HONEY COMBS IN CONCRETE AND REMEDIES:

Explain the repair procedure for sealing of honey combed areas with cement
mortar.

MEANING:

Honeycombs are hollow spaces and cavities left in concrete mass on surface or inside
the concrete mass where concrete could not reach. These look like honey bees nest.

Honeycombs which are on sides are visible to naked eyes and can be detected easily
as soon shuttering is removed. Honey combs which are inside mass of concrete can
only be detected by advanced techniques like ultrasonic testing etc.

Honeycomb is due to non-reaching of concrete to all places due to which cavities and
hallow pockets are created.

REASONS:

1) Improper vibration during concrete.

2) Less cover to reinforcement bars.

3) Use of very stiff concrete (this can be avoided by controlling water as per slump test).

4) Places like junction of beam to beam to column and to one or more beams are the
typical spots where honey combs are observed. This is due to jumbling of reinforcement
of beams and column rods at one place.

5) Presence of more percentage of bigger size of aggregate in concrete also prevents

concrete to fill narrow spaces between the reinforcement rods.

REMEDIES FOR HONEYCOMBS IN CONCRETE:

Strictly speaking wherever honeycombs are observed, concrete should be broken and
the portion should be re concreted after applying grouting chemical to the old surface.
Honeycombs as a defect not only reduces the load bearing capacity but water finds an
easy way to reinforcement rods and rusting and corrosion starts. In case of honey
combs on surface pressure grouting with cement based chemicals which are non-
shrinkable can be adopted after taking opinion of the designer and acting as per his
advice.

At places of junction of columns and beams concrete with strictly 20mm and down
aggregates should be used with slightly more water and cement to avoid honeycombs.
Taping with wooden hammer the sides of shuttering from outs side during concreting
and vibrating will help minimizing honeycombs to a great extent in case of columns and
beams. Use of thinner needle say 25mm or less with vibrator at intricate places of
concreting will also help in reducing honey combs.

WHAT IS DRY PACK?

A specification requires us to use "dry pack" mortar to fill deep holes in a

concrete wall. What is dry pack mortar and how is it installed?

Dry pack mortar is a stiff sand-cement mortar that is typically used to repair small
areas that are deeper than they are wide. According to the Bureau of
Reclamation's Guide to Concrete Repair, dry pack mortar contains (by dry
volume or weight) one part cement, 2.5 parts sand, and enough water to produce
a mortar that will just stick together while being molded into a ball with the hands.
The ball should neither slump when placed on a flat surface, nor crumble due to
lack of moisture. Place dry pack mortar immediately after mixing it. Compact the
mortar in the hole by striking a hardwood dowel or stick with a hammer. The
sticks are usually about 8 to 12 inches long and no more than one inch in
diameter. Use a wooden stick instead of a metal one because metal tends to
polish the surface of the mortar, making bonding less certain and filling less
uniform. Place and pack the mortar in layers to a compacted thickness of about
3/8 inch. Direct the tamping at a slight angle toward the sides of the hole to
ensure maximum compaction in these areas. Overfill the hole slightly, then place
the flat side of a hardwood piece against the hole and strike it several times with
a hammer. If necessary, a few light strokes with a rag may improve its
appearance.
EPOXY INJECTION FOR REPAIR OF CRACKS:
One of the most versatile, problem solving products available in epoxy systems today is
Epoxy Injection Resin. Structural restoration of concrete by epoxy injection is very often
the only alternative to complete replacement. It therefore results in large cost savings.
Injection protects the rebar and stops water leakage.

Epoxy Injection Resin is a system for welding cracks back together. This welding
restores the original strength and loading originally designed into the concrete. Epoxy
injection restores the structural qualities the concrete design intended. In other words
under most conditions it makes the concrete as good as new. It creates an impervious
seal to air, water, chemicals, debris, and other contamination.

A crack, obviously, is a sign of failure caused by stresses, inadequate design, improper

curing, etc. One of the dangers of a structural crack is the effect that it has on the
reinforcing bar. The reinforcing represents one of the main structural values of the
concrete.

Cracks left unprepared allow moisture, road salts and other contaminants to penetrate
and attack the rebar. The rebar deteriorates, losing the structural value. Losing the
entire structure is often the result.

Epoxy injection resin has two purposes. First, it effectively seals the crack to prevent the
damaging moisture entry. Secondly, it monolithically welds the structure together. Most
people assume that this welding of the structure is the most important result of the
repair. Actually what is most important is the sealing.

The sealing property of the injection prevents premature deterioration of the reinforcing.
This can be of equal, or in some cases greater importance than the structural welding. It
would theoretically always be desirable to get this welding effect.

DURABILITY OF CONCRETE STRUCTURES

COATINGS FOR STEEL AND CONCRETE:

Concrete structures in aggressive environment (Marine / Industrial area), are subjected

to chloride attack. In order to protect concrete structures from chloride attack in
aggressive environment, it is necessary that protective coatings are applied to concrete
and steel both to prevent ingress of Chlorides.

Coatings for Steel:

The metallurgists and electrochemical engineers have developed several methods for
protection of steel from corrosion in concrete. The most commonly known systems of
protection of steel from corrosion in concrete are as listed below.

1) Use of Corrosion Resistance Steel Reinforcement Bars.

Cement-Polymer-Composite Coating System (New Method).
3) Fusion Bonded Epoxy Coated Re bars (FBECR).

1) Corrosion Resistant Steel Reinforcement Bars:

A number of manufacturers have come up with a new type of higher strength re-bars
which are claimed to be corrosion resistant. These bars have dual micro structures i.e.
the surface layer is tempered marten site while the inner shell is ductile ferrite-pearlite.
To increase corrosion resistance of these bars certain elements like nickel, chromium,
copper and phosphorus are also added. These bars form a protective layers on the
surface when they come in contact with atmospheric oxygen and moisture. This layer is
formed over a period of time. In concrete oxygen is not available. Hence, the protective
coating may not form when such bars are used as reinforcement in concrete. Obviously,
there appears to be no advantage in using such bars in place of mild steel. Even, when
exposed to atmosphere in marine environment the chlorides present in the air break the
protective layer thereby reducing corrosion resistance. Therefore, in marine atmosphere
these bars do not give good resistance to corrosion as in normal atmosphere. Secondly,
their chemical composition is such that it may lead to pitting corrosion which is highly
undesirable. In mild steel bars conforming to IS:1786, although is less corrosion
resistance, but corrosion occurs all over the surface without pitting.

2) Cement-polymer composite coating system (CPCC):

This is a new method developed by CECRI. This system has been developed to
overcome demerits of inhibited cement slurry coating system.

This system consists application of one coat of rapid setting primer followed by a coat of
cement polymer sealing product. The primer and sealing products have thermoplastic
acrylic resin as basic raw material. Sealing product is formulated with resin mixed with
cement as a pigments. Rapid setting primer and sealing coats both are patented item.
This system has been developed mainly as a factory / shop process. The approach
behind development of this system is that the base metal of re-bars, contains 
electrons which get readily released in corrosive environment leading to oxidation of
iron and thereby formation of Fe2O3 (rust) as principal deterrent. In order to prevent this
oxidation a surface coating capable of interacting/nullifying the released electrons is
provided. Further prestressing and reinforcing steel, in concrete during service life, are
exposed to an alkaline environment and this necessitates introductions of a top coat
which should be compatible to primer and alkaline environment. To meet these two
contingencies, suitable polymers are carefully tailored through the formation of a single
phase in the polyblend which provides the necessary mechanical and physical
properties.

Steps involved in the process:

Surface preparation:

The surface of the steel reinforcing bars to be coated is cleaned by abrasive (dry sand)
blast cleaning to the near white metal in accordance with SSPC-SP10/NAC No.2-1994.
It includes the following procedures.

a) Prior to blast cleaning visible deposits of oil or grease are removed by suitable
cleaning method.
b) Clean dry compressed air is used for nozzle blasting.
 c) Dry uniformly graded silica sand is used for blast cleaning which should be free
from contaminants.
d) Dust and residues are removed from prepared surface by brushing, blowing off
With clean, dry air, vacuum cleaning.
e) The prepared surface shall meet the visual standards of comparisons as in
SSPC-VIS 1 of SSPC-VIS 2.

Application of the coating:

a) The coating is applied to the cleaned surface as soon as after cleaning and
before oxidation of the surface discernible to the unaided eye occurs. However,
the application of the coating should not be delayed more than 4 hr. after
cleaning.
b) A rapid setting primer shall be applied over the prepared surface of the
reinforcing steel either by brushing or dipping.
c) After 30 minutes of application of the primer a cement polymer sealing coat shall
be applied either by brushing or dipping.
d) The coated rods shall be handled after 6 hours.

Inspection and testing:

Coated re-bars shall be checked for minimum average dry film thickness, uniformity of
thickness, defects such as cracks, peeling, bulging and uncoated areas etc. Coating
shall be tested for adhesion bond strength, abrasion resistance, chemical resistance, as
per specifications laid down by the manufacturer.

Merits & Demerits of the System:

Merits:

The composition has corrosion resistance, making it suitable for corrosion protection
of steel in concrete structures in marine and industrial environments.
Being cement based composition; it is more compatible in concrete medium.
It is a passivating-cum-barrier type of coating and hence any Localized defect in the
coating may not lead to severe undercutting.
It can be brush applied or sprayed and hence defects in the coating can be easily
patch repaired.
It has good bond strength and hence bond between coated rod and concrete is not
affected.
This system is suitable for the protection of prestressing steel strands also.
The system can be adopted as in situ process also. The shelf life of treated bars is 6
months.
Considerable reduction in process time as compared to inhibited cement slurry
system.

Demerits:

This system is newly developed system and the long term results are not known.

Performance:

This system is now being used on three fly over bridges in Mumbai at Goregaon,
Andheri and Mankhurd. As the system is a newly developed system, hence field
performance is not known. However laboratory performance of the system, as reported
by CECRI, is very good. The system has passed bond ability test, chemical resistance
test, salt spray test, impressed voltage test and abrasion resistance test as per test
procedure described in ASTM A77/775M-94. From structural point of view, the coated
bars have shown greater bond strength as compared to uncoated bars. This coating is
superior to old CECRI coating and can be used effectively in marine structures in future.

The cost of the coating is about 3200-8000/MT.

3) Fusion bonded epoxy coating (FBEC):

The Fusion Bonded Epoxy Coating is a process where epoxy powder is applied by
electrostatic spray on hot steel at pre-set temperature level. The powder, when in
contact with the hot bar, melts, flows, gels, cures cools and produces a well-adhered
continuous corrosion resistant protective coating. This thermosetting is an irreversible
process and provides the best protection to rebar against corrosion. It prevents attack of
chloride ion on the metallic surface and occurrence of electro-chemical reaction
initiating corrosion of steel. The epoxy coated rebars were first tried in Pennsylvania
State in 1973 and commercially produced in the USA since 1976. Subsequently this
system is introduced in Western Europe and Japan. In India M/s PSL Holdings Ltd, 386,
Veer Savarkar Marg, Prabhadevi, Mumbai-400 025, are producing Fusion Bonded
Epoxy Coated Rebar (FBECR) at their plant atWapi ( Daman ) near Mumbai .

Steps involved in the process:

The process involves following steps to be performed in a plant controlled by automatic

quality control system.

Degreasing: Bars are first cleaned from surface contamination such as oil, grease etc.
by chemical process before shot blasting.

Cleaning: The reinforcement bars are cleaned by shot blasting or grit blasting to white
or near white stage.

Heating: The blast cleaned bars are then heated through induction heaters at preset
temperature level around 2300C.

Coating: Hot bars are then fed to the coating booth, where the epoxy powder is
sprayed electro statically.

Curing and cooling: Coated bars are then cured and forced cooled by water spraying
to enable handling and testing.

Inspection and testing:

Fusion Bonded Epoxy Coated Re-bars are tested at the coating plant to the codal
requirements as specified in IS:13620-1993. On line and off line holiday checks,
thickness checks are carried out. The adhesion of the coated bars are also tested
frequently by bending of the bar. Beside this, various other tests are performed in
laboratory like chemical resistance, short spray, resistance in continuance boiling water,
abrasion resistance and impact resistance etc. These are conducted on every batch
of production.

Handling transportation and working:

FBECR bars are required to be handled with extreme care so that coating is not
damaged during transportation. Handling / concreting. Thus, Fusion Bonded Epoxy
Coated Bars require padded contacts during transportation, stacking, handling and till
the concreting is done. The cut ends, welded spots and handling damages are required
to be repaired with special liquid epoxy compatible with the coating material as per
specification of the coating agency.

Merits & demerits:

Merits:

As the technique is factory based, better quality control is achieved. It gives uniform
thickness of coating.
The bonding of coating with steel rebars is high as it has excellent adhesives property.
It is flexible to allow straight bars to be bend during fabrication on a special mandrill to
protect the coating from damage.
The Fusion Bonded Epoxy Coating acts as insulator for electrochemical cells and offer
barrier protection to steel which prevents entry of chloride ions through it.
There are well established criteria for acceptance for this coating (IS :13620-1993 and
ASTM 775/A 775M-1992)

Demerits:

There is a reduction in bond strength between coated rebars & concrete (Clause A.5
of IS:13620).
As the technique is plant based, double transportation/handling is involved.
It requires careful handling as coating may get damaged. Performance of the system
depends upon least defect in the coating.
Patching may not always be effective.
Even the smallest damage in coating can initiate corrosion in severe environment.

Performance:

In US Pennsylvania Department of Transportation had undertaken a project to evaluate

and compare the effectiveness and cost of various bridge deck protective systems.
Evaluation was done by conducting field survey. The protective systems evaluated in
this study included epoxy coated reinforcing steel, galvanized reinforcing steel, water
proofing membranes, latex modified concrete of salt contaminated decks and low slump
dense concrete. This field evaluation was carried out after 9 years of construction. Field
survey revealed that:-

Rebar coating provide the most effective corrosion protection to the Re-bar.
Epoxy coated rebar has been generally rated in excellent condition, despite high
chloride contents in surrounding concrete. Based on the deterioration rate and life
expectancy, epoxy coated rebar decks have performed better than calculated rates.
However, during 1986 to 1990 in Florida severe corrosion of epoxy coated reinforcing
bars has been recorded at major construction project in subtropical marine
environments. The Florida key bridge has been put out of commission.

A study has been conducted by the Canadian Strategic Highway Research Programme
(C-SHRP). It included extensive testing of epoxy coated rebar (ECR) from coaters as
well as from 19 field structures in Canada and the United States. This study showed
that epoxy-coated rebar technology is flawed (as practiced in North America) and, as a
result, epoxy coated rebar will not provide long-term protection to reinforcement in salt
contaminated concrete. The study found that this was the case even in perfect-coated
re-bars, namely coated bars which have zero holidays, zero bare areas and comply with
all other aspects of specifications. The reason for these failures are not understood.
As far as lab performance is concerned, this coating has performed well in all the test.
But patching is found not always effective.
The cost of treatment is about Rs.4500 to Rs 13,000/MT.

Coatings for concrete:

The protective surface coating, as the name implies, protects the concrete surface from
aggressive chemical attack. Surface coating of the concrete reduces the ingress of
oxygen, water gases and chemicals present in the industrial and other aggressive
environment. So surface coating for concrete is an effective method of protecting life of
reinforcement steel. The coating on concrete should be breathing type.

Epoxy coating:
They are well proven for concrete surfaces. When formulated with liquid epoxy resin,
liquid curing agents and highly penetrating solvents, they give good performance. They
are classified as under:
a) Solvent base epoxy with relatively high molecular weight
b) Thin thrixotropic liquid epoxy based primer.
c) Thick epoxy coating applied by trawl or by spray.

Thickness of coating ranges between 8 to 15 microns.

Coal tar epoxy:

They have both properties of coal tar and epoxy. They have good adhesion to concrete
and chemical resistance. They are applied by roller, conventional means or by airless
spray. They are applied in two coats having total thickness of 15 to 20 microns. These
have been used in 1987 to 1991 in Thane Creek Railway bridge on the piers in the tidal
& splash zones. The coatings are intact as seen in 1998. This is the cheapest and best
coating for substructure and coating over liner plates provided in the tidal & splash
zone.