BASF Concrete Repairs
description
Transcript of 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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Sl no Repair technique Distress addressed Materials used
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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Sl no Repair technique Distress addressed Materials used
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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Sl no Repair technique Distress addressed Materials used
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
Structural crack injection methods
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Adhesive
Structural crack injection methods
Low pressure syringe
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Structural crack injection methods
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Adhesive
Structural crack injection methods
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.
Structural crack injection methods
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Adhesive
Surface seal to
contain adhesive
Structural crack injection methods
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
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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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Patch repairs to vertical members
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Patch repairs to vertical members
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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Form & pour repairs - Microconcrete
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Form & pour repairs - Microconcrete
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!