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-- -- S k S k Annual Concrete Seminar 2009 Annual Concrete Seminar 2009 Concrete for Repairs in Existing Buildings Concrete for Repairs in Existing Buildings -- -- Concrete for Achieving a Sustainable Environment Concrete for Achieving a Sustainable Environment Concrete for Repairs in Existing Buildings Concrete for Repairs in Existing Buildings an Integrated Development Approach an Integrated Development Approach Speakers: Speakers: Introduction & Part I Introduction & Part I ………………………… ………………………….. Ir K.C. Lau .. Ir K.C. Lau Part IIa Part IIa ……………………… ……………………….…………………… …………………… Ir K.C. Lau Ir K.C. Lau 1 Part IIb Part IIb ……………………………… ……………………………….…………… …………… Ir W.B. Chan Ir W.B. Chan
Transcript
Page 1: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

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S kS k

Annual Concrete Seminar 2009Annual Concrete Seminar 2009

Concrete for Repairs in Existing BuildingsConcrete for Repairs in Existing Buildings ----

Concrete for Achieving a Sustainable EnvironmentConcrete for Achieving a Sustainable Environment

Concrete for Repairs in Existing BuildingsConcrete for Repairs in Existing Buildings an Integrated Development Approachan Integrated Development Approach

Speakers:Speakers:

Introduction & Part IIntroduction & Part I …………………………………………………….. Ir K.C. Lau.. Ir K.C. Lau

Part IIaPart IIa ………………………………………………..………………………………………… Ir K.C. LauIr K.C. Lau

11

Part IIbPart IIb ………………………………………………………………..………………………… Ir W.B. ChanIr W.B. Chan

Page 2: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

e e a e a an appe e a e a an app

qq

i i i d i fi i i d i f

in a in a

Integrated Development ApproachIntegrated Development ApproachIntroductionIntegrated Development ApproachIntegrated Development Approach In the process of our structural related repair works forIn the process of our structural related repair works for

isting b ildings dopting oach ofisting b ildings dopting oach of

Introduction

¾¾ with thewith the industries experts & specialistsindustries experts & specialists

existing buildings, we are adopting an approach ofexisting buildings, we are adopting an approach of integratingintegrating::

industries ¾¾ with thewith the industries, experts & specialistsindustries, experts & specialists zz in researching, developing and introducing newin researching, developing and introducing new

construction techniques and materialsconstruction techniques and materials

industries

zz in achieving effective and economic ways to sustainin achieving effective and economic ways to sustain our buildingsour buildings

zz incorporating our experiences and views ofincorporating our experiences and views of stakeholdersstakeholders

zz in creating a peoplein creating a people--oriented, continuously improving,oriented, continuously improving,

22

creating peoplecreating people oriented, continuously improving,oriented, continuously improving,safe, comfortable and healthy living environment thatsafe, comfortable and healthy living environment thatcan meet our tenants’ needscan meet our tenants’ needs

Page 3: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

CSIPCSIP

qq

ii

Integrated DevelopmentIntegrated Development ProcessProcess identify needs,identify needs,

defects & constraintsdefects & constraints

Integrated DevelopmentIntegrated Development ProcessProcess

formulateformulate requirementsrequirements

implementationimplementationour CSIPour CSIP

develop repairdevelop repair methodsmethods

ourour

IndustriesIndustries

HousingHousingspecificationsspecifications

laboratorylaboratory trials & teststrials & tests

technicaltechnical ourour

industryindustry expertsexperts

TrialsTrials & Tests& Tests

trials & teststrials & tests

simulation trialssimulation trials

reviewsreviewsourour DrDr our SEsour SEs

33 onon--sitesite

actual trialsactual trials

our Drour Dr & SSEs& SSEs

Page 4: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

----

Concrete for Repairs in Existing BuildingsConcrete for Repairs in Existing Buildings ----Concrete for RepairsConcrete for Repairs Existing BuildingsExisting BuildingsConcrete for Repairs in Existing BuildingsConcrete for Repairs in Existing Buildingsan Integrated Development Approachan Integrated Development Approach

Concrete for RepairsConcrete for Repairs Existing BuildingsExisting Buildings an Integrated Development Approachan Integrated Development Approach

-- development of thedevelopment of the HPCHPC

-- problemsproblems to be resolved for sustainabilityto be resolved for sustainabilityproblemsproblems to be resolved for sustainabilityto be resolved for sustainability

44

-- solutionssolutions jointly developed with the industriesjointly developed with the industries

Page 5: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

----

Part I

Concrete for Repairs in Existing BuildingsConcrete for Repairs in Existing Buildings ----Concrete for RepairsConcrete for RepairsConcrete for Repairs in Existing BuildingsConcrete for Repairs in Existing Buildings an Integrated Development Approachan Integrated Development Approach

Concrete for RepairsConcrete for Repairs

-- development of thedevelopment of the HPCHPC

55

Page 6: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

…itit sttartts from our needsneeds…

HPCHPCHPCHPC High Performance ConcreteHigh Performance Concrete

66

Page 7: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

t th

Our needs HPCOur needs HPCOur needs HPCOur needs HPC high

flow ability

compaction not needed

low long-term

shrinkage

our needs

strength achieved quickly drying

shrinkage crack free

good

high bond strength

77 low elastic modulus

g impermeabilit

y to water

Page 8: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

our HPCour HPCour HPCour HPC major types using currently by Housing Department:major types using currently by Housing Department:

CC (f f )(f f )¾¾ HPCHPC –– F (for floor)F (for floor) ¾¾ HPCHPC –– C (for ceiling)C (for ceiling)( g)( g)

a kind of thea kind of the PMCPMC amongst the followingamongst the followinga kind of thea kind of the PMCPMC amongst theamongst followingthe following concrete using polymers:concrete using polymers:

•• Polymer Impregnated ConcretePolymer Impregnated Concrete -- PICPICPolymer Impregnated ConcretePolymer Impregnated Concrete PICPIC •• Polymer ConcretePolymer Concrete -- PCPC •• Polymer Portland Cement Concrete /Polymer Portland Cement Concrete /

88

Polymer Portland Cement Concrete /Polymer Portland Cement Concrete / Polymer Modified ConcretePolymer Modified Concrete -- PPCC /PPCC / PMCPMC

Page 9: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Housing Department: HPCHousing Department: HPC Performance SpecificationsPerformance Specifications

Properties Requirements 1.5 hr. Comp. Strength > 5 MPa for HPC-F

28-day Comp. Strength > 30 MPa (HPC-F) > 20 MPa (HPC C)> 20 MPa (HPC-C)

Initial Setting Time < 40 minutes (HPC-F) Long Term Shrinkage at 28-day < 0.015%

Coutinho Ring Test No Cracks Bond Test at 7-day > 1 MPa Water Absorption < 2%

Modulus of Elasticity at 28-day < 25 Gpa Flow Test > 150 mm (HPC-C)

99

Flow Test 150 mm (HPC C) Maximum Chloride Content < 0.35%

Page 10: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

t t

Hi h Adh i Mi i i R b d

Key Ingredients in the HPCKey Ingredients in the HPC hi h S ifi i R ihi h S ifi i R ito achieve the Specification Requirementsto achieve the Specification Requirements

Requirements Additives UsedAdditives UsedRequirements Additives UsedAdditives Used

Fast Initial Setting Time & 1.5 hr. Comp. Strength (for HPC-Early Strength Only) (1) Chloride Free Mineral Accelerator(1) Chloride Free Mineral Accelerator

Low Long Term Shrinkage (2) Mineral Shrinkage Reducing Agent(2) Mineral Shrinkage Reducing Agent

Crack Control (Coutinho Ring Test) (3) Micro(3) Micro--CelluloseCelluloseCrack Control (Coutinho Ring Test) (3) Micro(3) Micro CelluloseCellulose

High Bond Strength; Low Water Absorption & Elastic Modulus compatible

ld (4) Redispersible Emulsion Powder(4) Redispersible Emulsion Powder

to old concrete High Flow Workability

(for HPC-Early Strength Only) (5) Polycarboxylate High Range Water(5) Polycarboxylate High Range Water

Reducing AgentReducing Agent (6) R l i l Hi h D f Hi h(6) R l i l Hi h D f Hi h

1010

High Adhesion to Minimize Rebound Loss when Spray (for HPC-Spray Only)

(6) Relatively High Dosage of High(6) Relatively High Dosage of High Viscosity Cellulose EtherViscosity Cellulose Ether

Page 11: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

for concrete for concrete

t tt t

Effects of Special Additives in HPCEffects of Special Additives in HPC--FF

(1)(1) Chloride Free Mineral AcceleratorChloride Free Mineral Accelerator:: ¾¾ Accelerate the hydration process of cement and thus ableAccelerate the hydration process of cement and thus able¾¾ Accelerate the hydration process of cement and thus ableAccelerate the hydration process of cement and thus able

to achieve the requiredto achieve the required early strengthearly strength

Possible Side Effect:Possible Side Effect: ¾¾ Fast workability loss (facilitate with mechanicalFast workability loss (facilitate with mechanical

equipment for concrete placing)equipment for concrete placing)equipment placing)equipment placing) ¾¾ Fast development of heat of hydration (not a problem forFast development of heat of hydration (not a problem for

thin section structures less than 500 mm)thin section structures less than 500 mm) ¾¾ I h ibilit f h i k ki ( dI h ibilit f h i k ki ( d¾¾ Increase the possibility of shrinkage cracking (preventedIncrease the possibility of shrinkage cracking (prevented

by adding Cellulose Ether)by adding Cellulose Ether)

1111

Page 12: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

gg (( ))

))

⋅⋅

⋅⋅

⋅⋅ ⋅⋅ ⋅⋅

⋅⋅ ⋅⋅ ⋅⋅ ⋅⋅

⋅⋅ ⋅⋅⋅⋅ ⋅⋅

Mechanism of the Accelerator to develop theMechanism of the Accelerator to develop the early strengthearly strength of concreteof concreteearly strengthearly strength of concreteof concrete

¾¾ Main Ingredient: AlMain Ingredient: Al22(SO(SO44))3322 44 33

¾¾ Mechanism: It increases the SOMechanism: It increases the SO44 --22 content in the paste and reacts very fast withcontent in the paste and reacts very fast with

the Althe Al22OO33, CaO & CaSO, CaO & CaSO44 in Portland Cement to form Cin Portland Cement to form C33A (tricalciumA (tricalcium aluminate: 3CaO.Alaluminate: 3CaO.Al22OO33)) 22 33

¾¾ AlAl22(SO(SO44))33 + 3CaO + 5H+ 3CaO + 5H22O

3CaSO

O

3CaSO

44 2H2H22O + 2Al(OH)O + 2Al(OH)22

¾¾ Al(OH)Al(OH)22 + NaO

NaAlO2

+ NaO

NaAlO2

HH22OO

¾¾ 2NaAlO22NaAlO2 HH22O + 3CaO + 6H2O

3CaO

O + 3CaO + 6H2O

3CaO

AlAl22OO33 6H6H22O + 2NaOHO + 2NaOH

¾¾ 3CaO3CaO AlAl22OO33 6H6H22O + 3CaSOO + 3CaSO44HH22O + 25 HO + 25 H22OO CC33AA 3CaSO3CaSO44 31H31H22OO

¾¾ The CThe C33A content helps increasing the early strength of concrete (also evolvesA content helps increasing the early strength of concrete (also evolves heat during hydration)heat during hydration)

1212

CC33S (tricalcium silicate 3CaOS (tricalcium silicate 3CaO SiOSiO22), C), C22S (Dicalcium Silicate 2CaOS (Dicalcium Silicate 2CaO SiOSiO22) & C) & C44AFAF Tetracalcium aluminoferrite 4CaOTetracalcium aluminoferrite 4CaO AlAl22OO33 FeFe22OO33 contribute concrete strength at a latercontribute concrete strength at a later stage.stage.

Page 13: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Effects of Special Additives in the HPCEffects of Special Additives in the HPC

(2)(2) Mineral Shrinkage Reducing AgentMineral Shrinkage Reducing Agent:: ¾¾ reduce long term dryingreduce long term drying shrinkageshrinkage byby ettringiteettringite¾¾ reduce long term dryingreduce long term drying shrinkageshrinkage byby ettringiteettringite

formation that, other than itsformation that, other than its slight expansion propertiesslight expansion properties in cement paste, grows into gel voids of hardenedin cement paste, grows into gel voids of hardened cement paste and reduce the hardeningcement paste and reduce the hardening shrinkageshrinkage andandcement paste and reduce the hardeningcement paste and reduce the hardening shrinkageshrinkage andand dryingdrying shrinkageshrinkage..

¾¾ reduce heat of hydrationreduce heat of hydration

Possible Side Effect:Possible Side Effect: ¾¾ Prolonged setting time (compensated by adjustingProlonged setting time (compensated by adjusting¾¾ Prolonged setting time (compensated by adjustingProlonged setting time (compensated by adjusting

dosage of the Mineral Accelerator)dosage of the Mineral Accelerator)

1313

Page 14: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

MechanismMechanism (pictorially)(pictorially)MechanismMechanism (pictorially)(pictorially) MinerMineraal Shrinkagel Shrinkage RReeducing Agentducing Agent

space in cement pastespace in cement pastematrixmatrix

calciumcalcium withwith ingringredientsedients && thethe freefree limelimewithwith ingringredientsedients && thethe freefree limelime agentagent …… rereaaccttiioonn aluminatealuminate CaOCaOoccurringoccurring 3CaO3CaO…… ⋅⋅ 33AlAl22OO33 ⋅⋅ CaSOCaSO44

…… etettringitringite fte foormation:rmation:

¾¾ filling up spacesfilling up spacesincluding vincluding vooids,ids, crcracksacks,,,, …… calciumcalciumcalciumcalciumslight expansionslight expansion waterwater¾¾

¾¾ rreesulting insulting in sulfatesulfateshrinkageshrinkage HH2200 CaCacompensationcompensation ⋅⋅ SSOO44

(eg. free(eg. free GypsumGypsum))

Microscopic Picture of Ettringite Crystal Formed 1414

Page 15: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

s e s o es s d o ocess e s ds e s o es s d o ocess e s d

aa

⋅⋅yy

⋅⋅

t tt t ⋅⋅ ⋅⋅

Mechanism of the Shrinkage Reducing AgentMechanism of the Shrinkage Reducing Agent

¾¾ main ingredient: crushed sintered compound ofmain ingredient: crushed sintered compound of calcium sulfo luminatecalcium sulfo luminatecalcium sulfo aluminatecalcium sulfo aluminate

¾¾ consisting mainly of three minerals:consisting mainly of three minerals: zz Hauyne: 3CaOHauyne: 3CaO ⋅⋅ 3Al3Al22OO33 CaSOCaSO4422 33 44

zz Free lime: CaOFree lime: CaO zz Free Gypsum: CaFree Gypsum: Ca SOSO44

¾¾ h d i f h i l d ih d i f h i l d i tt i ittt i it¾¾ hydration of these minerals producinghydration of these minerals producing ettringiteettringite (3CaO(3CaO AlAl22OO33 3CaSO3CaSO44 ⋅⋅ 32H32H22O) thatO) that zz is a very small crystal of several microns.is a very small crystal of several microns.zz is a very small crystal of several microns.is a very small crystal of several microns. zz grows into the voids of cement paste gels and reduces hardening shrinkagegrows into the voids of cement paste gels and reduces hardening shrinkage

of the gel and drying shrinkage.of the gel and drying shrinkage. zz has expansion properties in its hydration process (at early stage) andhas expansion properties in its hydration process (at early stage) and

1515

p p ope y p ( y ge)p p ope y p ( y ge) compensates also shrinkage in the HPC.compensates also shrinkage in the HPC.

Page 16: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

H O

Reactions leading toReactions leading to ettringiteettringite formationformation by the Shrinkage Reducing Agent in the HPCby the Shrinkage Reducing Agent in the HPC

CaSO4

H2Oagen

t

CaO

2

Ca(OH)2

duci

ng a

H2O

3CaO·3A12O3 · [3CaO・Al2O3・CaSO4・ 3CaO・Al2O3・

nkag

e re

d

CaSO4 H2O 12H2O-2{3CaO・Al2O3・

Ca(OH)2・12H2O}]

3CaSO4・32H2O

Ettringiteshrin

1616

Page 17: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

se ese e oo

C ll l E hC ll l E h f h HPCf h HPC F ll d d )F ll d d )

Effects of Special Additives in the HPCEffects of Special Additives in the HPC

(3)(3) MicroMicro--CelluloseCellulose:: ¾¾ increasingincreasing water retentionwater retention for hydration of the HPCfor hydration of the HPC¾¾ increasingincreasing water retentionwater retention for hydration of the HPC,for hydration of the HPC, ¾¾ reducing bleeding, segregation andreducing bleeding, segregation and plastic shrinkageplastic shrinkage ¾¾ modifying themodifying the viscosityviscosity (a relatively high dosage of high(a relatively high dosage of high

iscositiscosit Cell lose EtherCell lose Ether d in th HPCd in th HPC C tC t red ce rebo ndred ce rebo nd))

Possible Side Effect:Possible Side Effect: ¾¾ p the HPC

viscosityviscosity Cellulose EtherCellulose Ether usedu in the HPCsed in the HPC--C toC to reduce reboundreduce rebound))

rolonged setting time (forprolonged setting time (for the HPC--F: compensating byF: compensating byadjusting dosage of the mineral accelerator; for the HPCadjusting dosage of the mineral accelerator; for the HPC--C:C: allowing more time for finishing)allowing more time for finishing)

¾¾ slight air entrainment (controlling the dosage to preventslight air entrainment (controlling the dosage to preventexcessive air entrainment)excessive air entrainment)

¾¾ affecting flowability (for the HPCaffecting flowability (for the HPC--F: using a low viscosityF: using a low viscosity

1717

Cellulose EtherCellulose Ether; f; or the HPCfor the HPC--F: a controlled dosage)F: a controlled dosage)

Page 18: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Polymer Chain of Micro-Cellulose in HPC

H CH2OROR

OO

H

H

O

H

OO

H

O H HH

O

CH2OR OROR

xx R: H or CH3

The viscosity of the paste in concrete induced by the micro-cellulose and the van

1818

The viscosity of the paste in concrete induced by the micro cellulose and the van der Waals force of its long polymer chain exerted to the water ions restrict the water molecules from escaping from the concrete easily.

Page 19: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

:

t

Effects of Special Additives in the HPC

(4) Redispersible Emulsion Powder:(4) Redispersible Emulsion Powder enhance adhesive strength to existing concrete reduce water absorption of the HPCp increase flexibility of the HPC to achieve an elastic modulus compatible to existing old concrete

P ibl Sid EffPossible Side Effect: prolonged setting time (compensated by adjusting dosage of the mineral accelerator)

1919

adjusting dosage of the mineral accelerator)

Page 20: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Polymer Chain of Redispersible Emulsion Powder Ethylene Vi l hl id Vinyl laurate

H H H H H H

Ethylene Vinyl chloride Vinyl laurate

H

C C C C C C

H H H OCl m n

C

CH H

O m n

C

C

H H

H HContributes

Contributes

H x Contributes flexibility

water resistance

2020

Contributes water

resistance

Page 21: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

C ll l E h )C ll l E h )

Effects of Special Additives in HPC-F

(5) Polycarboxylate High Range Water Reducing Agent:Agent: largely reducing the mixing water required and loweringlargely reducing the mixing water required and lowering the W/C ratiothe W/C ratio providing high flowability for the HPCproviding high flowability for the HPC

Possible Side Effect: increased bleeding (compensated by addition of theincreased bleeding (compensated by addition of the Cellulose Ether)Cellulose Ether) prolonged workability retention and stiffening time of theprolonged workability retention and stiffening time of the HPC (compensated by the Mineral Accelerator)HPC (compensated by the Mineral Accelerator)

2121

HPC (compensated by the Mineral Accelerator)HPC (compensated by the Mineral Accelerator)

Page 22: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Polymer Structure of Polycarboxylate Admixture

known as the 3rd generation superplasticizer consisting of backbone based on poly-carboxylic salts or ether with grafted side chains of Ethylene Oxide (EO) and Propylene Oxide (PO). usually called EOPO copolymer, also called comb co-polymer

M l lMolecular Structure: 1RR 1 R 2 R 2

H C CH 2 C - CH 2 C - CH 2 H

NaSO 3 CO 32 R CO 32 R n m

O p

CHCH 2

CH 2

O q CH 3

2222

Page 23: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Mechanism (pictorially)Mechanism (pictorially)Mechanism (pictorially)Mechanism (pictorially) 1. EOPO (comb shape & negatively

Polycarboxylate High Range Water Reducing Agent in the HPCPolycarboxylate High Range Water Reducing Agent in the HPC

2. … and expelling each other

( p g y charged) copolymer adhering to cement particles …

each other …

cement

cement w

w

cementw

2323 3. … releasing water molecules

trapped … enhancing workability

Page 24: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

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Part IIPart IIaa

Concrete for Repairs in Existing BuildingsConcrete for Repairs in Existing Buildings ----Existing BuildingsExisting BuildingsConcrete for Repairs in Existing BuildingsConcrete for Repairs in Existing Buildingsan Integrated Development Approachan Integrated Development Approach

Existing BuildingsExisting Buildings

-- problemsproblems to be resolved for sustainabilityto be resolved for sustainabilityproblemsproblems to be resolved for sustainabilityto be resolved for sustainability

In the following two parts are two examples of the problems dealing with by using the HPC:

24242. slab ceiling2. slab ceiling 1. slab floor (Choi Hung Empty Bays)1. slab floor (Choi Hung Empty Bays)

Page 25: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Choi Hung EstateChoi Hung Estate High BlockHigh Block Empty BaysEmpty BaysEmpty BaysEmpty Bays

2525

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200 h b200 h b

Empty BaysEmpty BaysEmpty BaysEmpty Bays over 200 such baysover 200 such bays in Choi Hung Estatein Choi Hung Estate

2626

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Empty BayEmpty BayEmpty BayEmpty Bay

2727

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After rainingAfter rainingAfter rainingAfter raining ……

2828

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flats underneathflats underneath (l i )(l i )(less serious case, e.g. …)(less serious case, e.g. …)

SpallingSpallingSpallingSpalling

2929

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serious casesserious casesserious cases …serious cases …

3030

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causes of the defectcauses of the defect

yoyouunnggeerr layelayerr

older laolder layyeerr

delaminateddelaminated

3131

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R i & I tR i & I tRepair & ImprovementRepair & Improvement MethodsMethodsMethodsMethods

measures …measures …22

3232

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measure #measure # :: replace the grille blocks …replace the grille blocks …11measure #measure # :: replace the grille blocks …replace the grille blocks …11

BeforeBefore AfterAfter

3333

Page 34: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

50 thi k50 thi k max. 80 mmmax. 80 mm

measure #measure # :: slab & floor Improvementsslab & floor Improvements22

trafficabletrafficable

existingexisting floor screedfloor screed

trafficabletrafficable waterproofingwaterproofing spallingspalling toto

be repairedbe repairedhigh performancehigh performance concrete (concrete (HPCHPC))

HPCHPC max. 80 mmmax. 80 mm

floor

(( ))

max. 50 mm thickmax. 50 mm thick HPCHPC thick locallythick locally

concrete slab steel bar

existingexisting concrete slabconcrete slab

steel bar

3434 spalled concrete to bespalled concrete to be removed & repairedremoved & repaired

spalling being repairedspalling being repaired

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3535

EMAC & District Member ConsensusEMAC & District Member ConsensusEMAC & District Member ConsensusEMAC & District Member Consensus

Page 36: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

---- Concrete for Repairs in Existing BuildingsConcrete for Repairs in Existing Buildings ----Concrete for Repairs in Existing BuildingsConcrete for Repairs in Existing Buildings an Integrated Development Approachan Integrated Development Approachan Integrated Development Approachan Integrated Development Approach

3636

-- solutionssolutions jointly developed with the industriesjointly developed with the industries

Page 37: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Measure #Measure #22Measure #Measure #22

3737

Page 38: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

measure #measure #22 … a measure after completion… a measure after completion

f th #f th #11 ( i d ll)( i d ll)of the measure #of the measure #11 (windows on wall) …(windows on wall) …

3838previous situation after raining

Page 39: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

High Performance ConcreteHigh Performance Concrete (HPC)(HPC)(HPC)(HPC)

&& IdeasIdeas

3939

Page 40: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

resolution ideas

think

knowledge

technical meeting

presentations

g & experience

meetings studies

analysis consultations

4040

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pp p p p yp p p y

f ff ff ff f

ApplicationApplication CharacteristicsCharacteristicsApplicationApplication CharacteristicsCharacteristics

our basic ideas, requirements,our basic ideas, requirements,our basic ideas, requirements,our basic ideas, requirements, ……

¾¾ a prea pre--packed proprietary HPCpacked proprietary HPC ¾¾ for repair and patch up works like floors, toilet infill andfor repair and patch up works like floors, toilet infill and

similar applications for old buildingssimilar applications for old buildings ¾¾ allows early foot traffic after applicationallows early foot traffic after application ¾¾ high early strength within an hour of time … fasthigh early strength within an hour of time … fast

application early opening to public allowing foot trafficapplication early opening to public allowing foot trafficapplication … early opening to public allowing foot trafficapplication … early opening to public allowing foot traffic ¾¾ flowable consistency for efficient placingflowable consistency for efficient placing

4141

Page 42: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

ow waterow water

MaterialMaterial CharacteristicsCharacteristicsMaterialMaterial CharacteristicsCharacteristics our basic ideas, requirements,our basic ideas, requirements, ……

¾¾ premixed in factorypremixed in factory ¾¾ easy handling and storageeasy handling and storage ¾¾ high flowabilityhigh flowability ¾¾ high workabilityhigh workability ¾¾ fast settingfast setting¾¾ fast settingfast setting ¾¾ high early strengthhigh early strength ¾¾ extremely low shrinkageextremely low shrinkage ¾¾ extremely l absorptionextremely l absorption

…. Specifications

¾¾ extremely low water absorptionextremely low water absorption ¾¾ high adhesion strengthhigh adhesion strength ¾¾ similar elastic modulus with old concretesimilar elastic modulus with old concrete

4242

Page 43: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

p yp y

Fast SetFast Set

HPCHPCHPCHPC High Flow AbilityHigh Flow Ability

Low Water AbsorptionLow Water Absorption Compatible Modulus of ElasticityCompatible Modulus of Elasticity contradictorycontradictory

Low ShrinkageLow Shrinkage Fast SetFast Set

parameters/requirementsparameters/requirements

……

Ideas + Techniques + Efforts + MethodsIdeas + Techniques + Efforts + Methods to accomplishto accomplish

4343

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TrialTrial MixesMixes && TestsTestsTrialTrial MixesMixes && TestsTests

4444

Page 45: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

the HPC raw materialsthe HPC raw materialsthe HPC raw materialsthe HPC raw materials

4545

Page 46: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

laboratory trial mixlaboratory trial mixlaboratory trial mixlaboratory trial mix

4646

Page 47: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

some of the testssome of the testssome of the testssome of the tests

4747

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samples for testssamples for testssamples for testssamples for tests

4848

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Simulation TrialsSimulation TrialsSimulation TrialsSimulation Trials

4949

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prototype panel for trialprototype panel for trialprototype panel for trialprototype panel for trial

5050

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level marks for concretinglevel marks for concretinglevel marks for concretinglevel marks for concreting

5151

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the HPC raw materialsthe HPC raw materialsthe HPC raw materialsthe HPC raw materials

5252

Page 53: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

mixer used in initial trialsmixer used in initial trialsmixer used in initial trialsmixer used in initial trials

5353

Page 54: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

water quantity measurementwater quantity measurementwater quantity measurementwater quantity measurement

5454

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mixing trialmixing trialmixing trialmixing trial

5555

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mixingmixingmixingmixing

5656

Page 57: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

HPC deliveryHPC deliveryHPC deliveryHPC delivery

5757

Page 58: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

transportation trialtransportation trialtransportation trialtransportation trial

5858

Page 59: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

transportation trialtransportation trialtransportation trialtransportation trial

5959

Page 60: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

concretingconcretingconcretingconcreting

6060

Page 61: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

flowing & leveling trialflowing & leveling trialflowing & leveling trialflowing & leveling trial

6161

Page 62: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

flowing & leveling trialflowing & leveling trialflowing & leveling trialflowing & leveling trial

6262

Page 63: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

--

finishingfinishingfinishing …finishing …

…… adjusted subsequently:adjusted subsequently:

•• the initialthe initial--set from 40 to 60 minutesset from 40 to 60 minutes

6363

•• the initialthe initial set from 40 to 60 minutesset from 40 to 60 minutes

•• the 5 MPa strength development from 1 hr. to 1.5 hr.the 5 MPa strength development from 1 hr. to 1.5 hr.

Page 64: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

finally a new HPC was bornfinally a new HPC was bornfinally ... a new HPC was bornfinally ... a new HPC was born

t ith it h t i ti d itt ith it h t i ti d it 6464

to cope with its characteristics and siteto cope with its characteristics and site constraints, we developed …constraints, we developed …

Page 65: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

… mechanical device for multi uses in many… mechanical device for multi uses in many such similar bays and public areas …such similar bays and public areas …

6565

Page 66: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

e t oduced a ot e ee t oduced a ot e e

… we introduced another mixer …… we introduced another mixer …

for Choi Hungfor Choi Hung empty baysempty bays

in lieu of the mixer tried initiallyin lieu of the mixer tried initially

6666

Page 67: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

controllerscontrollersmixer adopted for Empty Bays inmixer adopted for Empty Bays in controllerscontrollersChoi Hung EstateChoi Hung Estate

Needle Valve Mixing

Water to Mixing Tube

Mixing Tube

Water Flow Meter

Water Inlet

6767Electric Valve Water Pressure

Gauge Pressure ReducerHPC

Outlet

Page 68: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

6868

material mixing proportionmaterial mixing proportion l &l &controls & testscontrols & tests

Page 69: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

saw blade

mixing & concretingmixing & concretingmixing & concretingmixing & concreting onon--site actual trialsite actual trial

6969

Page 70: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

mechanized sweepingmechanized sweepingmechanized sweepingmechanized sweeping onon--site actual trialsite actual trial

7070

Page 71: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

level sweeping nearly finishedlevel sweeping nearly finishedlevel sweeping nearly finishedlevel sweeping nearly finished onon--site actual trialsite actual trial

7171

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7272

Page 73: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Trafficable WaterproofingTrafficable Waterproofing

on Top of the HPCon Top of the HPCon Top of the HPCon Top of the HPC

7373

Page 74: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

waterproofing finishes newly completedwaterproofing finishes newly completedwaterproofing finishes newly completedwaterproofing finishes newly completed

7474

Page 75: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

floor completed wall paintingfloor completed wall paintingfloor completed …wall painting…floor completed …wall painting…

7575

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completed internallycompleted internallycompleted internallycompleted internally

7676

Page 77: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

well received with appreciationwell received with appreciation l & f ll d b ‘fi ’ h bl & f ll d b ‘fi ’ h bclaps & followed by ‘first’ thumbsclaps & followed by ‘first’ thumbs

7777

Page 78: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

----

Part IIPart IIaa

Concrete for Repairs in Existing BuildingsConcrete for Repairs in Existing Buildings ----Existing BuildingsExisting BuildingsConcrete for Repairs in Existing BuildingsConcrete for Repairs in Existing Buildingsan Integrated Development Approachan Integrated Development Approach

Existing BuildingsExisting Buildings

-- problemsproblems to be resolved for sustainabilityto be resolved for sustainabilityproblemsproblems to be resolved for sustainabilityto be resolved for sustainability

In the following two parts are two examples of the problems dealing with by using the HPC:

78782. slab ceiling2. slab ceiling 1. slab floor (Choi Hung Empty Bays)1. slab floor (Choi Hung Empty Bays)

Page 79: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Occupied Flat

Slab SemiSlab Semi--recastingrecasting A CustomerA Customer--focused Slab Restoration Solutionfocused Slab Restoration Solution

Vacant Flat

7979

Page 80: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Slab SemiSlab Semi--recastingrecastingSlab SemiSlab Semi recastingrecasting

Structural restoration ofStructural restoration of adversely deteriorated slabsadversely deteriorated slabs

�� Extensive concrete spallingExtensive concrete spalling

�� Rebars badly corrodedRebars badly corroded

�� Serious chloride contaminationSerious chloride contamination

�� Structural integrity impairedStructural integrity impaired

8080

Page 81: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Flat aboveFlat above

Vacating my flat ? No way !!

???

FlatFlat aboveabove

Flat belowFlat below with ceilinwith ceilingg slab slabggbadly deterioratedbadly deteriorated

8181

Page 82: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Slab SemiSlab Semi--recastingrecastingSlab SemiSlab Semi recastingrecasting

ObjectivesObjectives;;

�� No decantation to the upper flatNo decantation to the upper flat�� No decantation to the upper flatNo decantation to the upper flat

�� Original slab thickness maintainedOriginal slab thickness maintained

�� Sustainable repairsSustainable repairs

�� Short field working timeShort field working time�� Short field working timeShort field working time

8282

Page 83: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Susta ab eSusta ab e

�� o r o s ars ao r o s ars a

��

L biliL bili

Slab SemiSlab Semi--recastingrecastingSlab SemiSlab Semi recastingrecasting

Technical requirements:Technical requirements:qq�� SafetySafety

T tal eplacement f lab bottom b ndT tal eplacement f lab bottom b nd�� Total replacement of slab bottom bars andTotal replacement of slab bottom bars and lower zone concretelower zone concrete Nuisance mitigationNuisance mitigation�� Nuisance mitigationNuisance mitigation

�� High performance sprayed concreteHigh performance sprayed concrete -- Low water permeabilityLow water permeability -- Compatible with old concreteCompatible with old concrete -- SustainableSustainable

8383

-- High workability and low reboundHigh workability and low rebound

Page 84: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Integrated Development Process

Housing Authority

Development ofDevelopment of Slab SemiSlab Semi­-recastingrecastingConcrete

Supplier

Tenants of Public Housing

Cutting &Spraying

Specialists

8484

Specialists

Page 85: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

b d lb d l

SawSaw--cutting and chipping forcutting and chipping for 3600

rebar and concrete removalrebar and concrete removal

2000

Slab to be semiSlab to be semi­-recastrecast

100

mm

�� Risk of overRisk of over--breakingbreaking Concrete and bottomConcrete and bottom bars to be removedbars to be removed

1

�� Noise and vibration nuisancesNoise and vibration nuisances bars to be removedbars to be removed

Solution:Solution:

SawSaw--cutting + chipping to form orthogonal grooves for :cutting + chipping to form orthogonal grooves for :­-�� Removal existing concrete and rebarsRemoval existing concrete and rebars

8585

�� Laying of new galvanized rebarsLaying of new galvanized rebars

Page 86: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Groove Cutting ExperienceGroove Cutting Experienceg pg p

Mounting problem;Mounting problem;

33--phase electricityphase electricity

600mm Hydraulic Saw-cutter

Grooves toGrooves to House newHouse new rebarsrebars y

11--phase electricity;phase electricity;

Not powerful enoughNot powerful enough

rebarsrebars

6” ceiling-mounted Saw-cutterNot powerful enoughNot powerful enough

8686 3” Saw-cutter

Page 87: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Noise MitigationNoise MitigationNoise MitigationNoise Mitigation SyntheticSynthetic

rubberrubberrubberrubber

Synthetic rubber noise barrier mat

StoneStoneStoneStone woolwool

Stone wool noise curtain

8787

Page 88: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

=

C ibili

t t

High Performance Sprayed ConcreteHigh Performance Sprayed ConcreteHigh Performance Sprayed ConcreteHigh Performance Sprayed Concrete

Requirements:

Compressive strength > 20 MPa at 28 days (original concrete = grade 20) Compatibility (original concrete grade 20)

Elasticity modulus < 25kN/mm2 at 28 days

Integrity Bond strength > 1 5 MPa at 28 daysIntegrity Bond strength > 1.5 MPa at 28 days

Low permeability Long term shrinkage < 0.015% at 28 days

C ti h i N k t 28 d Sustainability

Coutinho ring test No crack at 28 days

Water absorption < 2.0% at 28 days

W k bilit R b d d i i Mi i l

8888

Workability Rebound during spraying Minimal

Page 89: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Slab semiSlab semi--recastingrecasting

1st Trial1st Trial 2nd Trial

SaSa c tting pl sc tting pl s

3rd Trial

Refine grooveRefine groove Chipping forChipping for lower zonelower zone concrete removalconcrete removal

SawSaw--cutting pluscutting plus chipping forchipping for groove formationgroove formation

NuisanceNuisance

Refine grooveRefine groove formation techniqueformation technique

Improve concreteImprove concrete mixmix

8989

More nuisanceMore nuisance and higher riskand higher risk

NuisanceNuisance mitigation barriermitigation barrier addedadded

mixmix

Galvanized steelGalvanized steel usedused

Page 90: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Performance TestsPerformance TestsPerformance TestsPerformance Tests

Pull-offPull off test

Failure surfaceFailure surface at old concreteat old concrete

Rebar fullyRebar fully encapsulatedencapsulated Sand stockpile forSand stockpile for

load testload test Old/New concreteOld/New concrete

interfaceinterface

9090

(for trial case only)(for trial case only)

Page 91: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

ggSlab SemiSlab Semi--recasting Workflowrecasting Workflow

Falsework setupFalsework setup 0.5 day0.5 day

Concrete cuttingConcrete cutting 1 day1 day

Rebar fixingRebar fixing 1 day1 day

9191

Concrete sprayingConcrete spraying 0.5 day0.5 day

TowelingTowelingFinishFinish

Page 92: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

t tt t

Slab semiSlab semi--recastingrecastinggg

R lReal case Implementation in Jan 09

Flat aboveFlat above in Jan 09

Flat requiringFlat requiring llstructuralstructural

restoration ofrestoration of ceiling slabceiling slab

SlabSlab restorationrestoration completedcompleted

9292

Page 93: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Slab SemiSlab Semi--recastingrecastingSlab SemiSlab Semi recastingrecasting A CustomerA Customer--focused Slab Restoration Solutionfocused Slab Restoration Solution

The new method removes my worries of requiring me to move out

9393

Page 94: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

Thank YouThank YouThank YouThank You

9494

Page 95: Annual Concrete Seminar 2009Annual Concrete Seminar 2009 ...

th t t l b hi dth t t l b hi d

The American The American Concrete Concrete InstitutInstitute e (ACI): defines the HPC (ACI): defines the HPC asas concrete meetingconcrete meeting special combinations of special combinations of performance performance andand

ifif itit ii ttununififormormitity requy requiiremenrementtss ththaatt canno cannott a allways ways bbe ace achihieveevedd routinely routinely when using when using conventional constituents conventional constituents and and normalnormal mixing, placing mixing, placing and curing practices.and curing practices.

Related commentary Related commentary states: states: a HPC a HPC is one in which is one in which certaincertain characteristics characteristics are developed are developed for for a particular application a particular application andand environment. E.g. of characteristics are:environment. E.g. of characteristics are: ¾¾EaseEase ofof placementplacement¾¾EaseEase ofof placementplacement ¾¾Compaction without segregationCompaction without segregation ¾¾Early age strengthEarly age strength ¾¾LongLong--termterm mechanicalmechanical ppropertiesroperties¾¾LongLong termterm mechanicalmechanical propertiesproperties ¾¾PermeabilityPermeability ¾¾DensityDensity ¾¾Heat of hHeat of hyydrationdrationyy ¾¾TToughnessoughness ¾¾VVoolume stabilitylume stability ¾¾Long life in severe environmentsLong life in severe environments

9595


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