Bridge repair techniques with ease of handling

repair techniques

1. c ons t r uctive so lu tio n s . V i j a y Ku l k a r ni P r o d uct S e g m e nt M a n a g e r - G r ou ts , R e p a i r s & P r o te c ti ve C oa t i n g s R e ha b i l i t a t i on a n d R e t r o f itt i ng o f T r an s p o r t a t i o n 1 S t r u c t u r e s

2. Con c r e t e D e t e ri o r a t i o n C o n c r e t e d e t e r i o r a t e o r f a i l t o p e r f o rm d u e t o F a u l t y d e s i gn m i x L ow s t r e n g t h , h o n e y c o m b i n g , c r a c k s , e ro s i on d u e t o a b r a s i on e t c . F a u l t y s t r u c t u re d e s i gn – S t r u c t u re f a i l u r e , c r a c k s , c o l l a ps e Poor c o n s t r u c t i on p r a c t ic e – H o n e y c o m b s , p i n h o l e s , e t c A b u s e of s t r uc t u r e s – M e c h a n ic a l d a m a g e s Ch e m ic a l – C a r bo n a t i o n , c h l or id e , S u l ph a t e a t t a c k , AAR , l e a d i n g t o s p a ll i n g W a t e r l ea k a g e s i n u n d e r g ro u n d s t r uc t u r e s 2

3. Co m pon e n t s o f B ri d g e s 3

4. Th e m o s t im po r t a n t f a c t o rs a c t i n g o n b ri dg e s d u r i n g t h e ir s e r v i c e 4

5. Co mm o n D e f e c t s in RC C B ri dg e s C o mm on D e f e c t s i n R C C B r i d g e s Be a r in g R epa i rs E x pansi on J o i n t R e pai rs 5

6. Co mm o n D e f e c t s in M as on ry B ri dg e s C o mm on D e f e c t s i n M a s o n ry B r i d g e s 6

7. T y p i c a l N D T T e s t s Condu c t e d o n c on c r e t e U l t r a s o n i c P u ls e V e l o c i t y – S o un d n e s s of conc r e t e Di r e ct m e t hod In d i r e ct m e t hod R e b o und H amm e r T e s t – H a r d n e s s of c o n c r e t e C o r e Cut – In Si t u Com p r e ssi ve St r e n g t h P h e no l p h t ha l e i n T e s t – Ca r b o na ti o n of Conc r e t e H a l f C e l l P o t e n t i al – C o r r o si o n L e v e l i n conc r e t e W e n n e r P r o b e M e t h o d – R e si s t i v it y of conc r e t e 7

8. K e y T e rms R e pai r - me ans t o me n d , t o put in t o g ood s h a p e or w o r k i ng or d e r a g ain, t o r e c on d ition, t o r e nova t e , to r e s t ore and t o corr e ct . R e p l a c eme n t - me ans t o s u b s titu t e , t o c ha n g e and t o e x cha n g e . S ome elem e nts of b r i d g e st ruct u res , mo s tly e quipm e n t el e me n ts , a r e u s ual l y re p l ac e d, e . g ., e xpa n sion joi n t s , b e ar i n g s , b arrie r s , e t c . R e h ab i li t a t i o n - me ans t o r e s t or e , to ma k e s u i t a b l e , t o p ut back in g ood c on d ition, t o r e - e s t a b li s h on a f irm, s o und b a s i s , t o b ring b ack t o f u l l u s e , to r e in s t a t e , t o r e n e w and t o r e viv e . R e t r o f i t/ S t r e n g t h e n ing - m e a n s t o incr e a s e loa d - c ar r yi n g c apa c ity b y a d d i ng more ma t e r i al , ad d iti o nal c omp o n e nts ( e . g ., c ar b on and g la s s f i b e r w r a p p i ng a nd lam i na t es ) . 8

9. R e p a ir m a t e ri a ls P r o p e r t i e s r e q u i r e d f o r r e p a i r m at e r i a l s . Sh r i n k a ge c o mp e ns a t i o n . G ood bo n d s t r e n g t h w i t h e x i s t i n g s u b s t r a t e . C o mp a t i b l e C o e f f i ci e n t of t h e r m a l e x p a n s i on w i t h p a r e n t s u b s t r a t e . C o mp a t i b l e or Hi g h e r M e c h a n ic a l P r o p e r t i e s t h a n h o s t s u b s t r a t e 9

10. R e p a ir m a t e ri a ls P r o p e r t i e s r e q u i r e d f o r r e p a i r m at e r i a l s . L ow P e r m e a b i l i t y & E f f e c t i v e C o v e r t o p r o t e c t s t e e l . H i g h A br a s i on R e s i s t a n c e . R e s i s t a n c e t o e d ge s p a l l i n g i .e h i gh t e n s i l e a n d bo n d s t r e n g t h s Q ui c k T u rn a r o u n d t i m e i . e R a p i d S t r e n g t h G a i n . 10

11. R e p a ir/ R e s t o r a t i o n M e t hod s C r a c k F i l l e rs & S e a l e rs F a i r C o a t & P l u gg i n g M o r ta rs R e p a i r M o r t a rs M i c r o c o nr e t e J a ck e t i ng I n j e c t i o n G r o ut i n g F R P S t r e n g t h e n i n g 11

12. T y p i c a l D e f e c t s O b s e r v e d F o l l o wi ng a r e t h e ty p i c a l d e fe c t s o c c u r r e d in eit h e r o l d o r n e w stru c t u r es : P l a s t e r C r ac k s S tructu r al C r ac k s W at e r L e a k ing C r a c k s C o n s truction Jo i nt s / N o n S tructu r al C r ac k s H on e ycom b s S p alling P i nhol es / B low H o l e s F o l l o wi ng a r e str u c tu r al s t re n gt h e n ing re q u i r em e n t s RC C B e am / Co l umn Jac k e ting F R P F i b e r W r a p pi n g S y s t e ms C F RP L a m ina t e s – S lab S tr e n g t h e n i ng 13

13. S ou t h W e s t e rn R a i l w ay s - B a ng a l o re 3 2

14. c ons t r uctive so lu tio n s 3 3 P on d i c h e r r y N H - B ri d g e– R e n d e r oc RG H ig h S tr e n g t h M i c r oconc r et e u s e d f or j a c k e ti ng o f d e c k sl a b s o f t h e b ri d ge s

15. F R P S t r u c t u r a l S t r e n g t h e n i n g S y s t e m s 16

16. W h y S t r e n g t h e n ? I n c r e a s e t h e l o a di n g :  Re q u ire add i t i o n a l le v e l s t o a b u i l d in g  r e q u i r e add i t i o n al a bi l i t y t o t ak e l ive l o a d ( t r af f i c )  Ch a n ge of b u i l d i n g u s e  Win d l o ad i n g L o s s of R e i n f or c e m e n t :  C u t h o l e s a n d o pen i n gs in s l a b  F i r e  C or r o s i on  M e c h a n i c a l D ama ge  L o s s of p r e - s t r es s f or c e  Rem ove c o lu mns / s u pp or t i n g w a l l s Ch a n ge t o d e s i gn c o d e  B u i ld i n g c h a n g e s u s e  Re q u ir emen t s of s a f e t y f a ct ors  Se i smi c c o d e s  B l a s t p ro t e c t ion C o n s t r u c t i on D e f e c t s  I n a d e q u a t e d esi gn  Poor q u a l i t y c o n s t r u ct i on 17

17. F i b e r R e i n f o r c e d P o l y m e rs Po l y m e r ( R e s i n ) 18 F i b e r R e i n f or c e m e n t

18. F i b e r R e i n f or c e m e n t Pr i m a ry f u n c t i o n : “To ca rry l o a d a l o n g t h e l e n g t h o f t h e f i br e , p ro v i d e s s t r e n g t h a n d or s t i f f n e s s i n o n e di r ec t i o n ” F i b e rs ca n be or i e n t e d t o p ro v i d e p ro p e r t i e s i n di r e c t i o n s of p r i m a ry l o a d s R e s i n s : To t r a n s f e r s t r e s s e s ac r o s s t h e f i br e s . 19

19. C o mm on F R P C o ns ti t u e n t M a t e r i a l s R e s i n s E p o x y V i ny l e s t e r Po l y e s t e r F i br e s C a rbon E- g l a s s A r a m i d 20

20. C a rbon F i b e rs V e r y h i gh s t r e n g t h a n d s t i f f n e s s L o w u l t i m a t e s t r a i n L o w C T E T h e r m a l l y s t a b l e u p t o 3 5 00 º F ( 1 9 27 º C ) L o w i mp ac t r e s i s t a n c e  E x c e l l e n t m o i s t u re a n d c h e m ica l r e s i s t a n c e S e n s i t i v e t o g a lv a n i c c orro s i on H i g h l y c o n d u c t i v e 21

21. G l a s s F i b e r s H i gh S t r e n g t h L o w S t i f f n e s s C TE s i m i l a r t o s t e e l a n d c o n c r e t e S o f t e n a t t e mp e r a t u r e s o v e r 1 5 ºF ( 8 1 6 º C ) L o w r e s i s t a n c e t o s u s t ai n e d a n d c y c l i c l o ad s S e n s i t i v e t o a l k a l i n i t y a n d m o i s t u re H i g h l y i ns u l a t i v e 22

22. A r a m i d F i b e rs H i gh S t r e n g t h U s a b l e t e mp é r a t u re r a n g e : ± 3 5 ºF ( 1 7 7 º C ) E x c e l l e n t i mp ac t r e s i s t a n c e S e n s i t i v e t o U V e x p o s u re R e s i s t a n t t o c h e m ica l a tt a c k F i b e rs s w e l l w i t h e x p o s u re t o m o i s t u re L o w C o n d u c t i v i t y 23

23. F i b e r O r i e n t a t i on U n i - d i r ec t i o n a l F i b e rs B i - d i r e c t i o n a l F i b e rs 24

24. F R P – C a rbon v s G l a s s F i b e r s * T h u m b R u l e 25 C o n d i t i o n C a rbon Gl a s s R e m a r k s A l k a l i ne a nd A c i d i c C o a s t a l En v i r o nm e n t / I n d u s t r i a l I m p a c t To l e r a n c e Bl a s t m i t i g a t i on / S ei s mi c R e t ro f i t t in g T h e r ma l E x p a n s io n C r ee p & F a t ig ue B r i d g e s E l ec t r i c a l C o n d u c t ivi ty S e rv e r - roo ms , P h a r m a , e t c

25. A n t i C a r bo n a t i o n C o a t i ng s . 26

26. N e e d f or An t i C a rb o n a t i on Pro t e c t i v e C o a t i n g N o r mal a i r con t a i n s . 4 % of C O 2 H ig h e r Conc e n t r a ti on i n u r ban and Indu st ri al a r e as 27 A l k a li n i t y of con c r e t e re duc e s t o l e s s t han pH 8 P a ss i v it y l a y e r on s t ee l l o s t w h e n a l k a l i n i t y l o s t C or r o s i on c o mm e nc e s ! ! C O 2 + H 2 O —— > H 2 C O 3 H 2 C O 3 + C a O — —> C a C O 3 + H 2 O

27. F a c t ors af f e c t i n g C a r b o n a t i on Pe r m e ab ili t y D e p t h o f c o v e r T i me Ra t e of Ca r bona t i on d e p e nds on f o ll o w i ng f ac t o r s : R e l a t i v e H u m i d i t y G r ade o f C on c r e t e 28

28. F a c t ors af f e c t i n g C a r b o n a t i on 29

29. D e te c t i n g C a rbo n a t i on C o ncr et e s a mp l ing is done thou g h core c utting machin e s and tre a t e d wit h ph e no l ph t a l ei n s olution P u r p le C o lor in d ica t e s – N o t a f f e c t e d N o C olour C h an g e - C ar b o n at e d 30

30. C o m b i n e d C a r b o n a t i on & Ch l or i n a t i o n af f e c t e d c o n c r e t e C o m b i n ed C ar b o n a t i o n a n d C h l o r i d e A tt a c k 31

31. C r a c k B r id g i n g It c a n b e d e f i n e d as a b ility of a co a t i ng t o a c c o mmoda t e e x p a nsions and c o n t r a c t ions i n s t r u ctur e s and s e a l / brid g e ov e r t h e c r ac k s arising in c oncr et e e l e m e nts d u e t o m a ny f a c t o r s s u c h as th e rmal s t r ess e s , d ynamic, f ati g u e l oa d s , et c a n d t h e r e by pr e v e nting in g r e s s of CO 2 , har mf ul e l e me n ts . c h l o rid es , s u l p h a t e s , w at e r and o t h e r C ra c k B r i dg i n g T e s t o n D e k g uar d E 2 00 32 S p e c i f i c a ti on R e qu i r e m e n t : C r a ck B r id g in g g r e a t e r th a n 2 m m s t a ti c c r a cks a n d 1 m m c y c l i c m o m e n t s . S t a nd a r d Co d e – A S T M C 8 3 6 - M o di f i e d

32. T e n s i l e S t r e n g t h & E l o n g a t i on Elon g a ti o n is p r op e r ty w hich i mpa r ts e l a s ti c i ty t o c o a t ing w hi c h is al s o re l a te d t o cr a c k b r i d g ing a b i l i t y . H i g h e r the e lo n g a tion, b ett e r i s the c r ack accommo d at i on capacit y . Elon g ati o n a l s o d e p e n d s on t he t hic k n es s o f c o atin g . S p e c i f i c a ti on R e qu i r e m e n t : T e n s i l e S t r e n g t h = 3 M P a E l o n ga ti o n g r e a t e r t h a n 2 % 33 S t a nd a r d Co d e – A S T M D 4 1 2 T e s t S p e c i me n B e f ore & A f t e r T e sting

33. T ea r S t r e n g t h T ear s t r e n g t h is t h e mea s u r e o f h o w m uc h t e n s ile s t e s s c an t h e m a t erial w i t h s t a n d in a s p e c i f ic c a s e, i . e. w h en a t ear h as b een i nt r o du c ed in t h e m a t er i al, S p e c i f i c a ti on R e qu i r e me n t : T e a r S t r e n g t h e qu a l t o 1 2 N / m m S t a nd a r d Co d e – A S T M D 6 2 4 34

34. U V R e s i s t a n c e U V R e s i s t a n c e is a b i lit y o f a c o a t i n g t o r e ma i n s t a b le w h e n e x p o s ed t o s u n l i g h t w it h o u t b e c omi n g b r i t t le a n d l o s i n g p h ys i c a l a n d c h e mi c al p r o p e r t ies or f a di n g o f a n y p i gm e n t s a n d di sc o l o r a t io n . I t is o n e of t h e c rit i c al p r o p er t y of an e x t er n al a pp lied c o a t i n g s y s t em. S p e c if i c a t i on R e q u i r e me n t : G r e a t e r t h a n 50 H o u r s N o s i g n of y e ll o w i n g ,ch a l k i n g & d i s c o l o r a t i on. Sam p li n g of c o a t i n g 35 QU V – 8 h r s U V , 4 h r c o nd e n s a t ion Z e r o c olo u r a t ion in s p e c t r om et er S t a nd a r d Co d e – A S T M D 4 58 7 ,Co ndi ti on E C y c l e 1 f r om A S T M G 1 5 4

35. S o l a r R ef l e c t i v e I n de x S o l ar r e f le c ti v it y or r e f le c t a n c e is t h e a bi l it y of a m a t e rial t o r e f le c t s o l ar e n e r g y f r om it s s u r f a c e b a c k i nt o t h e a t mos p h e r e S p e c if i c a t i on R e q u i r e me n t : S o l a r Re fl e x t i v e I n d e x > 1 5 ( a t H i g h Wind condition – 30 w / m 2 /K ) E m i ss i vi t y > 9 3% D i r e ct S o l a r R ef l e c t a n ce ( S R ) > .83 S t a nd a r d Co d e – A S T M E 1 9 8 L E E D R e qui r eme n t : SR I > 7 8 E n e r g y S t a r R e qui r e mr n t : S R > . 6 5 36

36. Ch l or id e Ion P e n e t r a t i on A nt i - C ar b on a t i o n c o a t i n g s m u s t h a v e h i g h c h l o ri d e i o n r e s i s t a n c e t h a t is l o w c h l o r i d e i o n p e n e t r a t i o n t o p r e v e n t i n g r e s s o f ch l o r i d es w h i c h l ead t o c o r r o s i o n o f s t eel a n d r el a t ed p r ob l em s . C h l o ri d e i o n p e n e t r a t i o n is t e s t ed b y R a p id C h l o ri d e P e n e t r a t i o n t e s t . S p e c i f i c a ti on R e qu i r e me n t : C h l o r i d e I on P e n e t r a ti o n – V e r y L ow (1 t o 10 C ) S t a nd a r d Co d e – A S T M C 1 2 02 - 3 37

37. B r e at h a b i l i t y I t is th e p r o p e r t y o f th e c o a tin g t o a ll o w wa t er t o m o v e i n a n d o u t o f c o n c r e t e w it h f l u c tu a t ion o f h u mi dit y a n d t em p e r a tu r e. I f m oi s tu r e mo v e me n t i s r e s t r ai n e d in c o n c r e t e , it lead t o in c r ea s e in o s m o t ic p r e ss u r e a n d e v e n t u a lly lea di n g t o d e b on d i n g of co a t i n g . B r e a th a b le c o a tin g s a l s o e nh a n c e s d r y in g of i nt e r n al c o n c r e t e t h e r e b y a r r e s t i n g c or r o s i o n a n d in c r ea s in g d u r a b i lit y of s t r u c tu r e s . S p e c if i c a t i on R e qu i r e m e n t : W a t e r V a po u r T r a ns m i s s i on : > 1 g / s q m /d a y 38 S t a n d a r d Co d e – U NE - E N I SO 7 7 8 3 : 2 12

38. W a t e r Ba s e d C o a t i n g An A nt ic a r b o nat i o n c o at i n g s h o u ld b e p r e fe r a b l y w at e r ba s e d fo r f o ll o wi n g b e n ef i t s : It e l i m i n a te s u s a g e of h a z a r do u s s o l v en ts d u r i n g a p p l ic at i o n a n d cl ea n u p p r o c e ss w h i ch b r i n g s do w n e m i s s i o n of V o l at i l e O r g a n i c C o m po u n d s (V O C ) . T h e se p a i n ts h a v e l e s s o d ou r . W a t e r B a s e d c o a t i n g s p r e v e n t d r y i n g, c r a c ki n g a n d fa d i n g w he n e x p o s e d t o s un l i g ht. T h e y a l so p r e v e n t t h e g r o w th of m i l d e w . W a t e r B a s e d c o a t i n g s po ss e ss b ett e r e l a st i c i t y a n d a r e not b r i t t l e . T h e s e c oat i n g s t a ke l e s s e r t i m e to d r y c om p a r e d to s o l v e nt e d c oat i n g s 39