Chapter 7 Isolated Partial Depth Concrete Repair
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Transcript of Chapter 7 Isolated Partial Depth Concrete Repair
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From… Maintenance Technical
Advisory Guide (MTAG)
Chapter 7Isolated Partial Depth Concrete
Repair
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Partial-Depth Repairs
3-4.2
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Learning Objectives
1. List benefits of partial-depth repairs2. Describe the advantages and disadvantages
of different available repair materials3. Describe recommended construction
procedures4. List important quality control activities5. Describe potential unexpected adjustments
or construction quality problems6. Identify troubleshooting solutions
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Presentation Outline
Introduction Design considerations Construction Quality control Troubleshooting
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Removal and replacement of small, shallow areas of deteriorated PCC at spalled or distressed joints.
Definition
Introduction
Distress limited to upper 1/3 of slab Existing load transfer devices are functional
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Benefits
Restores structural integrity Improves ride quality Extends the service life Restores a well-defined uniform joint
sealant reservoir
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Good Candidate Projects
Spalling associated with joint inserts Spalling caused by intrusion of
incompressibles Spalling associated with localized areas
of scaling, weak concrete, clay balls, or high steel
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Poor Candidate Projects
Joint spalling associated with dowel bar misalignment or lockup
Spalled cracks Spalling associated with durability
problems or reactive aggregate
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Good candidate?
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Good candidate?
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Good candidate?
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Good candidate?
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Good candidate?
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Presentation Outline
Introduction Design considerations Construction Quality control Troubleshooting
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Design, Materials & Specifications
From… Maintenance Technical
Advisory Guide (MTAG)
Module 7-1
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Design Considerations
Selecting repair boundaries Material selection Curing Opening to traffic
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DULL SHARP
Unsound-Delaminated Solid
Sounding the pavement:• Hammer
• Steel rod
• Steel chain
Selecting Repair BoundariesDetecting Deteriorated Concrete
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Selecting Repair BoundariesSounding
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Selecting Repair Boundaries Repair Dimension Recommendations
Minimum dimensions• Length: 300 mm (12 in)
• Width: 100 mm (4 in)
• Depth: 50 mm (2 in)
Extend repair 75 to 100 mm (3 to 4 in) beyond visible deterioration
Combine close patches (<0.6 m [2 ft]) Repair entire joint if > 2 patches
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Cementitious• PCC-based
• Gypsum-based
• Magnesium phosphate
• High alumina
Polymeric• Epoxy
• Methyl methacrylate
• Polyester-styrene
• Polyurethane
Bituminous
Material SelectionRepair Material Types
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Enhances repair to pavement bond Sand-cement grouts used with PCC repair
materials Epoxy bonding agents used with both PCC
and proprietary materials
Material SelectionBonding Agents
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Material Selection Factors
Allowable lane closure time Ambient temperature Cost Size of repair Estimated performance
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Curing
Cure to avoid shrinkage cracks Hot-weather curing—curing compound,
moist burlap, or polyethylene Cold-weather curing—insulating blanket
or tarp Follow recommendations for proprietary
materials
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Opening to Traffic
Opening criteria
• Minimum strength (20.7 MPa [3,000 psi])
• Minimum time
Opening based on actual PCC strength is preferred
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Typical Item CodesItem Code Description
120090 Construction area signs
120100 Traffic control system
128650 Portable changeable message sign
150846 Remove concrete pavement
150306 Repair spalled concrete
156515 Repair spalled and unsound surface area
401108 Replace concrete pavement (rapid strength concrete
413101 Repair corner breaks
413111 Repair spalled joint
413114 Replace joint seal (existing concrete pavement)
413115 Seal joint (existing concrete pavement)
420201 Grind existing concrete pavement
511040 Concrete surface finish
511055 Concrete surface texture
515028 Repair spalled surface area
http://i80.dot.ca.gov/hq/esc/oe/awards/#item_code
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Construction and Inspection
From… Maintenance Technical
Advisory Guide (MTAG)
Module 7-2
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Presentation Outline
Introduction Material selection Construction Quality control Troubleshooting
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Construction Steps
1. Marking repair boundaries2. Concrete removal3. Repair area cleaning4. Joint preparation5. Bonding agent application6. Patch material placement7. Curing8. Joint sealing
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Marking Repair Boundaries
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Concrete Removal
Saw-and-patch (recommended) Chip-and-patch Mill-and-patch Hydrodemolition
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Concrete RemovalSaw-and-Patch Method
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Concrete RemovalChip-and-Patch Method
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Concrete RemovalMill-and-Patch Method
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Concrete RemovalMill-and-Patch Method
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Concrete RemovalHydrodemolition
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Repair Area CleaningSandblasting
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Repair Area CleaningAir Blowing
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Joint Preparation
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Plan View
Profile View
Bond breaker
Patch
Pavement
75 mm (3 in)
75 mm (3 in)
Scoring
25 mm (1 in)
Joint
Joint Preparation
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Bonding Agent Application
Patch area must be clean Application techniques Coat horizontal and vertical surfaces Apply uniformly
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Bonding Agent Application
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Patch Material PlacementGeneral Guidelines
Batch small quantities Temperature recommendations Some epoxy materials placed in lifts Overfill patch area by ~3 mm (1/8 in) Consolidate material Screed and hand trowel
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Patch Material PlacementGrout Mixer
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Patch Material PlacementAdding Admixture
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Patch Material PlacementMixing an Epoxy Patching Material
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Patch Material PlacementConsolidation
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Patch Material PlacementFinishing
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Curing
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Joint Sealing
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Finished Patch
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Construction Process
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Presentation Outline
Introduction Material selection Construction Quality control Troubleshooting
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Quality Control
Verify repair boundaries Monitor to assure no damage to
surrounding concrete Inspection of repair preparation material
placement, and finishing Proper curing techniques
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Quality ControlClass Exercise
Break into three groups• Preliminary responsibilities
• Equipment inspection, weather requirements, and traffic control
• Construction inspection considerations
Identify importance of each item Use Reference Manual and your
experience
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Project Checklist
Preliminary Responsibilities • Document Review
• Project Review Materials Checks
• Concrete patch material
• Other materials
• Joint Sealing
• General
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Project Checklist
Equipment Inspections • Concrete Removal Equipment
• Patch Area Cleaning Equipment
• Mixing and Testing Equipment
• Placing and Finishing Equipment
• Other Equipment Others
• Weather Requirements
• Traffic Control
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Project Checklist
Project Inspection Responsibilities
• Patch Removal and Cleaning
• Patch Preparation
• Placing, Finishing, and Curing
• Patch Material
• Resealing Joints and Cracks
Cleanup Responsibilities
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Presentation Outline
Introduction Material selection Construction Quality control Troubleshooting
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Troubleshooting
IdentifyProblem
DetermineCause
IdentifySolution
Unexpected adjustments and construction quality problems
Approach:
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Deterioration beyond original boundaries
TroubleshootingUnexpected Adjustments
Solution?
Problem
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Deterioration deeper than upper 1/3 of the slab thickness
TroubleshootingUnexpected Adjustments
Solution?
Problem
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TroubleshootingWhat is wrong here?
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Patch material flows into joint
TroubleshootingConstruction Quality Problems
Potential causes?
Problem
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Cracking or debonding of patch material
TroubleshootingConstruction Quality Problems
Potential causes?
Problem
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Troubleshooting Guide – Causes and Solutions
More deterioration than expected Exposed steel Patch material in crack or joint Patch cracking
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Presentation Outline
Introduction Material selection Construction Quality control Troubleshooting
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Learning Objectives
1. List benefits of partial-depth repairs2. Describe the advantages and disadvantages
of different available repair materials3. Describe recommended construction
procedures4. List important quality control activities5. Describe potential unexpected adjustments
or construction quality problems6. Identify troubleshooting solutions