basf concrete repairs

Concrete Repairs

Structural Approach

Vijay B Kulkarni, Regional Marketing Manager

BASF India Ltd

Construction Chemicals Division.

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Index

� BASF brief Introduction

� Why concrete deteriorates

� BASF CC Philosophy of concrete repairs

� Types of repairs and methods

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BASF - At a glance

BASF – The Chemical Company

Sales 2006: €52.6 Billion

Employees as of December 31, 2006: 95,247

� The world’s leading

chemical company

� Our portfolio ranges

from chemicals, plastics,

performance products,

agricultural products and

fine chemicals to crude oil

and natural gas

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Eras in BASF’s history

1901 – 1925The age of fertilizers

1925 – 1945New high-pressure syntheses

1945 – 1953Reconstruction and new beginning

1953 – 1965The beginning of the plastics age

Since 2005The Chemical Company

1865 – 1901Founding of BASF– the age of dyes

1965 – 2005From Ludwigshafen to the world

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Organisation of BASF

14 operating divisions

6 regional units support business

and create an infrastructure

8 corporate divisions and

departments,

and 11 competence centers

perform

on a Group-wide basis

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Stepwise to the global No. 1

1967/1968 1980 1990 1996 2001

national/

international

international

global

globalInvention and

the start of

MELMENT

production.

Construction

Chemicals is

born.

Acquisition of:

1974 / 1978

1978

1994

1994

19881996

Merger Degussa

-Hüls and SKW

Trostberg

1999 UCRETE

THORO

2006

Acquisition

by BASF

global

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� Established as Master Builders in 1906 - 100 years pedigree

� Inventors metallic aggregate dry shake hardener, 1909

� Inventors of precision non-shrink grout, 1934

� Developed the world’s first epoxy grout, 1954

� First Superplasticiser based on Melamine 1966

� Invented DELVO, the hydration control admixture, 1989

� Patented the most versatile APS resin system for repairs that sets at -25oC to +45oC,

1993

� Invented PCE based Hyper Plasticizers Glenium in Japan, 1986

� First Self compacting Concrete (SCC) in Japan, 1989

� First Concrete Produced in Space with NASA, 1994

� Zero Energy Concrete System, 2001

� GLENIUM SKY – Total consistency control for ready mix concrete, 2004

� RheoFIT – Fit for value for manufactured concrete product makers, 2006

Innovations - Highlights

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Inspection and Diagnosis

Repair Methodology And Techniques

Repair Materials

Application

Protection

Systematic Approach to Repairs

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Repair techniques & Materials

Commonly used techniques for repair and rehabilitation

Sl no Repair technique Distress addressed Materials used

1 Injection grouting Seal cracks and pores in

concrete.Arrest leakages

Epoxies / Polyurethane

cements also used

2 Gunniting / Shotcreting Replace cover

concrete.Reinstate locally

damaged areas.Build up

thickness in overhead

situations

Gunites / Shotcretes and

Admixtures

3 Jacketing Reinstatement of extensively

damaged concrete

members,strengthening for

load enhancement

Concrete with water

reducing / shrinkage

compensating admixtures

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4 Stitching Repair of cracked concrete Holes grouted with Epoxy

/ polyester cement with

non shrink additives

5 External prestressing For cracked concrete

members.

HST bars + Anchors

6 Micro concrete encasement Extensively damaged

concrete beams and columns.

Enhance load carrying

capacity. Increase flexural

rigidity

shrinkage compensating

free flow micro concretes

7 Epoxy steel plate bonding Strengthening weakened

members.reduce deflection

Anchor grout / epoxy for

bonding

Continued

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8 Under water repairs Cracks under water,

strengthening of structures,

reinstatement of worn out

areas , localized damages etc

Under water admixtures,

anti washout micro

concretes, moisture

insensitive epoxy resins

and putties

9 Patch repairs Localized reinstatement of

worn-out concrete

Polymer modified / latex

modified mortars,epoxy

mortars

10 Composite fiber wrapping Strengthening of distressed /

weakened concrete members,

seismic retrofitting

E-glass / carbon / aramid

fibers with epoxy primer

and saturant

Continued

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11 E-chem repairs Long term corrosion protection,

prevention of formation of

incipient anodes

Corrosion Inhibitors,

Protectosil CIT

12 General grouting To densify porous concrete

slabs, retaining walls etc

Non shrink, plasticising

additives

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REPAIR

LOAD ENVELOPE

PHYSICAL

LOAD

MECHANICAL

LOAD

CHEMICAL /

ENVIRONL

Repair philosophy

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Rheologicalcharacteristics

Chemical compatibility

Electrochemicalcompatibility

Dimensional compatibility

Monolithic

Durability

Repair Philosophy

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Determine project

objectives

Determine material properties

needed to meet project

objectives

Identify materials or systems which

will produce the required properties

Select the material or system that

provides optimum balance of

performance, risk, and cost factors

Owner

requirements

Causes of

deterioration

Service

conditions

Application

conditions

Product selection process

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� Treatment to Cracks

� Surface Preparation & Priming

� Concrete Volume Replacements

� Protection

Repair system components

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CRACKS

Superficial Structural Leaking

EPOXY/PUPolymer Cement Acrylate/PU

Treatment to cracks

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Dead Cracks : Epoxy

Live Cracks : Flexible PU

Structural crack treatment

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Structural crack injection methods

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Gravity Feed


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Adhesive


Low pressure syringe

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Adhesive


Drilled hole packer injection

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STEP 1: THE PACKER IS ATTACHED

TO THE INJECTION LANCE AND

PUSHED INTO THE HOLE

STEP 3:WHEN THE INJECTION OF

THE HOLE IS FINISHED, THE VALVE

CLOSES ITSELF. THE INJECTION

LANCE IS DISCONNECTED BY

SCREWING BACK THE TIGHTENING

LEVER, WHILE THE RUBBER SLEEVE

ON THE PACKER REMAINS

EXPANDED.

STEP 2: THE PACKER IS EXPANDED

IN THE DRILLHOLE USING THE

TIGHTENING LEVER. THE INJECTION

CAN START.


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Adhesive

Surface seal to

contain adhesive


Surface mounted port injection

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� Remove all identified defective concrete.

� Saw cut perimeters - 15mm depth.

� Expose steel until no corrosion is evident.

� Expose the full circumference of the steel and beyond by 25mm.

Surface Preparation

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Surface Preparation

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Surface Preparation

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Surface Preparation

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Surface Preparation

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� Mechanically abrade the steel to SA 2½.

� Dry grit blasting.

� Wet grit blasting.

� Hydro-jetting.

� Wash down to remove contaminants.

Surface Preparation - rebars

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Surface Preparation

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� Prime immediately after cleaning.

� Apply a continuous coat of active zinc rich epoxy primer.

� Attention must be paid to the underside of the bars

Priming of rebars

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Surface Preparation

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� Water saturation.

� Polymer bonding emulsions.

� Epoxy bonding agent - chloride contaminated areas.

Priming to concrete substrate

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1. COSMETIC COVER REPAIRS

2. PATCH REPAIRS OF FLOORS/PAVEMENTS

3. PATCH REPAIRS VERTICAL/OVERHEAD

4. FORM & POUR (MICROCONCRETE)

5. LARGE AREA SPREY REPAIRS

6. UNDERWATER REPAIRS

Volume repairs types

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� REPAIRS OF COVER CONCRETE

� USING POLYMER MODIFIED MORTARS

� MORTAR IS MADE AT SITE

� ACRYLICS FOR EXPOSED AREA

� SBR FOR SUBMERGED AREA

� DESIGN MIX IS ADVISEABLE FOR RIGHT CHOICE

� FINE AGGREGATES NEEDS TO BE FREE OF IMPURITES

Cosmetic repairs

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Patch repairs to pavements

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Patch repairs to pavements – EMACO R650

Compressive strength 2 hours 15 MPa

24 hours 25 MPa

28 days 50 MPa

Tensile Strength 28 days 3.2 MPa

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Patch repairs to vertical members

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EMACO S88C T

•Thickness of 50mm and above

•low permeability

•No bonding agent

•Shrinkage compensating

•Strength > 70Mpa at 28D

> 25Mpa at 1 D

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Form & pour repairs - Microconcrete

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Emaco S66T

� Thickness of 40mm and above

� Self compacting

� Shrinkage compensating

� Strength > 65Mpa at 28D

> 25Mpa at 1d

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Spray applied repairs for large surface area

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Spray applied repairs for large surface area

SHOTPATCH 10

�CAN BE APPLIED 150MM

�LESS REBOUND

�RAPID STRENGTH GAIN

�24HR STRENGTH 15MPA

�28D STRENGTH 40MPA

�CEMENT BASED

�SINGLE COMPONENT

�MODIFIED WITH MICROSILICA

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Under water repairs

MASTERFLOW 88UW

� No significant cement washout

� can flow in gaps up to 20mm thin

� Comp. Strength 1 day – 14 MPa

� Comp. Strength 28 D – 60 MPa

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Low Permeability

Freeze - Thaw

Durability

Shrinkage Control

Modulus

Bond

Compressive Str.

Flexural Str.

Mechanical Physical

Consider All Relevant Loads

STRUCTURE

Chemical

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Thank You!

basf concrete repairs

Documents

cover concrete

damaged concrete members

energy concrete system

ready mix concrete

self compacting concrete

repair technique distress

diagnosis repair methodology

fine chemicals