Strengthening and Repair of Reinforced Concrete Structures. Ian Wienholt Business Development Manager
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1 Strengthening and Repair of Reinforced Concrete Structures Ian Wienholt Business Development Manager
2 34 years of Concrete Repair and Strengthening Experience Over 12,000 Repair Project Over 25,000 PT Projects 1,500 Employees 22 Offices- International UAE and UK
3 Structural Group delivers services, systems and technologies that build, repair, protect, strengthen and reinforce concrete, steel, masonry, wood, timber and soils.
4 Concrete Repair & Waterproofing
5 Masonry Restoration
6 Building Envelope Group: Historic Division
7 Building Envelope Group: Multi-Family Division
8 Concrete Repair Services Construction Defects Missing Reinforcement Honeycombs
9 General Repair Group: Strengthening Division
10 Agenda Strengthening Case Studies CFRP & NSM Rod External / Internal PT Section Enlargement / Supplemental Beams
11 CFRP & NSM
12 Externally Bonded FRP Sheet 550,000 psi Tensile 10x that of steel Lightweight Does NOT corrode
13 FRP Design Guidelines 440.2R R-08 ACI 440.2R-08 Emerging Technology To Date: Nationwide 15-18M sqft installed SPS 7M sqft installed on over projects
14 FRP Materials SEM Image of FRP Resin Fiber
15 What Is FRP Flexural Strengthened R/C? Yield Tension Steel Positive Moment FRP carries TENSION
16 What Is FRP Flexural Strengthened R/C? FRP carries TENSION Tension Negative Moment TOP Yield Steel Concrete carries COMPRESSION BOTTOM Column Compression
17 What Is FRP Shear Strengthened R/C? SHEAR
18 CFRP Installation Step 1 Surface Grinding / Shot Blasting to open pores
19 CFRP Installation Step 2 VE primer
20 CFRP Installation Step 3 VE putty
21 CFRP Installation Step 4 VE tack coat
22 Carter Ave Bridge Upgrade Tack coat QC
23 CFRP Installation Step 5 CFRP saturator
24 CFRP Installation Step 6 CFRP sheet lay up
25 CFRP Installation Step 7 Embedding of CFRP in tack coat
26 CFRP Installation Step 8 Rib rolling
27 CFRP Installation Completed Finished CFRP- Top, Sides, Bottom
28 Carter Ave Bridge Upgrade
29 Carter Ave Bridge Upgrade Acrylic / Intumescent Topcoat installation
30 CFRP Finished Product
31 Supplemental Strengthening ONLY w/frp! FRP? 2 4
32 Supplemental Strengthening ONLY w/frp!
33 CFRP Interfacial Shear Failure
34 FRP Plates
35 FRP Rods
36 Flexural Strengthening Case Study FRP Rod Installation
37 Parking Garage Ramp
38 Parking Garage Ramp FRP Sheet
39 NSM Rods Parking Garage Ramp
40 Damaged Double T Dropped 2T in Parking Garage
41 Shear upgrade of 2T stem with FRP
42 Flexural Detailing Guidelines Step plies U Wrap
43 Quality Control Field Application
44 Quality Control- Cure Test Cups Daily 1Gal. BA Pour off sample To verify cure
45 Sounding and Bond Tests Puck Ping ` Tap test or other Pull test
46 Sounding 6
47 Witness Panels for Testing
48 Pull off Bond Test Min. 200psi
49 Locate Bond Test Dollies outside work area or on an additional piece of FRP
50 Locate Bond Test Dollies outside work area or on an additional piece of FRP Ear plug to protect threads
51 Frequency for Pull Testing 1 PULL PER INSTALLATION DAY MINIMUM OR PER ENGINEER S SPEC (per sqft installed)
52 Repair Procedure 1 - Identify Repair Area Less than 2 Sq. In. / 5% Total Area Max. OK If 2 to 4 sq. in. inject with low pressure
53 Repair Procedure
54 Repair Procedure Step 2 - Remove Composite Material If greater than 4sq. In. grind or sawcut area
55 Repair Procedure Step 3 - Prepare Lap Area Minimum repair lap = 6 inches 6
56 New Loads or low strength concrete
57 CFRP Column Confinement Increased: Axial Capacity Buckling Resistance Bomb Blast Resistance
58 General Concept
59 Structural Upgrade Resorts Casino- Atlantic City
60 Structural Upgrade Resorts Casino- Atlantic City
61 Structural Upgrade-Buckling Resistance Resorts Casino- Atlantic City
62 Structural Upgrade Resorts Casino- Atlantic City
63 Blast Mitigation for Columns Truck bomb at curbside
64 Blast Mitigation for Columns Truck bomb at curbside No FRP
65 Blast Mitigation for Columns Truck bomb at curbside No FRP
66 Blast Mitigation for Columns Truck bomb at curbside
67 Guggenheim Museum NYC 1959
68 Guggenheim Museum NYC
69 Guggenheim Museum NYC
70
71 Guggenheim Museum NYC Goal: Extend the life of the structure by 100 years Exhaustive investigative survey completed and found 11 coats of paint on the exterior All exterior surfaces would be restored so that the original form lines would once again be visible
72
73
74 Original Construction Photo Circa 1957
75 Destructive testing to open crack
76 Rebar Discontinuous Steel T-Section
77 Original Construction Photos
78 Guggenheim Museum
79 Guggenheim Museum- Analysis & Monitoring Circumferential Forces Vertical Forces
80 Initial repair concept FRP
81 Steel brackets b/n web walls Bond Grout
82 Double Barrier Walls Museum remained open!
83 Surface Preparation 8,000 psi 1,674,345,869 Diamond Cup Wheels Used!
84 Extensive Crack Repair Required
85 Rout & Seal vs. Epoxy Injection
86
87 CFRP Installation
88 Web Wall Brackets
89 Gunite wall to apron slab bracket FRP Bracket
90 Apron bracket Stainless Steel Grout
91 Shear transfer plate across cracks
92 Completed repair prior to insulation and drywall
93 Pier expansion design included new pre-cast deck panels as well as a new 92 ramp for RO/RO cargo Change in use and heavier loads required strengthening upgrade to pier caps CFRP system designed for increased strength and long-term durability in marine environment South Locust Point Marine Terminal Roll-On / Roll-Off Platform
94 South Locust Point Marine Terminal Roll-On / Roll-Off Platform Challenge #1: Time Critical Schedule
95 South Locust Point Marine Terminal Roll-On / Roll-Off Platform Challenge #2: Weather conditions
96 South Locust Point Marine Terminal Roll-On / Roll-Off Platform Challenge #3: Access via work floats
97 South Locust Point Marine Terminal Roll-On / Roll-Off Platform Challenge #4: Coordination with other trades Crane
98 South Locust Point Marine Terminal Roll-On / Roll-Off Platform Challenge #5: Employee safety Water danger Wind / Waves Boat wakes Rising tides Enclosed space
99 South Locust Point Marine Terminal Roll-On / Roll-Off Platform Change of Scope: Concrete repair performed per ICRI guidelines
100 South Locust Point Marine Terminal Roll-On / Roll-Off Platform CFRP Termination Detail NSM CFRP Rods 1 2 Concrete Pile Cap CFRP Fabric U Wrap
101 South Locust Point Marine Terminal Roll-On / Roll-Off Platform Completed CFRP Strengthening
102 South Locust Point Marine Terminal Roll-On / Roll-Off Platform Completed Platform Ready for Cargo
103 Why do we love core drills?
104 - They keep us in business
105 - They challenge us.
106 - They make us laugh..
107 Penetrations and the Core Drill Shortest distance between 2 points is a straight line
108 Process for New Slab Penetrations Variables- Quantity of bars cut and size of Hole
109 New Penetrations Column strip
110 New Penetrations
111 Internal & External Post Tensioning
112 External Post Tensioning NEW LOAD F TENSION Live end Dead end F Uplift at Deviator
113 Flexural Strengthening Case Study Environmental Overload US Census Bureau HQ Suitland, MD.
114 Flexural Strengthening Case Study Environmental Overload
115 Flexural Strengthening Case Study Environmental Overload Tension Tension YIELD
116 Flexural Strengthening Case Study Environmental Overload
117 Flexural Strengthening Case Study Environmental Overload ¼ Amplitude Form & Pump
118 Flexural Strengthening Case Study Environmental Overload Dowel Hole Drilling High Pressure Water Blasting Dowel Insertion
119 Flexural Strengthening Case Study Environmental Overload
120 Flexural Strengthening Case Study Environmental Overload
121 Flexural Strengthening Case Study Environmental Overload
122 Flexural Strengthening Case Study Environmental Overload
123 Flexural Strengthening Case Study Environmental Overload
124 Flexural Strengthening Case Study Environmental Overload 43
125 Internal PT Drill PT
126 Higher Loads on 2T- Load Path
127 Heat Resistant Tendon Polyethylene Sheathing Polyethylene Sheathing 270k P.T.Strand Intumescent Fire Retardant Coating Grease
128 Higher Truck Loads- Ext. PT & Overlay Anchorage pin External PT Deviator
129 Higher Truck Loads- Ext. PT & Overlay
130 Higher Truck Loads- Ext. PT & Overlay
131 Higher Truck Loads- Ext. PT & Overlay
132 Higher Truck Loads- Ext. PT & Overlay Deviator
133 Higher Truck Loads- Ext. PT & Overlay Center Z Anchor
134 Higher Truck Loads- Ext. PT & Overlay Anchorage pin External PT Deviator
135 Section Enlargement & Supplemental Beams
136 East Coast Ski Resort Transfer Slab Upgrade
137 Transfer Slab Cracking
138 Foundation & Column Enlargements
139 Foundation & Column Enlargements 18 Column Enlargements
140 Demo and Prep PAM Machine in Action
141 Supplemental Beam-Column Connection
142 Mechanical Anchoring and Reinforcement Cage 3000 Hilti Studs 2000 Undercut Anchors
143 Through-Bars at Column Head
144 SCC Pumping Anyone??? 40 Tons of Steel 1100 LF
145 Enlargement Prep & Placement Existing New
146 Finished Product 185 CU YDS / 375 Tons of Concrete
147 Finished Product
148 Finished Product
149 Repair, Upgrade and Strengthening Process Repair, Upgrade and Strengthening Process Existing Capacity New Demand Engineering Material Science Test/Verification Constructability Aesthetics Economics
150 Repair and Strengthening Process Existing Capacity New Demand Engineering Material Science Test/Verification Constructability Aesthetics Economics Reverse Engineer
151 Concluding Remarks THANK YOU! Contracting Services Preliminary Design and Estimate Support D/B Capabilities Optimizing Repairs Load Testing Comprehensus
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