. Acomplete record should invariably be kept on all important aspects ofthe work such as specificauons ofthe materials actually used, the field test data for ensuring requisite process control in making good quality concrete and periodic maintenance inspection report as already highlighted in tis office circular letter of even number dated March 31, 1981 along with the performance data of the structure Enclosure to leer NO. RW/PLEI7 (14/76-Vol I d 4.182 Interim specifications for new concrete bridges to be constructed in marine environments and susceptible to corrosion 1 Scope: Till such time the final results ofthe detailed condition survey of concrete bridge structures located in marine environment, suscept- ‘ble to corrosion, and findings of research undertaken by the Ministry, are available, the interim specifications contained herein should be adopted. 2 Durability and zones of exposur Tnorderto ensure longterm serviceability ofthe structure, both durability of concrete and immunity against corrosion ofembedded reinforcements are the essential requirements and these ae achieved by concrete properly proportioned with low-water-cement ratio low ‘permeability, welllaid and compacted and dense with the absence of cracks joints, adequate curing, etc. It has been noticed thatthe effects ‘of corrosion vary considerably in various zones of exposure which could be delimited forthe purpose of applying this specification as under: '») Submerged Zone : That part ofthe structure which falls below the splash zone. Jn this area, the primary concera i to prevent chemical deterioration of concrete corrosion of embedded steel and abrasion. ') Splash zone : area ofthe structure subjected to repeated wetting and drying by sea water, viz. the difference between the highest andthe lowest water levels reached by the waves with a statistical retum period of months superimposed on te highest and lowest level of spring tes plus one metre above highest tide level. Inthis area, attention has tobe paid to chemical deterioration of concrete and corrosion of embedded steel. tn very cold climate the aspect of freezing and thawing has also to be considered though the same is not generally applicable to India.