REHABILITATION OF BRIDGES AND
CASE STUDIES
Webinar for KHRI
Er. VIVEK NAIK
Past President – Indian Concrete Institute
MD – Apple Chemie India Pvt. Ltd.
Innovations
Successfully commercializing a product, process or service as per
demand of the market or targeted consumers.
Jugaad is not wrong- It is innovative!
Frugal innovation, or as we call it Jugaad is not
something lower in quality. It is a cheaper
solution to a standard problem without
compromising on performance and utility. It is
the answer to a problem where standard
solutions are not affordable, feasible or
applicable.
Unknowingly, we use these in everyday life. But
Jugaad is used everyday in construction and
repair industry. It is the uncommon way to solve
common problems!
3R
REPAIR
• Making up old/new building component to give balance serviceable
life. It will not increase the load carrying capacity of the building after
Repair.
REHABILITATION
• Structural Repair to building component – this comes under failure of
performance of the part of building, leading to unsafe or impossible
use of building for the performance for which it is designed.
It includes strength of the structure
RETROFITTING
• Repair, Rehabilitation and further modification of structure to make it
suitable for modern look, change of aesthetics, functions, strength
criteria & other technical requirements etc.
Life Sciences of Concrete Repairs
At the Dentist
•Repairing a tooth is often
similar to repairing damaged
concrete
Key Stages at the Dentist
Examine
teeth
Further
Future investigation
maintenance
e.g. search
e.g. regular for voids,
cleaning
X-Ray?
Select the
repair Options
e.g. gold e.g. extract,
amalgam, fill?
composite?
*
5 Key Stages in Concrete Repair
Future •Assessment of
maintenance the structure
Select repair
Diagnose cause
process
of deterioration
Step
3
Options and
objectives of repair
*
5 Key Stages in Concrete Repair
Future •Assessment of
maintenance the structure
Select repair
Diagnose cause
process
of deterioration
Step
3
Options and
objectives of repair
*
The Condition Survey
Identify the cause
Determine the effect
What is the
consequence?
*
Content of Condition Survey
• Review past, current & future
1 use
• Visual aspects
2
• Non-destructive tests
• Probing or destructive testing
• Laboratory analysis
* Synopsis By Er. Vivek Naik
Methods of Diagnosis - NDT
* Synopsis By Er. Vivek Naik
5 Key Stages in Concrete Repair
Future •Assessment of
maintenance the structure
Select repair
Diagnose cause
process
of deterioration
Step
3
Options and
objectives of repair
*
Exposures on Reinforced Concrete
Cl-
Freeze /
Thaw
CO2
H2O NOx
SOx
*
The Carbonation of Concrete
Ca (OH )2 + Co2 + H20 CaCO3 + 2H20
Calcium + Carbon + Water Calcium + 2 x Water
Hydroxide dioxide carbonate
1st Phase : Diffusion inwards of Relative air rate of
carbon dioxide Humidity : carbonation :
2nd Phase: Reaction between carbon
Less than 30% low
dioxide and water molecules
40 to 75% high
3rd Phase : Reaction between resultant
carbonic acids & the alkaline
m. Than 75% low
components of concrete.
CaCo3 is white/brittle and slightly soluble in water 16
FACTORS INFLUENCING THE DEPTH OF CARBONATION
• GRADE OF CONCRETE
• WHETHER CONCRETE IS PROTECTED OR
NOT
• PERMEABILITY OF CONCRETE
• TIME
• DEPTH OF COVER
• THE ENVIRONMENTAL INFLUENCES
FACTORS INFLUENCING THE DEPTH OF CARBONATION
Concrete Defects and Damage
Mechanical damage
Mechanical Impact
Overloading
Movements (Settlement)
Explosion
Vibration
Chemical damage
Alkali Silica Reaction
Sulphates, Salts
Acids, Soft water
Biological (Acids)
Physical damage
Freeze-Thaw Action
Thermal Movements
Erosion/Abrasion
Shrinkage
*
Reinforcement Corrosion
Chemical attack
Carbonation
Acids
Corrosive contaminants
Chlorides
Stray electrical current
*
5 Key Stages in Concrete Repair
Future •Assessment of
maintenance the structure
Select repair
Diagnose cause
process
of deterioration
Step
3
Options and
objectives of repair
*
Options for the Owners
Do nothing
Downgrade structure
Reduce further damage
Repair and restore
Part reconstruction
Demolition
*
13
Considerations for Owners
Costs
Design life
Performance requirements
Temporary works
Construction
Future maintenance
*
Objectives for Concrete Repair
1. Replace defective concrete
2. Restore structural integrity
3. Restore durability
4. Restore aesthetic
appearance
5. Restore geometric
appearance
*
5 Key Stages in Concrete Repair
Future •Assessment of
maintenance the structure
Select repair
Diagnose cause
process
of deterioration
Step
3
Options and
objectives of repair
*
Selection of Method of Repair
Non structural
repairs
Structural
repairs
*
Selection of Method of Repair
STEPS IN BOTH THE CASES OVERLAP TO SOME EXTENT
STEPS FOR STRUCTURAL REPAIRS :
• Injecting the structural crack with suitable material
• Strengthening the structure (Guniting/Polymer mortars)
• Cosmetic repairs , if required
• Surface coatings
STEPS FOR NON STRUCTURAL REPAIRS:
• Sealing of the cracks for stopping water leakages etc.
• Cosmetic repairs
IN CASE OF CHLORIDE CONTAMINATED CONCRETE, STEPS ARE:
•Providing a completely passive.barrier around reinforcement by removal
of all concrete around bars (theoretical and not very practical)
Resorting to Cathodic Protection
*
Method of Repair
Selection of Method of Repair and Material
Specifications of Repair products
*
Selection of Method of Repair
Polymer Repairs
Epoxy Repairs
FRP
Carbon Wrap/ Aramid Wrap
Post Tensioning
Plate Bonding
Composite Repairs
*
Specifications of Repair products / Materials
Cement / Cement Grouting + Polymer
Micro fine Cement + Micro Silica
Site Repair Composites
Ready to use Repair Composites
Epoxies
Low Viscosity Grouts
*
Structural Repairs – Core Strengthening
*
Structural Repairs – Core Strengthening
*
Structural Repairs – Core Strengthening
*
Substrate Preparation
Remove Defective Concrete
Water Jetting
Chiselling
*
Substrate Preparation
Defected area Proposed repair
area
Proposed repair
Defected area area
Mark perimeter of repair area.Layout should be simple geometric
shapes.
*
Substrate Preparation
<45 degree
90 degree
45 degree
Clearly Defined Edges at Angle > 45 Degree
*
Substrate Preparation
Remove concrete behind bars
Avoid under and over cutting sides
Roughen surface (2mm min)
*
Substrate Preparation
Clean bars
Use abrasive blast cleaning technique or
High pressure water jet (1100 bar)
“Correct preparation is key to a
successful concrete repair”
*
Application Method
Hand Application
*
Application Method
Shot Crete/Shot Gunite
*
Application Method
Application of mortar with pressure equipment and nozzle.
*
Application Method
Form & Pour:
*
Application Method
Form & Pour:
Pouring grout through openings
*
Application Method
Form & Pour (Machine)
*
Concrete Protection
Refurbishment is
incomplete without the
protection of concrete.
*
Levels of Concrete Protection
System 1: System 2: System 3:
Durable concrete protection Durable concrete and High performance protection
reinforcement protection for extreme conditions
1 2 3
2
1 1
1Deep penetrating 1 Migratory corrosion inhibitor 1 Migratory corrosion inhibitor
hydrophobic impregnation 2 Deep penetrating 2 Deep penetrating
hydrophobic impregnation hydrophobic impregnation
3 Protective coating
For exposed concrete structures For severely exposed or weak For severely exposed or weak
showing no visible concrete defects concrete with a high risk of concrete with a high risk of cracking
(crack width < 0.3 mm) steelcorrosion
*
Complete Process
Removal of damaged concrete Rust removal of Corrosion protection Bonding bridge
rebars layer
Rendering mortar Concrete Concrete
Application of repair mortar
protection protection
(1st layer) (2st layer)
*
5 Key Stages in Concrete Repair
Future •Assessment of
maintenance the structure
Select repair
Diagnose cause
process
of deterioration
Step
3
Options and
objectives of repair
*
Protection Coatings
*
Future Maintenance
Detailed records
Monitoring
Inspection instructions
Responsibilities
Local requirements
*
Case Study – I
Kaigaon – Toka Bridge on Nagpur
Mumbai Highway
Strengthening of Old Bridges
•Innovations
•Polymer Repair System
•Injection & strengthening system
•Carbonation protection system
REMEDIAL MEASURES
Replacement of existing
Neoprene bearings
•Repairs to articulations
joints
•Expansion joint
replacement
•Repairs to weak concrete
•Epoxy injection in cracks
Repair &
Rehabilitation
Kaigaon Toka Bridge on Godavari River
Flash
Case Study – II
Newaj Bridge on Indore Dewas
Highway
•Bridge Details
Spans -8 numbers
Length of each span -24.6 m
construction – 1975 (?)
Total length of Bridge – 210 m
Modification – 1980 (??)
WhatsApp Video 2019-11-25 at 3.08.33 PM.mp4
Bhima River Bridge
Bhima River Bridge
Bhima River Bridge
Bhima River Bridge
Bhima River Bridge
Bhima River Bridge
Bhima River Bridge
Bhima River Bridge
Bhima River Bridge
Case Study – III
Wanchoo Point Bridge, Indore
Indore Wanchoo Point
Indore Wanchoo Point
Indore Wanchoo Point
Indore Wanchoo Point
Indore Wanchoo Point
Thank you
