Strengthening and Repair of Reinforced Concrete Structures Ian Wienholt Business Development Manager
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
Structural Group delivers services, systems and technologies that build, repair, protect, strengthen and reinforce concrete, steel, masonry, wood, timber and soils.
Concrete Repair & Waterproofing
Masonry Restoration
Building Envelope Group: Historic Division
Building Envelope Group: Multi-Family Division
Concrete Repair Services Construction Defects Missing Reinforcement Honeycombs
General Repair Group: Strengthening Division
Agenda Strengthening Case Studies CFRP & NSM Rod External / Internal PT Section Enlargement / Supplemental Beams
CFRP & NSM
Externally Bonded FRP Sheet 550,000 psi Tensile 10x that of steel Lightweight Does NOT corrode
FRP Design Guidelines 440.2R-02 440.2R-08 ACI 440.2R-08 Emerging Technology To Date: Nationwide 15-18M sqft installed SPS 7M sqft installed on over 700 + projects
FRP Materials SEM Image of FRP Resin Fiber
What Is FRP Flexural Strengthened R/C? Yield Tension Steel Positive Moment FRP carries TENSION
What Is FRP Flexural Strengthened R/C? FRP carries TENSION Tension Negative Moment TOP Yield Steel Concrete carries COMPRESSION BOTTOM Column Compression
What Is FRP Shear Strengthened R/C? SHEAR
CFRP Installation Step 1 Surface Grinding / Shot Blasting to open pores
CFRP Installation Step 2 VE primer
CFRP Installation Step 3 VE putty
CFRP Installation Step 4 VE tack coat
Carter Ave Bridge Upgrade Tack coat QC
CFRP Installation Step 5 CFRP saturator
CFRP Installation Step 6 CFRP sheet lay up
CFRP Installation Step 7 Embedding of CFRP in tack coat
CFRP Installation Step 8 Rib rolling
CFRP Installation Completed Finished CFRP- Top, Sides, Bottom
Carter Ave Bridge Upgrade
Carter Ave Bridge Upgrade Acrylic / Intumescent Topcoat installation
CFRP Finished Product
Supplemental Strengthening ONLY w/frp! FRP? 2 4
Supplemental Strengthening ONLY w/frp!
CFRP Interfacial Shear Failure
FRP Plates
FRP Rods
Flexural Strengthening Case Study FRP Rod Installation
Parking Garage Ramp
Parking Garage Ramp FRP Sheet
NSM Rods Parking Garage Ramp
Damaged Double T Dropped 2T in Parking Garage
Shear upgrade of 2T stem with FRP
Flexural Detailing Guidelines Step plies U Wrap
Quality Control Field Application
Quality Control- Cure Test Cups Daily 1Gal. BA Pour off sample To verify cure
Sounding and Bond Tests Puck Ping ` Tap test or other Pull test
Sounding 6
Witness Panels for Testing
Pull off Bond Test Min. 200psi
Locate Bond Test Dollies outside work area or on an additional piece of FRP
Locate Bond Test Dollies outside work area or on an additional piece of FRP Ear plug to protect threads
Frequency for Pull Testing 1 PULL PER INSTALLATION DAY MINIMUM OR PER ENGINEER S SPEC (per sqft installed)
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
Repair Procedure
Repair Procedure Step 2 - Remove Composite Material If greater than 4sq. In. grind or sawcut area
Repair Procedure Step 3 - Prepare Lap Area Minimum repair lap = 6 inches 6
New Loads or low strength concrete
CFRP Column Confinement Increased: Axial Capacity Buckling Resistance Bomb Blast Resistance
General Concept
Structural Upgrade Resorts Casino- Atlantic City
Structural Upgrade Resorts Casino- Atlantic City
Structural Upgrade-Buckling Resistance Resorts Casino- Atlantic City
Structural Upgrade Resorts Casino- Atlantic City
Blast Mitigation for Columns Truck bomb at curbside
Blast Mitigation for Columns Truck bomb at curbside No FRP
Blast Mitigation for Columns Truck bomb at curbside No FRP
Blast Mitigation for Columns Truck bomb at curbside
Guggenheim Museum NYC 1959
Guggenheim Museum NYC
Guggenheim Museum NYC
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
Original Construction Photo Circa 1957
Destructive testing to open crack
Rebar Discontinuous Steel T-Section
Original Construction Photos
Guggenheim Museum
Guggenheim Museum- Analysis & Monitoring Circumferential Forces Vertical Forces
Initial repair concept FRP
Steel brackets b/n web walls Bond Grout
Double Barrier Walls Museum remained open!
Surface Preparation 8,000 psi 1,674,345,869 Diamond Cup Wheels Used!
Extensive Crack Repair Required
Rout & Seal vs. Epoxy Injection
CFRP Installation
Web Wall Brackets
Gunite wall to apron slab bracket FRP Bracket
Apron bracket Stainless Steel Grout
Shear transfer plate across cracks
Completed repair prior to insulation and drywall
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
South Locust Point Marine Terminal Roll-On / Roll-Off Platform Challenge #1: Time Critical Schedule
South Locust Point Marine Terminal Roll-On / Roll-Off Platform Challenge #2: Weather conditions
South Locust Point Marine Terminal Roll-On / Roll-Off Platform Challenge #3: Access via work floats
South Locust Point Marine Terminal Roll-On / Roll-Off Platform Challenge #4: Coordination with other trades Crane
South Locust Point Marine Terminal Roll-On / Roll-Off Platform Challenge #5: Employee safety Water danger Wind / Waves Boat wakes Rising tides Enclosed space
South Locust Point Marine Terminal Roll-On / Roll-Off Platform Change of Scope: Concrete repair performed per ICRI guidelines
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
South Locust Point Marine Terminal Roll-On / Roll-Off Platform Completed CFRP Strengthening
South Locust Point Marine Terminal Roll-On / Roll-Off Platform Completed Platform Ready for Cargo
Why do we love core drills?
- They keep us in business
- They challenge us.
- They make us laugh..
Penetrations and the Core Drill Shortest distance between 2 points is a straight line
Process for New Slab Penetrations Variables- Quantity of bars cut and size of Hole
New Penetrations Column strip
New Penetrations
Internal & External Post Tensioning
External Post Tensioning NEW LOAD F TENSION Live end Dead end F Uplift at Deviator
Flexural Strengthening Case Study Environmental Overload US Census Bureau HQ Suitland, MD.
Flexural Strengthening Case Study Environmental Overload 4-6 30
Flexural Strengthening Case Study Environmental Overload Tension Tension YIELD
Flexural Strengthening Case Study Environmental Overload
Flexural Strengthening Case Study Environmental Overload ¼ Amplitude Form & Pump
Flexural Strengthening Case Study Environmental Overload Dowel Hole Drilling High Pressure Water Blasting Dowel Insertion
Flexural Strengthening Case Study Environmental Overload
Flexural Strengthening Case Study Environmental Overload
Flexural Strengthening Case Study Environmental Overload
Flexural Strengthening Case Study Environmental Overload
Flexural Strengthening Case Study Environmental Overload
Flexural Strengthening Case Study Environmental Overload 43
Internal PT Drill PT
Higher Loads on 2T- Load Path
Heat Resistant Tendon Polyethylene Sheathing Polyethylene Sheathing 270k P.T.Strand Intumescent Fire Retardant Coating Grease
Higher Truck Loads- Ext. PT & Overlay Anchorage pin External PT Deviator
Higher Truck Loads- Ext. PT & Overlay
Higher Truck Loads- Ext. PT & Overlay
Higher Truck Loads- Ext. PT & Overlay
Higher Truck Loads- Ext. PT & Overlay Deviator
Higher Truck Loads- Ext. PT & Overlay Center Z Anchor
Higher Truck Loads- Ext. PT & Overlay Anchorage pin External PT Deviator
Section Enlargement & Supplemental Beams
East Coast Ski Resort Transfer Slab Upgrade
Transfer Slab Cracking
Foundation & Column Enlargements
Foundation & Column Enlargements 18 Column Enlargements
Demo and Prep PAM Machine in Action
Supplemental Beam-Column Connection
Mechanical Anchoring and Reinforcement Cage 3000 Hilti Studs 2000 Undercut Anchors
Through-Bars at Column Head
SCC Pumping Anyone??? 40 Tons of Steel 1100 LF
Enlargement Prep & Placement Existing New
Finished Product 185 CU YDS / 375 Tons of Concrete
Finished Product
Finished Product
Repair, Upgrade and Strengthening Process Repair, Upgrade and Strengthening Process Existing Capacity New Demand Engineering Material Science Test/Verification Constructability Aesthetics Economics
Repair and Strengthening Process Existing Capacity New Demand Engineering Material Science Test/Verification Constructability Aesthetics Economics Reverse Engineer
Concluding Remarks THANK YOU! Contracting Services Preliminary Design and Estimate Support D/B Capabilities Optimizing Repairs Load Testing Comprehensus