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HB
HB 84—2006

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Guide to
AND PROTECTION
CONCRETE REPAIR

3. Guide to Concrete Repair and Protection
A Joint publication of ACRA, CSIRO and Standards Australia.
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Originated as HB84-1996
2nd Edition 2006
ISBN 0 7337 7831 3
© Australian Concrete Repair Association 2006, Standards Australia Limited 2006
and CSIRO Australia 2006
Except where the Copyright Act allows otherwise, no part of this publication may be reproduced, stored
in a retrieval system in any form or transmitted by any means without prior permission in writing of the
Australian Concrete Repair Association, Standards Australia Limited and CSIRO Australia.

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Standards Australia develops Australian Standards® and other documents of public
benefit and national interest. These standards are developed through an open
process of consultation and consensus, in which all interested parties are invited to
participate. Through a Memorandum of Understanding with the Commonwealth
Government, Standards Australia is recognised as Australia’s peak non-government
national standards body. Standards Australia also supports excellence in design and
innovation through the Australian Design Awards.
For further information visit www.standards.org.au
286 Sussex Street, Sydney, NSW, 2000
GPO Box 476, Sydney, NSW, 2001
Telephone: +61 2 8206 6000
Email: mail@standards.org.au
Website: www.standards.org.au

5. AUSTRALIAN CONCRETE
REPAIR ASSOCIATION LTD
ABN 41 059 791 374
Level 6, 504 Pacific Highway
St Leonards NSW 2065
(Locked Bag 2011, St Leonards NSW 1590)
Tel: 61 2 9903 7733
Fax: 61 2 9437 9703
Email: acrabats@acrassoc.com.au
Website: www.acrassoc.com.au
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The Australian Concrete Repair Association (ACRA) was incorporated in 1991 with
the aim of providing a forum to promote excellence in all spheres of concrete repair
and protection work.
The Association is fundamental to the ongoing nationwide development of a
professional industry whose key objectives include providing the highest levels of
expertise, experience, training and quality. ACRA demands a continuing
commitment from its members to maintaining the quality standards it has set for the
concrete repair industry.
Through its membership base, which includes manufacturers, specialist contractors,
consultants and owners, ACRA provides stakeholders with confidence in the
remedial concrete repair process. This insistence on quality and best practise
underpins the increasing penetration of ACRA into the concrete repair market.
ACRA has established a scheme of awards for excellence in concrete repair which are
open to Corporate Members of the Association. These awards, which have been run
every two years since 1998, showcase the work of the member companies. The role
ACRA plays in the industry is clearly demonstrated in the levels of excellence on
display in all entries and the winning projects in particular.
ACRA is firmly committed to ongoing training of its members in the very latest
developments in both the technology and practical application of concrete repair and
protection. Maintaining up-to-date levels of knowledge and expertise is vital to
providing clients with the level of professional service expected of an ACRA
member. As such ACRA is extremely grateful to its fellow collaborators in the
production of this document, The Guide to Concrete Repair and Protection.

6. CSIRO AUSTRALIA
CSIRO
THE COMMONWEALTH SCIENTIFIC AND
INDUSTRIAL RESEARCH ORGANISATION
The Commonwealth Scientific and Industrial Research Organisation (CSIRO) is
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Australia’s national science agency and one of the largest and most diverse scientific
research organisations in the world. CSIRO has more than 6500 staff carrying out
research in a wide range of areas including construction, materials, energy, minerals,
agriculture and natural resources.
Manufacturing and Infrastructure Technology is a division of CSIRO that supports
the building, construction and engineering industries with research, consulting and
testing. With over 350 researchers, the division’s science spans building materials -
including concretes, timbers, polymers and tiles - to heating and cooling, air quality,
urban planning and infrastructure, IT applications for construction, fire testing, and
water systems and products.
CSIRO Manufacturing and Infrastructure Technology
Telephone: 1300 363 400
International: +61 3 9545 2176
Fax: +61 3 9545 2175
Email: cmit.enquiries@csiro.au
Web: www.cmit.csiro.au

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8. PREFACE
The original 1996 edition of this document was originally prepared by Dr Kwesi Sagoe-Crentsil
from the CSIRO division of Manufacturing and Infrastructure Technology at the request of the
Australian Concrete Repair Association (ACRA), who also provided the technical, editorial and
funding input.
The document is intended for widespread use by anyone engaged in the maintenance, repair
and production of concrete structures. However, this document is intended as an overview of
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the typical methods and practices in the industry but it should not be used as a standard or as
part of any contract relating to the repair of concrete.
In preparing this document, one of the fundamental aims has been to provide a publication that
can be read and understood by a diverse group of persons, ranging from professionals engaged
in specifying or carrying out repairs to concrete structures, to those involved in the management
of buildings and structures.
The guidance in this document has been specifically influenced by RILEM Technical
Recommendation 124-SRC, Guide to Repair Strategies for Concrete Structures Damaged by
Reinforcement Corrosion, 1993.
Previously available publications on investigatory and repair technologies for concrete are of
overseas origin. The development and support of this document by ACRA underlines its belief
that a document describing the local scenario for techniques and materials was necessary.
The new 2006 edition of this document has now been updated and modified to reflect the
advances and more wide-spread use of electrochemical prevention and protection systems.
Contact:
CSIRO Manufacturing and Infrastructure Technology
Telephone: 1300 363 400
International: +61 3 9545 2176
Fax: +61 3 9545 2175
Email: cmit.enquiries@csiro.au
Web: www.cmit.csiro.au
i

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ii
NOTES

10. CONTENTS
Preface i
Chapter 1 – Concrete Properties 1
1.1 Concrete 1
1.2 Material Properties 2
1.2.1 Concrete quality 2
1.2.2 Porosity 3
1.2.3 Curing 4
1.2.4 Durability 4
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1.2.5 Concrete properties and rebar corrosion 5
1.3 Acknowledgments 5
1.4 Further Reading 5
1.4.1 Standards 5
Chapter 2 – Causes of Concrete Deterioration 7
2.1 Internal Factors 7
2.1.1 Alkali-silica (alkali-aggregate) reaction 8
2.1.2 Other reactions 8
2.2 Extemal Factors 8
2.2.1 Sulfate attack 9
2.2.2 Carbonation 9
2.2.3 Effect of chlorides 9
2.3 Steel Reinforcement Corrosion 11
2.4 Summary 13
2.5 Acknowledgments 14
2.6 Further Reading 14
2.6.1 Standards 14
Chapter 3 – Formation and Types of Cracks 15
3.1 Cracking of Plastic Concrete 16
3.1.1 Plastic shrinkage cracks 17
3.1.2 Plastic settlement cracks 17
3.2 Cracking of Hardened Concrete 18
3.3 Other Types of Cracks 18
3.4 Impact of Cracks on Steel Reinforcement Corrosion 18
3.5 Acknowledgments 20
3.6 Further Reading 20
iii

11. Chapter 4 – Inspection Techniques 21
4.1 Condition Survey 22
4.2 Visual Inspection 23
4.3 Sampling and Testing 23
4.3.1 Lump Samples 23
4.3.2 Core Samples 24
4.3.3 Dust Samples 24
4.4 In Situ Testing 24
4.4.1 Delamination/Drummy Surveys 24
4.4.2 Rebound Hammer 24
4.4.3 Crack Width Measure 25
4.4.4 Reinforcement Depth/Location 25
4.4.5 Depth of Carbonation 25
4.4.6 Half-cell Potential Mapping 25
4.4.7 Concrete Resistivity 26
4.4.8 Ultrasonic Pulse Velocity (UPV) Measurements 26
4.4.9 Pull-Out Test 26
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4.4.10 Corrosion Rate Measurement 26
4.4.11 Ground-Penetrating Radar (GPR) 27
4.4.12 Gamma Radiography 27
4.4.13 Infra-Red Thermography 27
4.5 Laboratory Testing 27
4.5.1 Petrographic Tests 27
4.5.2 Chloride Profiles 28
4.5.3 Elastic Modulus 28
4.6 Structural Integrity 28
4.7 Summary 28
4.8 Further Reading 28
Chapter 5 – Protective and Remedial Systems 29
5.1 Patch Repair Systems (Repair Principle R) 30
5.1.1 Concrete removal 30
5.1.2 Surface preparation – concrete 31
5.1.3 Surface preparation – reinforcement 31
5.1.4 Materials for patch repair 31
5.1.5 Cement-based materials 32
5.1.6 Polymer concrete 32
5.1.7 Polymer-modified cement systems 32
5.1.8 Polymer impregnation 33
5.1.9 Hydrophobic impregnation 33
5.1.10 Joint sealants 33
5.2 Protective coatings 33
5.2.1 Sealers 36
5.2.2 Anti-Carbonation Coatings 36
5.2.3 Renderings 36
5.3 Moisture Barrier Systems (Repair Principle W) 36
5.2.1 Materials and methods 37
iv

12. 5.4 Coating on Steel Reinforcement (Repair Principle C) 37
5.4.1 Materials and methods 37
5.5 Cathodic Protection, Chloride Extraction and Re-alkalization (Repair Principle K) 37
5.5.1 Cathodic prevention 37
5.5.2 Cathodic Protection 38
5.5.3 Re-alkalisation 39
5.5.4 Chloride Extraction 40
5.6 New Methods 40
5.6.1 Externally bonded fibre-reinforced plastic (FRP) 40
5.6.2 Impregnating corrosion inhibitors 40
5.7 Acknowledgments 41
5.8 Further Reading 41
Chapter 6 – Repair Practices 43
6.1 Patch Repair Systems 44
6.1.1 Patch repair practice 44
6.1.2 Surface preparation – concrete 46
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6.1.3 Finishing 50
6.1.4 Curing 50
6. 1.5 Preparation of reinforcing steel 50
6.1.6 Repair procedures 52
6. 1.7 Repair mortars 52
6.2 Moisture Barrier Systems 53
6.3 Protection by Coating Steel reinforcement 54
6.4 Electrochemical Systems 54
6.4.1 Application of a Cathodic Prevention (CP) system 54
6.4.2 Application of an electrochemical re-alkalization system 56
6.4.3 Application of a chloride extraction system 57
6.5 Crack Repair 58
6.5.1 Crack filling 58
6.5.2 Crack sealing 59
6.5.3 Other processes 60
6.6 Quality Assurance 60
6.6.1 Concrete patch repair 60
6.6.2 Post-repair degradation 61
6.7 Conclusion 62
6.8 Acknowledgment 62
6.9 Further Reading 62
6.9.1 Standards 62
Chapter 7 – Case Studies 63
7.1 High-rise Building 63
7.1.1 Investigation 63
7.1.2 Specification for repair 64
7.1.3 The repair 64
7.2 Marine Structure 64
7.2.1 Investigation 64
7.2.2 Specification for repair 65
7.2.3 The repair 65
v

13. 7.3 Highway Bridge 65
7.3.1 Investigation 66
7.3.2 Specification for repair 66
7.3.3 The repair 66
7.4 Commercial Complex 66
7.5 Apartment Building 68
7.6 Retaining Wall 69
7.6.1 Introduction 69
7.6.2 History 69
7.6.3 Inspection 69
7.6.4 Remedial options 70
7.6.5 The trials 71
7.6.6 Summary 72
Appendix A – Repair Strategies for Carbonation-induced Steel Corrosion 73
A.1 Repair Principle R 73
A.2 Repair Principle W 74
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A.3 Repair Principle C 74
A.4 Repair Principle K 74
Appendix B – Repair Strategies for Chloride-induced Steel Corrosion 75
B.1 Repair Principle R 75
B.2 Repair Principle W 76
B.3 Repair Principle C 76
B.4 Repair Principle K 75
B.5 Re-alkalization and Chloride Extraction Techniques 76
Appendix C – Strategies for Crack Repair 77
vi

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HB 84-2006 Guide to Concrete Repair and
Protection
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