Professional Documents
Culture Documents
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NPCA 1
The Precast Show
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• Exposed surfaces
– Specified coatings
that require small
bug holes to be filled
LOADS
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NPCA 2
The Precast Show
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precast.org/education precast.org/education
NPCA 3
The Precast Show
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SPALLS SPALLS
Examples, Root Cause analysis Examples, Root Cause analysis
• Detail • Detail
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NPCA 4
The Precast Show
• Product • Detail
handling
and storage
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NPCA 5
The Precast Show
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NPCA 6
The Precast Show
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precast.org/education precast.org/education
NPCA 7
The Precast Show
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precast.org/education precast.org/education
precast.org/education precast.org/education
NPCA 8
The Precast Show
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precast.org/education precast.org/education
precast.org/education precast.org/education
NPCA 9
The Precast Show
X X X –
–
–
Mag floats for placing polymer mortars
Wood or sponge floats
May steel trowel after set
X
– Blisters!
• Mixing
X
– “WC” ratio
– Shear paddle
– Mix time
– Pot life
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NPCA 10
The Precast Show
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• Substrate should be SSD • Force material against edge • After filling repair, consolidate and • For multiple lifts, score top surface
before application begins of repair area working to the screed on each lift to produce a roughed
• Finish with steel, magnesium, substarte for the next lift.
• Mixed material should be center and compacting
wood, plastic floats, or damp • If previous layers are more than 6
scrubbed into substrate, around exposed sponges depending on desired hrs old, mechanically prepare
filling all pores and voids reinforcement surface texture
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NPCA 11
The Precast Show
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precast.org/education precast.org/education
NPCA 12
The Precast Show
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precast.org/education precast.org/education
precast.org/education precast.org/education
NPCA 13
The Precast Show
• Scrub coat
• Pour in to wet
• Screed to level
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Things to avoid:
• Feather edges
• Abrupt changes in width or depth
• High length/width ratio
• Undercutting
• Poor surface
• Temperature extremes
• Over finishing
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NPCA 14
The Precast Show
CRACKS CRACKS
Examples, Root Cause Analysis Examples, Root Cause Analysis
• Detail • Detail
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CRACKS CRACKS
Examples, Root Cause Analysis Examples, Root Cause Analysis
• Detail • Detail
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NPCA 15
The Precast Show
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precast.org/education precast.org/education
NPCA 16
The Precast Show
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precast.org/education precast.org/education
NPCA 17
The Precast Show
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precast.org/education precast.org/education
NPCA 18
The Precast Show
• Remove contaminates
– Surface
– Cracks
• Do not contaminate crack
– Grinding
– Drilling
– Flushing
• Exothermic reaction!
• Mass dependent!
• Produce heat – mixing time and dispersal critical
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precast.org/education precast.org/education
NPCA 19
The Precast Show
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NPCA 20
The Precast Show
CRACKS
Gravity Fed
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CRACKS
Gravity Fed
Caution!
• Venting
• Blowholes
• Volcanos
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Caution!
CRACKS CP1 – PRECAST CONCRETE REPAIR
•Gravity
What about
Fed the bottom? Structural Cracks – Pressure Injection
• Leaks
• Benefits
– Plumbers putty
– Basic silicone
– Permanent fix
– Epoxy paste – Fills the void rather than bridging it
– High bond and tensile strengths of the epoxies prevent
yawning and elongation of the crack
– Injected resin is not vulnerable to ultra violet rays,
weathering, traffic or vandalism.
• Methods:
– Hand (easy set up, economical)
– Low Pressure (economical, duration, better penetration)
– High Pressure (best performance, travel, penetration)
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NPCA 21
The Precast Show
• Types of Ports
– Surface Mount
– Corner Ports
– Insertion Ports
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NPCA 22
The Precast Show
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• Vacuum bit to
avoid impaction
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NPCA 23
The Precast Show
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• Purpose
• Dimensions
• Material selection
• Application
• Common mistakes
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NPCA 24
The Precast Show
Material Selection
• Strength
• Moisture tolerance
• Odor
• Dispensability
• Cure time
• Thermal compatibility
• Ease of removal
• Cost
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Mistakes:
• Capseal applied too thin
• Improper mixing of epoxy paste
• Insufficient cure time
• Poor material selection
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NPCA 25
The Precast Show
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precast.org/education precast.org/education
precast.org/education precast.org/education
NPCA 26
The Precast Show
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NPCA 27
The Precast Show
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• Caution!
• Not done yet!
• Force material
into substrate
• Leaks!
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NPCA 28
The Precast Show
• Remove ports
– Optional
– Grinding
– Heating and scraping
• Restore surface as necessary
• Verification
– Coring
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• Non-destructive
– Impact echo
– Ultrasonic pulse velocity
– Spectral analysis of surface waves
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NPCA 29
The Precast Show
Overview Color
• Similar methodology to structural spall repairs • Color of repair needs to be similar to the host concrete
– Root cause analysis, QC procedure, approvals • Matching repair surface with a repair materials is a challenge
because the ingredients and proportions are different
– Orientation of the repair
– Concrete has aggregate & sand with around 25% cement
– Surface preparation content vs. a packaged repair material that is up to 50%
– Application conditions: wind, humidity, temperatures cement with only fine aggregate
– Bond development: SSD, scrub coat, bonding agent – Different manufacturers of cement will influence color
– Finishing and curing – Different curing conditions affect color
• Materials – Change in water cement ratio affects color
– Service and appearance driven, rather than loads
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NPCA 30
The Precast Show
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NPCA 31
The Precast Show
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Materials:
• Site batching with your own
ingredients
• Pigment repair materials
– % of cement
– Use white based patching cement
• Pigmented prepackaged patching
cement
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NPCA 32
The Precast Show
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precast.org/education precast.org/education
precast.org/education precast.org/education
NPCA 33
The Precast Show
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precast.org/education precast.org/education
NPCA 34