1. REPAIR MANUAL Dr. Mohammed Maslehuddin Research Institute
King Fahd University of Petroleum and Minerals

2. Purpose of the Manual
Assist engineers in diagnosing concrete deterioration problems and planning repair and rehabilitation of deteriorating structures.

3. Contents of Repair Manual
Chapter 1: Guide to mechanisms of concrete deterioration
Chapter 2: Assessment of the extent of concrete deterioration
Chapter 3: Strategy for repair of deteriorated concrete structures
Chapter 4: Repair materials and their evaluation

4. Contents (contd.) Chapter 5: Repair procedures
Chapter 6: Repair systems
Chapter 7: Long-term monitoring strategies

5. Chapter 1 A guide to forms of concrete deterioration
Reinforcement corrosion
Carbonation
Sulfate attack
Salt weathering
Alkali-aggregate reactivity
Cracking of concrete
Acid attack
Damage due to fire
Attack due to micro-organisms

6. Chapter 2 Assessment of Concrete Deterioration
Preparation (preparatory desk work)
Preliminary investigation (visual inspection and appraisal)
Detailed investigation (data collection, field measurements, condition survey, sample collection, testing of samples, analysis and evaluation)
Conclusion and recommendations

7. Chapter 2 (contd.) Preparation prior to inspection
Design information
Plans/drawings, as-built drawings, specifications and other related information
Location of the structure and topology and accessibility
Structural drawings for reinforcement details
Service history

8. Chapter 2 (contd.) Preliminary investigation
Structural condition, extent of cracking, damage
Safety of the structure
Need for commissioning a detailed inspection
Accessories needed for detailed inspection
Traffic control requirements
Any unusual problems facing the structure

9. Chapter 2 (contd.) Detailed investigation
Data collection
Field measurements and condition survey
Sample collection
Testing and field samples
Analysis and evaluation
Report
Conclusions
Recommendations

10. Chapter 2 (contd.) Commonly used test methods
Methods for estimating in-situ concrete strength
Methods for determining properties other than strength
Methods for the physical evaluation of structures

11. Chapter 3 Strategy for repair of deteriorated concrete structures
Cause and extent of damage
Consequence of the damage
Time for intervention
Economics
Operational constraints

12. Chapter 3 Repair options
No repair
Repair
Cosmetic
Partial
Total
Partial repair or total replacement

13. Factors influencing the selection of repair strategy (No repair)
Minimal damage
No chance of re-occurrence of damage due to overload etc.
Expected service life is more than the design life
Appearance is not a problem

14. Factors influencing the selection of repair strategy (Repair)
Cosmetic repair
Limited deterioration
Rate of deterioration is too low as in the no repair option
Improve the appearance

15. Factors influencing the selection of repair strategy (Repair)
Partial repair (patch repair)
Rectify apparent defects
Structural safety is not affected

16. Factors influencing the selection of repair strategy (Repair)
Total repair
Advanced deterioration
Structurally unsafe
Operational constraints for total replacement

17. Factors influencing the selection of repair strategy for corrosion (No repair)
Active corrosion but corrosion rate is low
Low chloride concentration
Structural integrity is not compromised

18. Factors influencing the selection of repair strategy for corrosion (Repair)
Cosmetic repair
Active corrosion but corrosion rate is low
Chloride concentration is high
No spalling, localized delamination
Structural integrity is not affected

19. Partial repair (patch repair)
Factors influencing the selection of repair strategy for corrosion (Repair)
Partial repair (patch repair)
Active corrosion
Localized delamination or spalling
Structural safety is not affected

20. Factors influencing the selection of repair strategy for corrosion (Repair)
Total repair
Active corrosion
Uniform spalling or delamination
Excessive loss of cross section of bars at many locations

21. Factors influencing the selection of repair strategy for corrosion (Partial or total replacement)
Repair is economically not feasible
No operational constraints
Structure is structurally unsound

22. Chapter 4 Repair Materials and their Evaluation
Repair mortars
Cementitious repair mortars
Polymer modified cementitious mortars
Resin-based repair mortars
Sprayed concrete
Injection grout
Flowing micro concrete
Bond coat materials
Steel primers
Surface coatings

23. Chapter 4 Repair Materials and their Evaluation
Test methods
Compliance criteria

24. Chapter 5 Repair Procedures
Repair of cracked and deteriorated concrete
Shrinkage cracks
Settlement cracks
Thermal cracks
Dormant or dead cracks
Live cracks

25. Chapter 5 Repair Procedures (contd.)
Vacuum impregnation
Resin injection
Repair of surface defects
Repair of inadequate cover
Repair of deteriorated and cracked concrete due to sulfate attack and salt scaling
Repair of cracks caused by alkali-silica reaction
Repair of deterioration due to exposure to chemicals
Repair of deterioration and cracking due to exposure to high temperature and fire
Repair of spalled concrete

26. Chapter 6 Repair systems
Marine environments
System 7 or 1
Below ground structures
System 1 or 6
Sulfur fumes
System 6, 5 or 8
Acid exposure
System 6, 5 or
Sweet or saline water
System 9 or 10
Fire damage
System 7 or 8

27. Chapter 7 Long-term Monitoring Strategies
Visual inspection
Debonding
Monitoring chloride and moisture content
Measurement of carbonation depth
Assessing reinforcement corrosion
Resistivity
Corrosion potentials
Corrosion rate