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Repair of Concrete Superstructure and Substructure
Repair of Concrete Superstructure and Substructure
SUPERSTRUCTURE AND
SUBSTRUCTURE
COURSE OUTLINE
1. EPOXY INJECTION
2. CAULKING
3. PATCHING
4. RECASTING CONCRETE/GROUT
5. CARBON FIBER SHEET BONDING TO DECKSLAB
6. STEEL PLATE BONDING
7. PARTIAL DECKSLAB REPLACEMENT
8. WATERPROOFING ON DECKSLAB
9. FAST SETTING MORTAR CONTINUED DECKSLAB
10.PROTECTIVE MORTAR
11.PROTECTIVE COATING
12.CARBON FIBER SHEET/PLATE BONDING TO
CONCRETE GIRDER
13.JACKETING WITH CONCRETE
EPOXY INJECTION
Epoxy injection is used to restore
structural soundness of
structures exhibiting inactive
cracks. Cracks with more than
0.3 mm up to 3.0 mm widths can
be bonded and sealed by
injecting low viscosity epoxy.
Work Sequence
1. Cleaning of Cracks.
2. Fitting of Injector
3. Sealing of Cracks at the Surface
4. Fitting of Injector
5. Injection of Epoxy
6. Curing of Injected Material
Required Materials and
Tools/Equipment
Required Materials Required Equipment/Tools
1. Epoxy Resin for Injection 1. Epoxy Injection Pump or Gun
2. Epoxy Resin Adhesive 2. Power Disc Grinder/Cutter
3. Sealant (Epoxy Putty) 3. Portable Generator
4. Set of Injection Tool 4. Brush etc.
CAULKING
Crack widths could be more than
3.0 mm with depth of less than
300 mm. In this case, the top
surface edges should be chipped
or sawn to form a V-type or U-
type groove, in order to provide a
caulking for inlet of gravity flow
of resin into the crack by
injection pump.
Work Sequence
1. Cleaning of the cracks.
2. Preparation of Caulking
3. Drilling Holes and Fixing the
Injection Pipes
4. Injecting Epoxy Grout
5. Curing of Injected Material
Required Materials and
Tools/Equipment
Required Materials Required Equipment/Tools
1. Epoxy Grout 1. Epoxy Injection Pump
2. Sealant 2. Power Disc Grinder
3. Portable Generator
4. Brush
5. Set of Injection Tools
PATCHING
Patch repair is performed to restore small areas
where sound concrete is damaged by spalling,
REBAR
scaling and impact.
Patch repair is classified into two types
considering defective area and surface:
Type-A is applicable to surfaces without REPAIR MORTAR
1. Surface Preparation
2. Keep dry condition and avoid
sunshine
3. Weigh PCM with Lithium Nitrite
4. Weigh the emulsion
5. Mix Powder and Emulsion
6. Application of PCM with Lithium
Nitrite
7. Curing of PCM with Lithium Nitrite
PROTECTIVE COATING
if the bridge is located more than
1km from the coastal area, concrete
member will be deteriorated due to
carbonation. It is recommended that
protective coating should be applied
as preventive maintenance.
Protective coating is made from
acryl urethane based coating which
is effective against carbon dioxide,
weather/UV rays, chemical and oil
damage.
After repairing damage, protective
coating shall be applied on the
concrete member
Work Sequence
1. Surface Preparation
2. Mixing acryl urethane protective
coating materials
3. Application of protective coating
CARBON FIBER SHEET/PLATE
BONDING TO CONCRETE GIRDER
1. Epoxy primer
2. Epoxy putty
3. Epoxy resin
JACKETING WITH CONCRETE
Concrete jacket is applied to protect
the deteriorated concrete due to
corrosion of rebars, damage due to
rapid water flow or broken due to
continuous impact from materials
flowing in the channel such as drift
woods.
Work Sequence
1. Removal of Deteriorated
Concrete
2. Addition of Rebar
3. Setting-up of Formworks
4. Placing of Concrete
5. Curing of Concrete
Required Materials and
Tools/Equipment