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Infrastructure
Engineering
Asst. Prof. Dr. Aymen Jameel Alsaad
5
Assessment and Rehabilitation of infrastructures
Standard Methods of Concrete Repair

Portland Cement Mortar.
Portland cement mortar may be used for repairing defects on surfaces not prominently exposed, where the defects are too wide
for dry pack filling or where the defects are too shallow for concrete filling and no deeper than the far side of the reinforcement
that is nearest the surface. Repairs may be made either by use of shotcrete or by hand application methods. Replacement mortar
can be used to make shallow, small size repairs to new or green concrete, provided that the repairs are performed within 24
hours of removing the concrete forms
Materials.
Replacement mortar contains water, Portland cement, and sand. The cement should be same type as used in the concrete being
repaired. The water and sand should be suitable for use in concrete, and the sand should pass a No. 16 sieve. The cement to sand
ratio should be between 1:2 to 1:4, depending on application technique. Only enough water should be added to the cement-sand
mixture to permit placing.
Curing.—Failure to cure properly is the most common cause of failure of replacement mortar. It is essential that mortar
repairs receive a thorough water cure starting immediately after initial set and continuing for 14 days.
Dry Pack and Epoxy-Bonded Dry

Pack.—Dry pack is a combination of Portland cement and sand passing a No. 16 sieve mixed with just enough
water to hydrate the cement. Dry pack should be used for filling holes having a depth equal to, or greater than,
the least surface dimension of the repair area; for cone bolt, she bolt, core holes, and grout-insert holes; for holes
left by the removal of form ties; and for narrow slots cut for repair of cracks
The first method is the application of a stiff mortar or grout bond coat immediately before applying the dry pack
mortar. The mix for the bonding grout is 1:1 cement and fine sand mixed with water to a fluid paste consistency.
All surfaces of the hole are thoroughly brushed with the grout, and dry packing is done quickly before the
bonding grout can dry.
The second method of ensuring good bond starts with presoaking the hole overnight with wet rags or burlap.
A third method of ensuring good bond is the use of an epoxy bonding resin. The epoxy bonding resin should
meet the requirements of ASTM C-881 for a type II, grade 2, class B or C resin, depending on the job site
ambient temperatures. Epoxies bond best to dry concrete.
Materials.—Dry pack mortar is usually a mixture (by dry volume or weight) of 1 part cement to 2-1/2 parts
sand that will pass a No. 16 screen. While the mixture is rich in cement, the low water content prevents
excessive shrinkage and gives high strengths
Application.—Dry pack mortar should be placed and packed in layers having a compacted thickness of about
three-eighths of an inch. Thicker layers will not be well compacted at the bottom. The surface of each layer
should be scratchedto facilitate bonding with the next layer
Shotcrete.—Shotcrete is defined as "mortar or concrete pneumatically projected at high speed onto a surface"
(American Concrete Institute, 1990). There are two basic types of shotcrete—dry mix and wet mix. In dry mix
shotcrete, the dry cement, sand, and coarse aggregate, if used, are premixed with only sufficient water to reduce
dusting. This mixture is then forced through the delivery line to the nozzle by compressed air .
Dry mix shotcrete suffers high dust generation and rebound losses varying from about 15 percent to up to 50
percent. Wet mix shotcrete must contain enough water to permit pumping through the delivery line.
Materials.—Cement used for shotcrete should meet the same requirements as
cement used for replacement concrete. If sulfate exposure conditions exist,
type V Portland cement should be specified. Normally, however, type I-II, low
alkali cement is adequate. Water, sand, and coarse aggregate used in shotcrete
should also meet the requirements for replacement concrete, except that the
maximum size coarse aggregate should not exceed 3/8 of an inch.
Replacement Concrete.
Concrete repairs made by bonding new concrete to repair areas without use of an epoxy bonding agent or mortar
grout applied on the prepared surface should be made when the area exceeds 1 square foot and has a depth
greater than 6 inches and when the repair will be of appreciable continuous area.
Replacement concrete repairs should also be used for:
• Holes extending entirely through concrete sections
• Holes in which no reinforcement is encountered, or in which the depth extends 1 inch below or behind the
backside of the reinforcing steel and which are greater in area than 1 square foot and deeper than 4 inches,
except where epoxybonded concrete replacement is required or permitted as an alternative to concrete
replacement
• Holes in reinforced concrete greater than one-half square foot and extending beyond reinforcement
Epoxy-Bonded Epoxy Mortar. Epoxybonded epoxy mortar should be used where the depth of repair is less than
1-1/2 inches and the exposure conditions are such that relatively constant temperatures can be expected. Epoxy
mortars have thermal coefficients of expansion that may be significantly different from conventional concrete. If
such mortars are used under conditions of wide and frequent temperature fluctuations, they will cause failure just
below the bond surface in the base concrete. For this reason, current Reclamation practice precludes the use of
epoxy mortars under conditions of frequent or large temperature fluctuations. Epoxy mortar is properly used to
make thin repairs (1/2-inch to 1-1/2-inch thickness) to concrete under relatively constant temperature exposure
conditions.
Materials.—Epoxy resins used to prepare epoxy mortar for use in concrete repair should be two-component, 100-
percent solids type meeting the requirements of specification ASTM C-881 for type III, grade 2, class B or C.
Class B epoxy is used between 40(5 C) and 60 F (16 C).
Class C epoxy is used above 60 F up to the highest temperature defined by the epoxy manufacturer.
Curing.—Epoxy mortar repairs should be cured immediately after completion at not less than the temperature
range prescribed by the class of the epoxy until the mortar is hard.
Epoxy-Bonded Replacement Concrete

Epoxy-bonded concrete is used for repairs to concrete that are between 1.5 and 6 inches thick.
Shallow replacement concrete repairs, less than 6 inches thick, are subject to poor curing conditions
as a result of moisture loss to evaporation and to capillary absorption by the old base concrete. Such
repairs seldom develop acceptable bond strength to the old concrete.
The epoxy bonding resin is used to ensure a strong, durable bond between the old concrete and the
replacement concrete.
Materials.—The materials used in epoxy bonded concrete repairs consist of conventional Portland
cement concrete and epoxy resin bonding agent. The concrete used for epoxy-bonded repairs is the
same as that used for replacement concrete repairs except that the slump of the concrete when placed
should not exceed 1-1/2 inches.
Epoxy-injection
Epoxy resins cure to form solids with high strength and
relatively high moduli of elasticity. Cracks to be injected with
epoxy resins should be between 0.005 inch and 0.25 inch in
width.. The technique generally consists of establishing entry
and venting ports at close intervals along the cracks, sealing the
crack on exposed surfaces, and injecting the epoxy under
pressure. Epoxy injection has been successfully used in the
repair of cracks in buildings, bridges, dams, and other types of
concrete structures. However, unless the cause of the cracking
has been corrected, it will probably recur near the original
crack. The general procedure are given below.
https://youtu.be/eEXAWukRfD4
Polyurethane Resins
Polyurethane resins are used to seal and eliminate or reduce
water leakage from concrete cracks and joints. They can also
be injected into cracks that experience some small degree of
movement. Cracks to be injected with polyurethane resin
should not be less than 0.005 inch in width. Polyurethane
resin used for crack injection should be a two-part system
composed of 100-percent polyurethane resin as one part and
water as the second part. The polyurethane resin, when mixed
with water, should be capable of forming either a closed cell
flexible foam or a cured gel, dependent on the water to resin
mixing ratio.
Routing and Sealing

Routing and sealing of cracks can be used in condition requiring remedial repair and where structural
repair is not necessary. The method consists of enlarging the crack along its length on the exposed
surface, called chasing or routing, and sealing it with a suitable joint sealant. This is a common
technique for crack treatment and is relatively simple in comparison to the procedures and the training
required for epoxy injection. The procedure is most applicable to flat horizontal surfaces such as
floors and pavements.
The sealant may be of several materials, including epoxies, silicones, urethanes, polysulfide, asphaltic
materials polymer mortars. Cement grouts should be avoided due to the likelihood of cracking.
The procedure consists of preparing a groove at the surface ranging in depth, typically from 6 to 25
mm. A concrete saw, hand tools or pneumatic tools may be used. This groove is then cleaned by
plastic or sir blasting and allowed to dry. A sealant is placed into the dry groove and allowed to cure.
 Crack Repair by Stitching

The stitching procedure consists of drilling holes on both sides of the cracks, cleaning and anchoring
the legs of the stitching staples that span the crack, which either a non-shrink grout or an epoxy
resin-based bonding system. The stitching staples should be variable in length and orientation or
both, and located in the tension transmitted across the crack.
 Cracking repair by grouting

Based on grouting materials used , there are three
methods:
 Portland cement grouting.
 Chemical grouting.
 Epoxy grouting.
• Portland cement grouting.
cement mortar may be used for repairing or cement grouting,
repairs may be made either by use of shotcrete or by hand
application methods. Replacement mortar can be used to make
shallow, small size repairs to new or green concrete, provided
that
• Chemical Grouting
Chemicals used for grouting are sodium
silicates, urethanes and acrylamides. Two or
more chemicals are combined to form gel, a
solid precipitate or a foam as opposed to
cement grouts that consists of suspension of
solids particles in a fluid. The advantages of
chemical grouts include applicability in
moist environments and their ability to be
applied in very fine cracks.
 Epoxy grouting.
Traditional grout is made from a cement based mix. It’s not waterproof and actually absorbs water when it
becomes wet. It also absorbs stains easily. Epoxy grout on the other hand, is made of epoxy resins combined
with a filler powder. This makes it waterproof and almost completely resistant to stains. It’s durability
makes it the ideal choice for splash backs, floors and high-traffic areas.

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Infrastructure

Standard Methods of Concrete Repair

Dry Pack and Epoxy-Bonded Dry

Epoxy-Bonded Replacement Concrete

Routing and Sealing

 Crack Repair by Stitching

 Cracking repair by grouting

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