www bzfxw com BRITISH STANDARD BS EN 1504 10 2003 Incorporating Corrigendum No 1 Products and systems for the protection and repair of concrete structures — Definitions — Requirements — Quality contro[.]
General
The concrete substrate and reinforcement must be adequately prepared to meet the specific conditions and structural integrity required for proper application of products and systems This preparation should ensure that any protection or repair aligns with the relevant standards Detailed requirements for preparation are outlined in the subsequent sub-clauses and are associated with the repair and protection methods listed in Table 2.
04-10:2003 (E) Table 2 - Preparation of substrate M e th od nu m b ers
Pre pa ra tio n p ro ce ss
Su b-c la us e n um be rs
(b ac kg ro un d in fo rm ati on in A nn ex
Re fe re nc es
Me th od s i nv olv in g hy dro ph ob ic im pre gn ati on a nd im pre gn ati on
Me th od s i nv olv in g su rfa ce c oa tin g
Me th od s i nv olv in g
Fil lin g c ra ck s, vo id s o r i nte rs tic es
Me th od s i nv olv in g th e appl icatio n of mo rta r a nd co nc re te
Me th od fo r ad ding re in fo rc in g s te el ba rs
Me th od fo r in sta lli ng b on de d re ba rs in p re - fo rm ed h ole s
Me th od fo r p la te bo nd in g
Me th od s i nv olv in g co ati ng re inf orc em ent
1.1, 1.2, 2.1, 5.2, 8.11.3, 2.2, 5.1, 6.1 7.1, 8.2, 9.1 1.5, 4.5, 4.63.1, 3.2, 3.3, 4.4, 5.1, 6.1, 7.1, 7.2, 7.4 4.14.24.311.1, 11.2 General7.1XXXXXXXX Preparation of concrete substrate General7.2.1ENV 1504-9XXXXXX Cleaning7.2.2XXXXXX Roughening7.2.3XX Concrete removal7.2.4ENV 1504-9XX Preparation of reinforcement General7.3.1ENV 1504-9XXX Cleaning7.3.2ISO 8501-1XXX
Preparation of concrete
General
Weak, damaged and deteriorated concrete and where necessary sound concrete shall be removed in accordance with the principle and method chosen from ENV 1504-9.
If necessary cleaning shall be carried out after roughening or concrete removal to comply with 7.2.2 unless water based methods are used which may make this unnecessary.
Micro cracked or delaminated concrete, often resulting from cleaning, roughening, or removal techniques that compromise bond or structural integrity, must be addressed through removal or remediation A visual inspection of the finished surface is essential, and testing with a hammer should be conducted to identify any loose concrete.
Cleaning
To ensure effective application of protection and repair materials, the substrate must be thoroughly cleaned and free from dust, loose debris, and contaminants that could hinder bonding or wetting Additionally, if cleaning is not performed right before applying the materials, it is essential to protect the cleaned substrate from any potential contamination.
Roughening
For those methods which require roughening the following requirement shall be met.
The texture of the roughened surface shall be appropriate for the products and systems to be applied and shall be specified.
Concrete removal
When removing concrete, it is essential to adhere to specific requirements: the extent of removal must align with the chosen Principle and Method from ENV 1504-9, and should be minimized to preserve structural integrity Additionally, any removal should not compromise the structure's functionality, potentially necessitating temporary support It is crucial to assess the depth of carbonation and the concentration profiles of chlorides or other contaminants in the concrete Finally, the removal extent must be clearly defined according to the selected method.
1) the penetration resistance of the concrete against gases and fluids;
2) the nature and concentration of the contamination before and after the repair;
3) the depth of the contamination;
4) the depth of the carbonation;
5) the corrosion activity of the reinforcement;
7) the need for compaction of the repair material;
8) the need for bond to the substrate;
9) the need for treatment of reinforcement.
Preparation of reinforcement
General
Before implementing protection and repair systems, it is essential to prepare the existing and new reinforcement according to the specifications outlined in ENV 1504-9 and the required structural performance The scope of cleaning, coating, removal, or replacement must be clearly defined, considering the necessity for corrosion prevention and ensuring a strong bond between the repair products and the reinforcement.
Cleaning
To ensure effective cleaning for methods requiring it, several key requirements must be met: all rust, scale, mortar, concrete, dust, and other loose materials that could impair bonding or lead to corrosion must be removed; the entire circumference of exposed reinforcement should be uniformly cleaned, barring any structural limitations; cleaned substrates must be protected from contamination unless cleaning occurs just before applying protective products; reinforcement must be cleaned carefully to avoid damage to itself or the surrounding concrete and environment; if the reinforcement is contaminated with chlorides or other corrosive materials, it should be cleaned using water jets at a pressure not exceeding 18 MPa, unless electrochemical protection methods are employed; for Method 11.2, the cleaning standard should meet Sa2.5, while for Method 11.1 and other methods, the cleaning standard must be specified to ensure compatibility with the intended coating, considering factors such as bar congestion and access limitations.
8 Application of products and systems
General
The products and systems must be appropriate for the substrate and structure they are applied to, ensuring protection and repair that complies with this standard as well as EN 206-1 and ENV 13670-1.
Products shall be stored before use so that their properties shall not be impaired.
Access for the work shall be adequate so that products and systems can be prepared and applied in accordance with this standard.
Protection shall be provided so that preparation, application and subsequent curing shall be carried out in accordance with this standard.
When applying products and systems, it is essential to consider the substrate temperature, moisture content, and environmental characteristics such as temperature, relative humidity, dew point, and the rate of moisture change influenced by precipitation and wind.
Product and system mixing must adhere to EN 206-1 and ENV 13670-1 standards, or specific guidelines should be provided Additionally, the thickness of product and system layers must conform to these standards or be explicitly specified.
The bond of the repair material with the substrate and between layers of repair material, shall be not less than the bond strength specified.
The requirements for application are given in the following sub-clauses and are related to the methods of repair and protection in Table 3.
04-10:2003 (E) Table 3 - Application of products and systems M e th od nu m b ers
Su b-c la us e n um be rs
(b ac kg ro un d in fo rm ati on in A nn ex
Re fe re nc es
Me th od s i nv olv in g hy dro ph ob ic im pre gn ati on a nd im pre gn ati on
Me th od s i nv olv in g su rfa ce c oa tin gs
Me th od s i nv olv in g
Fil lin g c ra ck s, vo id s or in te rs tic es
Me th od s i nv olv in g th e a pp lic ati on o f mor ta r a nd c on cre te
Me th od fo r ad ding re in fo rc in g s te el ba rs
Me th od fo r inst alling bonded rebars in pre- fo rm ed h ole s
Me th od fo r p la te bo nd in g
Me th od s i nv olv in g co ati ng re inf orc em ent
4.14.24.311.1, 11.2 8.1XXXXXXX Defects in concrete and structural strengthening Bonding8.2.1EN 206-1XXXXX Hand applied mortar and concrete
8.2.2ENV 13670-1X*X* Sprayed mortar or concrete
X* Cast mortar or concrete8.2.4ENV 13670-1X* Curing8.2.5ENV 13670-1X*X Cracks and joints8.2.6ENV 1504-9XX* Surface coatings and hydraulic impregnation and impregnation
8.2.7XXX* * W he re r el ev an t to be continued
(b ac kg ro un d in fo rm ati on in A nn ex
Re fe re nc es
Me th od s i nv olv in g hy dro ph ob ic im pre gn ati on a nd im pre gn ati on
Me th od s i nv olv in g su rfa ce c oa tin gs
Me th od s i nv olv in g
Fil lin g c ra ck s, vo id s o r i nte rs tic es
Me th od s i nv olv in g th e a pp lic ati on o f mo rta r a nd co nc re te
Me th od fo r ad ding re in fo rc in g s te el ba rs
Me th od fo r in sta lli ng b on de d re ba rs in p re - fo rm ed h ole s
Me th od fo r p la te bo nd in g
Me th od s i nv olv in g co ati ng re in fo rc em en t
X b o n d in g E N V 1 9 9 2 2 -4 IS O 8 5 0 1 -1 D e fe ct s ca u se d b y re in fo rc em e nt c or ro si o n C o a tin g re in fo rc em e n t 8 3 1 X X R e m o va l 8 3 2 X R e p la ce m e n t 8 3 3 E N V 1 3 6 7 0 -1 X p rE N 1 0 0 80 -1 : 1 9 9 9 -0 7
Table 3 - Application of products and systems (continued)
Defects in concrete and structural strengthening
Bonding
Bonding requirements shall be specified and for applied mortar and concrete shall comply with prEN 1504-4:2000-04.
The water for wetting the substrate shall comply with the purity requirements for mixing water of EN 206-1 and
Hand applied mortar and concrete
For cementitious products or systems applied without a bonding primer, the concrete substrate must be adequately pre-wetted but should not have standing water on the surface during application When a bonding primer is utilized, the specific condition of the substrate must be clearly defined.
Repair mortar must be thoroughly applied to the prepared substrate, ensuring it is compacted to eliminate any air pockets This process is essential to achieve the necessary strength while also safeguarding the reinforcement from corrosion.
When constructing with repair mortar or concrete, it is essential to determine if the material will be applied in layers to avoid sagging or slumping Key specifications include the thickness of each layer, the time intervals between applications, and other necessary requirements If the application of layers is paused and wet-on-wet application is not possible, proper surface treatment for bonding to the previous layer must follow the guidelines outlined in sections 7.2.2, 7.2.3, and 8.2.1.
Sprayed mortar or concrete
Sprayed concrete and sprayed mortar used as repair material shall comply with the standard for sprayed concrete (see prEN 14487-1: 2002-06 &prEN 14487-2:2003).
The need for pre-wetting of the substrate shall be considered It depends upon its condition and the composition of the products and systems used.
Sprayed concrete and mortar must be applied to ensure there are no voids or loose rebound material, achieving the necessary strength while also safeguarding the reinforcement from corrosion.
Spray fog deposits or overspray and loose rebound material shall be removed from surrounding areas and from the substrate before sprayed concrete or mortar is applied.
When applying sprayed concrete or mortar in multiple layers, and not using a wet-on-wet method, it is essential that the intermediate surfaces adhere to the standards outlined in sections 7.2.2 and 8.2.1.
Treatment of sprayed mortar or concrete is prohibited unless the material is non-structural, as this could compromise bond integrity If treatment is necessary for structural sprayed concrete or mortar, it must be applied to the final layer that has not been placed wet-on-wet with the structural material.
Cast mortar or concrete
When applying cementitious products or systems without a bonding primer, it is essential that the concrete substrate is adequately pre-wetted but has no standing water on the surface Additionally, the condition of the substrate must be clearly defined when a bonding primer is utilized.
Concrete shall be replaced in accordance with ENV 13670-1 and shall be specified to avoid segregation bleeding and loss of cement paste.
Formwork shall comply with ENV 13670-1.
Formwork should be installed promptly after preparing the substrate according to clause 7 of this standard It is essential to safeguard openings in the formwork to prevent the intrusion of debris or contaminants.
Concrete must be vibrated to ensure proper compaction around reinforcement, eliminating any entrapped air pockets This process is essential for achieving the necessary strength and protecting the reinforcement from corrosion.
When casting with flowing concrete that relies on gravity for compaction, it is essential that the substrate meets the requirements outlined in clause 7 Additionally, the formwork must be watertight to the existing concrete and free from any obstructions that could hinder the flow of concrete, while also allowing for the escape of air and bleed water The introduction of concrete into the formwork should be done in a manner that facilitates the escape of air and water, and vibration should be avoided.
Curing
Where cementitious repair products and systems are used curing is necessary and shall comply with ENV 13670-1 and shall be specified.
The method and period of any wet curing shall be specified taking into account the nature of the products and systems, the thickness of the repair and environmental conditions.
Curing compounds shall not be used where they adversely affect subsequently applied products and systems.
Cracks and joints
When assessing a structure, it is crucial to consider the location and dimensions of cracks and joints, any substrate movement, and how these factors impact the stability, durability, and functionality of the building Additionally, it is important to evaluate the potential risk of inducing new cracks through any treatment applied.
Crack treatment must adhere to the principles outlined in ENV 1504-9, which includes several key steps: first, cracks should be thoroughly cleaned as specified in clause 7.2.2; second, to restore structural integrity, they must be filled with an appropriate bonding product or system; third, to prevent the ingress of harmful agents, cracks should be covered or filled; and finally, for cracks that require movement accommodation, repairs should create a joint that extends through the full depth of the repair material and is designed to allow for movement, utilizing flexible materials for filling or covering.
The treatment of joints shall ensure that the joint extends through any repair material so that the joint performance is maintained.
Surface coatings and other treatments
Smoothing coatings shall be applied and cured where necessary before surface coatings are applied to fill uneven surfaces and surface pores.
Coatings shall be applied within the specified maximum and minimum thickness.
The specified maximum and minimum temperatures, along with the moisture content of the substrate, as well as the ambient temperature and humidity, must be suitable for the hydrophobic impregnation or impregnation material used in surface coatings.
Anchoring
Anchoring reinforcement separately from the existing reinforcement to ensure its adhesion to the substrate concrete must comply with EN 1504-6:2001-12, ENV 13670-1, ENV 1992-2-4, and any other applicable European Standards or Technical Approvals.
Anchors shall not be installed in cracked concrete or reduce the structural or electrochemical performance of other reinforcement.
The texture and cleanliness of the surface of anchor holes and grooves shall be in accordance with Clauses 7.2.2 and 7.2.3 and shall be appropriate to the anchoring material.
Plate bonding
Plate bonding shall be carried out in accordance with EN 1504-4:2000-04, ENV 1992-2-4 and any other relevant
EN or European Technical Approval.
To ensure proper application of externally bonded reinforcement, the exposed concrete surfaces must be thoroughly cleaned, roughened, and any voids treated according to clauses 7.2.2 and 7.2.3 of the Standard Additionally, any weak, damaged, or deteriorated concrete should be removed in accordance with Clause 7.2.4 before applying the bonded external reinforcement.
The conditions of the surface at the time of application of the bonding agent shall comply with clause 7.1, 7.2.1 and 7.2.2 of this standard.
Replacement of removed concrete and the filling of voids and the treatment of cracks shall be in accordance with Clause 8 of this Standard.
The surface of the steel plates to be bonded shall be free of any contaminants and shall be cleaned to Sa2ẵ (see ISO 8501-1).
The surfaces of fibre reinforced or other plates intended for bonding must be prepared according to the specified guidelines Additionally, adhesives should be applied in accordance with the designated ambient conditions.
The exposed surface of plates shall be protected as specified.
Defects caused by reinforcement corrosion
Coating reinforcement
Bonding requirements shall be specified and shall comply with EN 1504-6:2001-12 The whole exposed circumference of the exposed reinforcement surface shall be uniformly coated.
Coating shall not be allowed to contaminate existing concrete if it is detrimental to the bond between the existing concrete and the repair products and systems.
The treatment of reinforcement to prevent corrosion shall comply with EN 1504-7 1)
Removal
If reinforcement is removed the following requirements shall be met: a) the concrete substrate shall not be damaged (see A.8.3.2); b) remaining reinforcement shall not be damaged.
Replacement
Added or replaced embedded reinforcement shall comply with Clause 8.2.8 of this Standard, ENV 13670-1,
EN 10080-1:1999-07 or other relevant EN or European Technical Approval.
To avoid the risk of creating conditions which may cause corrosion, reinforcement shall not make electrochemical contact with a dissimilar metal.
When applying electrochemical methods for protection and repair, it is essential that any added reinforcement maintains adequate electrical contact with the existing reinforcement to align with the selected principle and method.
General
The execution of the work shall be carried out in accordance with a quality plan prepared for the project.
The storage conditions and periods for use of products and systems shall comply with clause 5 of this standard and the specification.
Quality control tests and observations
Quality control of substrates, product suitability, application conditions, and the final properties of hardened products and systems is essential This process involves conducting tests and observations as outlined in Table 4.
Test methods are referenced according to EN and ISO Standards, and in the absence of a standard, informative Annex A provides alternative tests and observations, including relevant National Standards National Standards may be utilized when European Standards are not available.
Tests given in National Standards are informative.
The maximum and minimum parameters, along with the frequency of observation or testing, must adhere to the project specifications In the absence of specified frequencies, the values provided in the subsequent tables will be applicable Additionally, if maximum and minimum parameters are not defined, refer to the guidance in informative Annex A (A.9.2).
When excluded methods are used similar requirements for quality control are necessary.
The status of the characteristics to be tested is as follows:
For certain intended uses where required by the specific or operating conditions
For special applications ˆProducts and systems for the execution of work shall satisfy the quality control requirements in prEN 1504 parts 2 to 8.‰
04-10:2003 (E) Table 4 - Summary of tests and observations for quality control M e th od nu m b ers
Me th od s i nv olv in g h yd ro ph ob ic im pre gn ati on a nd im pre gn ati on
Me th od s i nv olv in g s urf ac e co ati ng
Me th od s i nv olv in g f ill in g c ra ck s, vo id s o r i nte rs tic es
Me th od s i nv olv in g t he a pp lic ati on of m ort ar and concret e
Me th od fo r a dd in g r ein fo rc in g ste el ba rs
Me th od for ins tal ling bo nded re ba rs in pref orme d h oles
Me th od fo r p lat e bo nding
Me th od s i nv olv in g r ein fo rc em en t co ati ng
Te st or ob se rv ati on n um ber -S ee C la us e A 9 2
Ch ara cte ris tic
Test m eth od or observat io n ( incl uding equi pme nt us ed w he re re le va nt)
Te st (T ) o r O bs erv ati on (O )
Eur op ea n o r I SO S ta nd ard re fe re nc e
Frequency of test or observation
Before and after preparation, it is essential to assess substrate conditions, including delamination through hammer sounding and cleanliness via visual inspection and wipe tests Surface unevenness should be evaluated visually before application, while roughness can be measured using sand tests or profile meters The cleanliness of the concrete substrate or hole is crucial, and water for mixing must be chemically tested if confirmation of potable water is unavailable Additionally, the consistency of grouting, whether cementitious or polymer-based, should be verified, along with the dry thickness of protective coatings on plates Finally, moisture content in cracks and surrounding concrete must be monitored.
EN 1504-10:2 Table 4 (continued) M e th o d n u m b e rs
Me th od s i nv olv in g H yd ro ph ob ic im pre gn ati on a nd im pre gn ati on
Me th od s i nv olv in g s urf ac e co ati ng
Me th od s i nv olv in g f ill in g cra ck s, vo id s o r i nte rs tic es
Me th od s i nv olv in g t he ap pli ca tio n o f m ort ar an d co nc re te
Me th od fo r a dd in g r ein fo rc in g ste el ba rs
Me th od fo r i ns ta lli ng b on de d re ba rs in p re fo rm ed h ole s
Me th od fo r p la te b on din g
Me th od s i nv olv in g re in fo rc em en t co ati ng
Te st or ob se rv ati on n um be r - S ee C la us e A 9 2
Ch ara cte ris tic
Te st me th od o r o bs erv ati on (i nc lu din g e qu ip me nt us ed w he re re le va nt)
Te st (T ) o r O bs erv ati on (O )
Eu ro pe an o r I SO S ta nd ard re fe re nc e
Fre qu en cy o f t es t o r o bs erv ati on
4 1 4 2 4 3 1 1 1 , 1 1 2 5 S ur fa ce te ns ile st re ng th o f su bs tr at e
The pull-off test TEN 15426 measures crack width and depth using mechanical or electrical gauges, as well as core and visual or ultrasonic methods.
The article discusses various measurement tools, including seven crack movement mechanical or electrical gauges, an eight vibration accelerometer, and the moisture content of substrates.
Visual site sampling and laboratory analysis are essential for conducting resistivity tests and utilizing relative humidity probes These methods provide critical data for understanding environmental conditions and material properties.
B ef or e an d du rin g ap pl ic at io n
04-10:2003 (E) Table 4 (continued) M e th od nu m b ers
Me th od s i nv olv in g H yd ro ph ob ic im pre gn ati on a nd im pre gn ati on
Me th od s i nv olv in g s urf ac e co ati ng
Me th od s i nv olv in g f ill in g cra ck s, vo id s o r i nte rs tic es
Me th od s i nv olv in g t he ap pli ca tio n o f m ort ar an d co nc re te
Me th od for a dd in g re inf orc ing ste el ba rs
Me th od for ins tall ing bo nded rebars in pref orm ed ho les
Me th od fo r p lat e bo nding
Me th od in vo lv in g r ein fo rc em en t co ati ng
Te st or ob se rv ati on n um be r - S ee C la us e A 9 2
Ch ara cte ris tic
Test m eth od or observat io n ( incl udi ng equi pme nt us ed w he re re le va nt)
Te st (T ) o r O bs erv ati on (O )
Frequency of test or observation
The article discusses various sections including 3.1, 3.2, 3.3, 4.4, 5.1, 6.1, 7.1, 7.2, and 7.4, focusing on the temperature of the substrate and the use of a thermometer throughout the application It also highlights the significance of carbonization and phenolphthalein tests, referencing the study conducted in 2003.
12 C hl or id e C on te nt S ite s am pl in g an d ch em ic al an al ys is
13 P en et ra tio n of ot he r co nt am in an ts
S ite s am pl in g an d ch em ic al an al ys is
T 14 C ra ck co nt am in at io n C or e an d ch em ic al an al ys is
T 15 E le ct ric al re si st iv ity W en ne r t es t T 16 C le an lin es s of ex is tin g re in fo rc em en t
V is ua l O IS O 8 50 1- 1 O nc e be fo re ap pl ic at io n 17 S iz e of ex is tin g re in fo rc em en t
V is ua l O to be continued
EN 1504-10:2 Table 4 (continued) M e th od nu m b ers
Me th od s i nv olv in g H yd ro ph ob ic im pre gn ati on a nd im pre gn ati on
Me th od s i nv olv in g s urf ac e c oa tin g
Me th od s i nv olv in g f ill in g c ra ck s, vo id s o r i nte rs tic es
Me th od s i nv olv in g t he a pp lic ati on o f mo rta r a nd c on cre te
Me th od fo r a dd in g r ein fo rc in g s te el ba rs
Me th od fo r i ns ta lli ng b on de d r eb ars in p re fo rm ed h ole s
Me th od fo r p la te b on din g
Me th od in vo lv in g r ein fo rc em en t co ati ng
Te st or ob se rv ati on n um be r - S ee C la us e A 9 2
Ch ara cte ris tic
Test m ethod or observat ion
(i ncludi ng equi pme nt used wh ere re le va nt)
Te st (T ) o r O bs erv ati on (O )
Eu ro pe an o r I SO S ta nd ard re fe re nc e
Fre qu en cy o f t es t o r o bs erv ati on
4 1 4 2 4 3 1 1 1 , 1 1 2 18 C or ro si on o f ex is tin g re in fo rc em en t
H al f c el l t es ts or v is ua l T O
19 C le an lin es s of re in fo rc in g pl at es
The Visual OENVI 8502-1, -4 is a comprehensive tool designed for assessing compressive strength through core and crushing tests, as well as rebound hammer tests, ensuring accurate evaluation before application.
A c c e p ta n c e o f p ro d u c ts a n d s y s te m s 20 Id en tit y of a ll ap pl ie d pr od uc ts
Before using the certification OTEN 1504-8:2000-10 EN 1008, it is essential to understand the conditions and requirements that must be met prior to and during the application process One critical factor to monitor is the ambient temperature, which should be measured using a thermometer throughout the application.
04-10:2003 (E) Table 4 (continued) M e th od nu m b ers
Me th od s i nv olv in g H yd ro ph ob ic im pre gn ati on a nd im pre gn ati on
Me th od s i nv olv in g s urf ac e c oa tin g
Me th od s i nvo lv in g f ill ing c ra ck s, vo id s o r i nte rs tic es
Me th od s i nv olv in g t he a pp lic ati on o f mor ta r a nd c on cre te
Me th od fo r ad ding re info rcing steel ba rs
Me th od fo r inst alling bo nded rebars in pref orme d h oles
Me th od fo r p lat e bo nding
Me th od invo lving reinf orce ment co ati ng
Te st or ob se rv ati on n um be r - S ee C la us e A 9 2
Ch ara cte ris tic
Test m ethod or observat ion
(i ncludi ng equi pme nt us ed w he re re le va nt)
Te st (T ) o r O bs erv ati on (O )
Frequency of test or observation
The article discusses various instruments and measurements related to environmental conditions It highlights the importance of ambient humidity, emphasizing the use of hygrometers, specifically the ISO 4677-1 & 2 standards Additionally, it covers the significance of precipitation visualization and daily monitoring Wind strength is measured using an anemometer, which is crucial for accurate data collection Lastly, the article mentions the dew point, which is assessed using both hygrometers and thermometers, underscoring the need for precise instruments in environmental applications.
O IS O 46 77 1 -2 T hr ou gh ou t ap pl ic at io n If p ro du ct re qu ire s it
The thickness of the coating on the Combor wheel gauge TISO 2808 after application is 26 W, while the consistency of concrete, mortar, and cement grout is also evaluated for quality and performance.
S lu m p te st V eb e te st F lo w t ab le t es t F lo w t ro u g h te st F lo w t ro u g h te st F lo w t ab le t es t O ve rh ea d te st
D ai ly o r fo r ea ch b at ch 6 to be continued
EN 1504-10:2 Table 4 (continued) M e th od nu m b ers
Me th od s i nv olv in g H yd ro ph ob ic im pre gn ati on a nd im pre gn ati on
Me th od s i nv olv in g s urf ac e co ati ng
Me th od s i nv olv in g f ill in g cra ck s, vo id s o r i nte rs tic es
Me th od s i nv olv in g t he ap pli ca tio n o f m ort ar an d co nc re te
Me th od fo r a dd in g r ein fo rc in g ste el ba rs
Me th od fo r i ns ta lli ng b on de d re ba rs in p re fo rm ed h ole s
Me th od fo r p la te b on din g
Me th od in vo lv in g r ein fo rc em en t co ati ng
Te st or ob se rv ati on n um be r - S ee C la us e A 9 2
Ch ara cte ris tic
Te st me th od o r o bs erv ati on (i nc lu din g e qu ip me nt us ed w he re re le va nt)
Te st (T ) o r O bs erv ati on (O )
Eu ro pe an o r I SO S ta nd ard re fe re nc e
Fre qu en cy o f t es t o r o bs erv ati on
3 1 , 3 2 , 3 3 , 4 4 , 5 1 , 6 1 , 7 1 , 7 2 , 7 4 4 1 4 2 4 3 1 1 1 , 1 1 2 28 A ir co nt en t o f fr es h co nc re te P re ss ur e m et ho d T E N 1 23 50 - 7 34 T hi ck ne ss o r co ve r of r ep ai r m at er ia l
C or e an d vi su al , C ov er m et er te st
E N 1 25 04 -1 O nc e af te r re pa ir
36 C om pr es si ve st re ng th C ub e an d cr us hi ng te st R eb ou nd ha m m er t es t
O nc e af te r re pa ir
40 P os iti on o f re in fo rc em en t V is ua l o r C ov er m et er O T O nc e be fo re ap pl ic at io n to be continued
04-10:2003 (E) Table 4 (continued) M e th od nu m b ers
Me th od s i nv olv in g H yd ro ph ob ic im pre gn ati on a nd im pre gn ati on
Me th od s i nv olv in g s urf ac e co ati ng
Me th od s i nv olv in g f ill in g cra ck s, vo id s o r i nte rs tic es
Me th od s i nv olv in g t he ap pli ca tio n o f m ort ar an d co nc re te
Me th od for a dd in g re inf orc ing ste el ba rs
Me th od for ins tall ing bo nded rebars in pref orm ed ho les
Me th od fo r p lat e bo nding
Me th od in vo lv in g r ein fo rc em en t co ati ng
Te st or ob se rv ati on n um be r - S ee C la us e A 9 2
Ch ara cte ris tic
Test m ethod or observat ion
(i ncludi ng eq uip me nt us ed w he re re le va nt)
Te st (T ) o r O bs erv ati on (O )
Frequency of te st or observation
In the analysis of various conditions, sections 3.1 to 3.3 and 4.1 to 4.3 highlight the significance of evaluating the efficiency of repair methods The final hardened condition, along with the delamination and hammer sounding techniques, plays a crucial role in assessing the performance of each element type This comprehensive approach ensures a thorough judgment of repair efficiency.
15 E le ct ri ca l re si st iv ity W en n e r T es t T 29 D ry t hi ck ne ss o f co at in g W ed ge c ut o r qu an tit y m ea su re m en t
T IS O 2 80 8 O nc e to ju dg e th e ef fic ie nc y
7 30 C ov er in g of co at in g V is ua l O IS O 46 28 -1 -6 : 20 03 -0 4
To evaluate the efficiency of penetration in the context of impregnation, it is essential to focus on both core visual aspects and quantitative measurements.
32 P er m ea bi lit y of co at in g or r ep ai r m at er ia l o r fil le d cr ac ks t o w at er
K ar st en t es t C or e an d pe ne tr at io n te st
O nc e to ju dg e th e ef fic ie nc y to be continued ˆ ‰
EN 1504-10:2 Table 4 (continued) M e th od nu m b ers
Me th od s i nv olv in g H yd ro ph ob ic im pre gn ati on a nd im pre gn ati on
Me th od s i nv olv in g s urf ac e co ati ng
Me th od s i nv olv in g f ill in g cra ck s, vo id s o r i nte rs tic es
Me th od s i nv olv in g t he ap pli ca tio n o f m ort ar an d co nc re te
Me th od fo r a dd in g r ein fo rc in g ste el ba rs
Me th od fo r i ns ta lli ng b on de d re ba rs in p re fo rm ed h ole s
Me th od fo r p la te b on din g
Me th od in vo lv in g r ein fo rc em en t co ati ng
Te st or ob se rv ati on n um be r - S ee C la us e A 9 2
Ch ara cte ris tic
Te st me th od o r o bs erv ati on (i nc lu din g eq uip me nt us ed w he re re le va nt)
Te st (T ) o r O bs erv ati on (O )
Eu ro pe an o r I SO S ta nd ard re fe re nc e
Fre qu en cy o f t es t o r o bs erv ati on
3 1 , 3 2 , 3 3 , 4 4 , 5 1 , 6 1 , 7 1 , 7 2 , 7 4 4 1 4 2 4 3 1 1 1 , 1 1 2 33 D eg re e of f ill in g of c ra ck s C or e an d vi su al or u ltr as on ic te st
34 T hi ck ne ss o f co ve r C or e, v is ua l o r co ve rm et er te st
E N 12 50 4- 1 O nc e pe r el em en t ty pe
35 A dh es io n of co at in g, ad he si on o f re pa ir m at er ia l
C ro ss c ut t es t P ul l- of f t es t
The article discusses the standards EN ISO 24 09-6 and ISO 4624 EN 1542, which specify testing methods for different surface types or members It highlights the importance of measuring compressive strength, core strength, and the use of a rebound hammer for assessing material integrity.
O nc e pe r el em en t ty pe
37 D en si ty o f ha rd en ed co nc re te
O ve n dr y m et ho d T E N 12 39 0- 7 O nc e af te r re pa ir (1 ) S ee T es t 3 5 in A nn ex A to be continued
04-10:2003 (E) Table 4 (continued) M e th od nu m b ers
Me th od s i nv olv in g H yd ro ph ob ic im pre gn ati on a nd im pre gn ati on
Me th od s i nv olv in g s urf ac e co ati ng
Me th od s i nv olv in g f ill in g cra ck s, vo id s o r i nte rs tic es
Me th od s i nv olv in g t he ap pli ca tio n o f m ort ar an d co nc re te
Me th od for a dd in g re inf orc ing ste el ba rs
Me th od for ins tall ing bo nded rebars in pref orm ed ho les
Me th od fo r p lat e bo nding
Me th od in vo lv in g r ein fo rc em en t co ati ng
Te st or ob se rv ati on n um be r - S ee C la us e A 9 2
Ch ara cte ris tic
Test m eth od or observat io n ( incl udi ng equi pme nt us ed w he re re le va nt)
Te st (T ) o r O bs erv ati on (O )
Frequency of test or observation
4 1 4 2 4 3 1 1 1 , 1 1 2 38 S hr in ka ge cr ac ki ng in re pa ir m or ta r an d co nc re te
O O nc e to ju dg e th e ef fic ie nc y
39 P re se nc e or vo id s in a nd be hi nd ha rd en ed re pa ir m at er ia l
U ltr as on ic te st o r ra di og ra ph y or co re a nd v is ua l
Informative references
The information and references in clause 2 apply to the references given in informative Annex A.
EN 12350-6, Testing fresh concrete – Part 6: Density.
ISO 565, Test sieves metal wire, perforated metal plates, Electro formed sheet.
Directive 89/106/EEC, Construction Products Directive.
Directive 92/57/EEC, Implementation of minimum safety and health requirements for temporary or mobile construction sites.
Definitions
The definitions in clause 3 apply to the annex
A.3.1 blasting removal of matter from the concrete substrate to a maximum depth of 2 mm
A.3.2 grit blasting blasting using abrasive as an additive in air
A.3.3 mechanical removal removal of substrate by percussive or abrasive means
A.3.4 non-selective hydrodemolition removal of concrete to a selected depth by using high pressure water techniques
A.3.5 selective hydrodemolition removal of damaged concrete leaving sound concrete of a selected strength using high pressure water techniques
A.3.6 soaking filling cracks in a horizontal surface by means of gravity using a pond of filling material above the crack
A.3.7 water blasting blasting using high pressure water with or without abrasives as an additive
Structural stability during preparation, protection and repair
Deterioration damage and repair processes can significantly reduce a structure's load-bearing capacity It is essential to consider this reduction when designing repair methods, which may involve the temporary or permanent removal of dead and live loads Additionally, providing temporary or permanent support and carefully planning the sequence of repairs are crucial to ensure the structure's safety during the repair process.
Repeated repairs to the same concrete structure, while often not impacting its structural integrity, can lead to progressive weakening This occurs as successive interventions involve cutting away existing structural concrete and replacing it with new material, potentially compromising the overall strength of the structure over time.
When replacing materials in a structure, it's crucial to ensure that the new material shares similar properties with the original Differences in material characteristics, such as shrinkage or thermal contraction, can lead to inadequate load-bearing capacity Additionally, existing stresses in the structure during the repair process can further complicate the effectiveness of the replacement material.
General requirements
When vibrations from construction activities or traffic are anticipated during the curing of repair concrete or mortar, it is essential to choose a product or system that can endure these vibrations without negative impacts Alternatively, efforts should be made to minimize or eliminate the sources of vibration as much as possible.
Methods of protection and repair
The excluded methods will be standardized in other European Norms (EN) or specified in different European Technical Approvals Below, we describe methods 1.4, 1.6, and 11.3, which currently lack an EN or approval.
The method is to seal cracks in the concrete to prevent the passage of agents.
Free movement shall be maintained Adhesive shall not be applied to free tape width.
If no other information is available pre-tests shall be carried out to determine the adhesion and tightness of bandages against penetrants.
The relevant characteristics to be tested are:
Status of test or Observation
Test method or observation (including equipment used where relevant)
Frequency of test or observation
Test Ref EN or ISO number or Test or observation number in clause A.9
SUBSTRATE CONDITIONS AND/OR AFTER PREPARATION
Cleanliness Visual After preparation and immediately before application
Surface tensile strength of substrate
Mechanical gauge, Core and Visual or Ultrasonic
Crack movement Strain gauge, crack magnifier or glass plates
Moisture content of surrounding concrete
Site sampling and Laboratory test Visual or resistivity test, relative humidity probes
CONDITIONS AND REQUIREMENTS BEFORE AND/OR DURING APPLICATION
Ambient temperature Thermometer Throughout application 21
Ambient humidity Hygrometer Throughout 22 application ISO 4677 - 1&2
Dew point Hygrometer and Throughout 25 thermometer application if product requires it
Adhesion Pull-off On completion 35
Method 1.6 Transferring cracks into joints
This approach incorporates existing cracks as a fundamental aspect of the structure The design of the joints and selection of materials must comply with ENV 1992-2-4 or other applicable European Standards or Technical Approvals Additionally, the formation of joints should adhere to the relevant European Norms.
Method 4.1 Adding or replacing embedded or external steel
There is a risk of promoting electrochemical action if new reinforcement is added to structures infected with chlorides
Method 7.1 Increasing cover to reinforcement with additional cementitious mortar or concrete or surface coating
The application of surface coatings can assist in the preservation of passivity.
Method 9.1 Limiting oxygen content (at the cathode) by saturation or surface coating
The effectiveness of saturation in preventing oxygen transmission to reinforcement relies on the level of impermeability attained when saturated with water Additionally, when surface coatings are applied, their effectiveness is influenced by the specific characteristics of the coating used.
Method 11.2 Painting reinforcement with barrier coatings
The success of the method relies on the coating's capacity to protect the reinforcement from its surroundings, making it crucial to ensure that the coating is free of any gaps.
Method 11.3 Applying inhibitors to the concrete
Inhibitors are applied as a surface treatment or are added to repair products and systems.
Inhibitors are chemical agents that prevent the development of anodic regions on reinforcement Their effectiveness relies on the product's and system's capacity to penetrate and influence the reinforcement's surface.
Preparation of substrate
General
Dust and fine particles remaining on the substrate after concrete removal may contain unhydrated cement that can harden when exposed to moisture While this material is weak, it can become challenging to eliminate from the rough surface once it sets, making it crucial to remove it before any hardening takes place.
Pull-off tests are effective for assessing the surface tensile strength of relatively flat surfaces Various methods for cleaning, roughening, and removal are employed in this process.
1 Cleaning Mechanical, percussion and abrasion
Grit and sand blasting Water Blasting with low pressure up to approximately 18 MPa and where low water volumes are necessary up to 60 MPa
2 Roughening Mechanical percussion and abrasion
Grit and sand blasting Water Blasting with high pressure up to approximately 60 MPa
Water Blasting with high pressure up to 60 MPa and very high pressure up to 110 MPa
Cleaning
Cleaning aims to eliminate dust, loose materials, and contaminants to enhance the adhesion between the substrate's cleaned surface and the applied material Effective methods for achieving this include water blasting, clean compressed air, and vacuum cleaning.
Where contaminants are on or have penetrated beneath the surface it may be necessary to remove them using methods for example involving the use of solvents or steam cleaning.
Chlorides and other contaminants may be detected by site sampling and chemical analysis reference prEN 14629:2003-03 for chloride content and as in BS 1881 part 124 for other chemical analysis.
Contaminants embedded in the surface may include tie wire, nails and timber.
Cleaning of concrete surfaces without removal of concrete is normally performed with water pressures up to 18 MPa.
Water blasting employs high-pressure water techniques for effective cleaning and superficial concrete removal, reaching depths of up to 2 mm This method is also effective in eliminating various materials, including membranes, asphalt residues, color markings, and laitance.
Cracks and joints can be cleaned with water jetting, flushing with water or compressed air.
When using compressed air care shall be taken that the air is clean and does not contaminate the substrate with oil.
Roughening
Roughening is a technique employed to remove concrete up to a depth of 15 mm, creating a textured surface that enhances the bonding of a new layer of concrete or mortar applied or sprayed onto the original concrete.
The extent of the removal should take into account the relevant factors and any need to provide uncontaminated cover on all sides of the reinforcement.
Structural considerations may limit the extent of the removal.
When applying methods 7.3, 7.5, and 10.1, it is essential to eliminate honeycombed or delaminated concrete, surface coatings, and prior repairs that exhibit excessively high resistivity However, there is no requirement to remove the original sound concrete surrounding the reinforcement.
Tying wire fragments, nails and other metal debris embedded in the concrete should be removed where possible.
To ensure effective bonding in concrete repairs, edges where concrete is removed must be cut at a minimum angle of 90° and a maximum angle of 135° This practice helps prevent undercutting and minimizes the risk of debonding with the adjacent sound concrete Additionally, the edges should be roughened adequately to create a mechanical key that enhances the connection between the original material and the repair product.
When corrosion is detected on the exposed circumference of a reinforcing bar after damaged concrete removal, it may be necessary to increase the depth of removal to fully expose the bar, as dictated by repair specifications To ensure proper compaction, the clearance around the reinforcement and the minimum distance between the reinforcement bar and the remaining substrate must be at least 15 mm or the maximum aggregate size of the repair material plus 5 mm, whichever is greater Additionally, any chloride-contaminated concrete should be removed from all sides of the reinforcement for a minimum of 20 mm.
If there is no corrosion on the reinforcement, carbonated and or chloride contaminated concrete may remain if electrochemical methods are used or the concrete is sufficiently dry.
In the thermal and mechanical removal of concrete, micro-cracks may develop in the remaining concrete, necessitating their removal through water blasting, with or without abrasives, or treatment to restore surface integrity if tensile strength is inadequate for subsequent applications Cracks can be identified by wetting the surface and observing dark lines as the water dries, indicating areas that retain moisture When employing thermal methods for concrete removal, it is crucial to control heat introduction to avoid damage; if damage occurs, additional removal methods should be utilized to eliminate any contaminated concrete.
Hydrodemolition is an efficient method for concrete removal that minimizes damage to sound concrete, preventing the development of micro-cracks This technique selectively removes unsound concrete while preserving the integrity of sound areas, based on a predetermined mean removal depth Effective execution requires reliable equipment to ensure precise differentiation between sound and unsound concrete, achieving a clean removal without leaving shadows or significant ridges beneath the reinforcement, and avoiding the creation of pits While a minimum depth of removal can be established, areas of localized weakness may necessitate deeper extraction.
Selective hydrodemolition typically utilizes equipment operating at pressures between 60 and 110 MPa It is essential to use prequalified equipment for this method The resulting surface roughness can vary significantly, influenced by factors such as the distance from the nozzle to the substrate, water pressure, water flow, feed rate, and the quality of both the equipment and the concrete.
Water pressure, which is usually metered at the pump can be categorised as follows:
Low Pressure Up to 18 MPa - Used for cleaning concrete and steel substrate;
High Pressure 18 MPa - 60MPa - Used for cleaning steel substrate and for removal of concrete;
Very High Pressure 60 MPa - 110 MPa - Used for concrete removal when low water volume are necessary.
High-pressure water cutting, also known as water jet cutting, involves using a water jet to create narrow slits or small holes This technique is commonly employed to remove sections or create openings in reinforced concrete Additionally, by incorporating abrasives into the water, it becomes feasible to cut through steel.
General
Structural performance may be changed by loss of section or pitting of the reinforcement.
Cleaning
For effective cleaning, it is essential to address the entire periphery of the bar, typically extending at least 50 mm beyond the corrosion's reach along its length However, structural limitations may restrict the amount of concrete that can be removed and the extent of cleaning performed Utilizing potential mapping can be beneficial in identifying areas of corrosion.
For method 11.1, the cleaning standard involves achieving Sa2, or "thorough blast-cleaning," when using coatings with active pigment In contrast, method 11.2 requires a higher standard of Sa2.5, known as "very thorough blast-cleaning," for barrier coatings However, achieving these cleaning standards can be challenging under site conditions.
In situations where cleaning access is obstructed by bar congestion, contact between bars, or proximity to the concrete substrate, it is essential to specify the cleaning method and standards Inadequate removal of corrosion products and contaminants, or inability to apply coatings to all intended areas, can adversely affect coating performance The standards for blast-cleaning are outlined in ISO 8501-1, and various cleaning methods, including grit blasting, are permissible.
The removal of chlorides from the surface or pits of steel is effectively accomplished using pressurized water, typically at low pressures below 18 MPa However, in cases where only small volumes of water are needed, pressures may need to reach up to 60 MPa.
Application of products and systems
General
The temperature of the substrate and repair mortar or concrete should not differ materially to avoid the risk of loss of bond and loss of hydration.
Surface working of concrete or mortar may cause the formation of shrinkage cracks as the treatment may give rise to a cement rich surface layer.
A rough surface profile enhances the bond between old and new concrete, as well as repair products and systems This roughness can be achieved through hydrodemolition or mechanical methods, with hydrodemolition providing the greatest surface roughness, followed by mechanical hammers and grit blasting When hydrodemolition is employed, a strong bond is typically established between the concrete substrate and the repair material, eliminating the need for mechanical connections to transfer shear and tensile stresses below 0.4 MPa.
A textured surface can be given to the surface of repair mortar or concrete before it has set to assist in the mechanical key for a subsequent layer.
When using cementitious or polymer repair products, it is essential to determine the necessity of a bonding primer Applying bonding coats can negatively impact adhesion if they cure before the subsequent products are applied.
When using cementitious repair products without a bonding primer, it is crucial to pre-wet the surface as specified in sections 8.2.2, 8.2.3, or 8.2.4 for a minimum duration, ensuring it does not dry before application However, surface pores and pits must remain free of water during the placement of the material to maintain bond integrity The ideal surface appearance should be a dark matte finish without any glistening This wetting process is essential to prevent water transfer from the repair product to the substrate, which could negatively impact the hydration of the repair material.
Polymer hydraulic mortars may set with a smooth polymer rich layer on the surface which is harmful to the bond of subsequent layers or surface treatment.
A.8.2.2 Hand applied mortar or concrete
It is essential to account for the differing properties of polymer mortar compared to concrete and other cementitious products Generally, polymer mortar exhibits higher coefficients of thermal expansion, superior resistance to water vapor, and lower fire resistance and tolerance to high temperatures when contrasted with traditional cementitious materials.
Polymer mortar and concrete are ideal for underwater applications and environments requiring high abrasion resistance They are particularly beneficial when rapid strength gain or thin layer applications are necessary, especially in situations where curing for traditional cementitious materials is not feasible.
Sprayed concrete and mortar can be applied by the wet or dry process
For optimal application, sprayed concrete or mortar should be directed at an angle close to 90 degrees to the substrate, maintaining a distance of 0.5 to 1.0 meters between the nozzle and the surface.
When applying sprayed concrete with a thickness exceeding 70 mm, it is essential to include reinforcement to mitigate shrinkage cracking and enhance mechanical bonding.
Care is required to avoid the formation of voids behind the reinforcement.
For sprayed concrete that has cured between layers and is not applied wet on wet, it is essential to clean the surface using low-pressure water or compressed air Typically, a bonding coat is not necessary for sprayed concrete.
An additional non structural layer can be applied if there are special requirements for the surface of the repair material e.g if finished with rule or hand tools.
Drainage layers on formwork surfaces prevent the formation of surface voids and decrease the water cement ratio of the surface layer.
To prevent cracks from plastic or drying shrinkage in hydraulic mortar and concrete, effective curing is essential The best method involves supplying excess water to the surface While manual watering throughout the curing period can be impractical, using perforated hoses to deliver water to absorbent materials, such as hessian, covered with transparent plastic sheeting proves to be both economical and highly effective, even in severe drying conditions.
During the hydration and hardening process of the concrete it is important that the temperature gradient throughout the structure is as flat as possible to avoid thermal cracking
Products and systems with polymer modifiers (PCC) require specific curing conditions to achieve optimal performance It is essential to maintain moisture levels for cement curing while simultaneously reducing moisture to enable the polymer component to form a strong film.
Crack filling can be achieved through injection, soaking, or vacuum techniques, but it is essential to remove contaminants like oil before proceeding The acceptable moisture level in cracks varies based on the filling material's properties Cleaning and drying methods include using water, solvents, and pressurized clean air When injecting cracks, sealing is crucial to ensure a smooth process, and nozzle materials must avoid electrochemical reactions Careful management of injection pressure is necessary to prevent additional cracks or damage to the substrate and surrounding environment, as thixotropic grouts can lead to excessively high pressures.
Surplus filling and sealing material is usually removed.
The equipment for soaking must ensure an adequate, uninterrupted flow of the crack-filling material until absorption has ceased.
Other methods of filling cracks are based on vacuum techniques.
To ensure effective filling and hardening, it is crucial to select the injection time when crack-width is at its maximum and within the product's workability period.
Crack filling is not appropriate if expansive reaction in the structure is likely.
Cracks should be completely filled if possible The degree of filling can be established by taking and examining cores or ultrasonic testing - see Test No.33.
Filling small cracks narrower than 0.1 mm can be challenging, but using low-viscosity epoxy resins and specialized fine cement or grout can yield effective results, provided that these methods are validated through preliminary testing.
Sealing cracks with bandages is often the best option when dealing with contaminated cracks, those that are too small to fill, or when there are longitudinal and/or shear movements exceeding 25% of the crack width In the absence of additional information, pre-tests may be required to assess the adhesion and effectiveness of the bandages.
Cracks should be transformed into joints when significant variations in crack width are anticipated, particularly from thermal effects or structural movement It is essential that new joints are compatible with existing ones If reinforcement needs to be cut, potential negative impacts on load-bearing capacity and corrosion risk must be considered The design and materials used for the joint must comply with ENV 1992-2-4 or other applicable European standards or technical approvals.
A.8.2.7 Surface coatings and other treatments
There is a danger of the occurrence of efflorescence when Electrochemical processes are used Unless it is removed it interferes with the bond between the coating and the concrete.
Surface applied inhibitors can leave a surface deposit which may hinder bond of a subsequent coating.
Impregnation and hydrophobic impregnation can be applied by hand, spray, vacuum method or via a gel.
For Hydrophobic impregnation using a silane or siloxane the penetration can be improved by applying the material in two stages, wet on wet.