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(Image: Attention!)

The concrete foundation must be prepared such that a tight and durable bond can be achieved between the repair grout to be applied and the old concrete. If the reinforcement is situated in the carbonised region of the concrete, then it must be exposed and de-rusted in the same manner as already described for reinforcement exposed by corrosion.

(Table: Processes for the pre-treatment of concrete surfaces before rehabilitation […

The required preparation of reinforcement rods depends on their condition, on the extent of the corrosion and the type of repair measures. For limited repairs of concrete spalling due to corroding reinforcement, the recommended method is conservation by means of anti-corrosion paints in accordance with the rules for steel construction. An anti-corrosion paint can be dispensed with if there is sufficient cover with reference to the rod diameter, …

For a durable bond between old concrete and repair grout, and with reference to the repair process, the concrete foundation must possess the following properties [Grube90] :

  • Roughness of the surface;
  • Quantity and sizes of cavities and pores;
  • Wear resistance;
  • Permissible cracks;
  • Bearing strength, if necessary, E-Modulus;
  • Carbonisation;
  • Permissible chloride content;
  • Moisture and temperature of the concrete.

The contact between old concrete and repair …

(Image: Attention!)

The application of the repair grout must be carried out before the bonding bridge is fully hardened (working "fresh on fresh"), otherwise there is the danger that the bonding bridge becomes a separating layer.

(Image: Applying the repair grout by hand [BDZ89])
(Image: Concrete repair system - adhesion bridge)

Adhesion bridge:

  • Mapei: Mapegrout Primer D
  • Keimfarben: Keim Concretal adhesion bridge
  • Brillux: PCC Basisschutz 801 (as corrosion protection and adhesion bridge)
  • MC-Bauchemie: Nafufill HB-HS
  • StoCretec: StoCrete TH 250
(Image: Concrete repair system - smoothing cement)

Repair mortar:

  • Mapei: Mapegrout 50 PCC
  • Keimfarben: Keim Concretal mortar
  • Brillux: PCC-coarse mortar 802, PCC-filling mortar 803, PCC-…
(Image: Local bad patches before rehabilitation)

Repairing bad patches

Local bad patches in the masonry are re-bricked with sewer bricks to DIN 4051 ensuring that they are correct in profile and flush and using corrosion-resistant plastic-modified cement mortar.

(Image: Newly installed sewer bricks)
(Image: Defective step in a masonry manhole)

Although sewer clinkers in masonry sewers are generally resistant to acids (for exceptions , the cement-bound grout joints are destroyed with corresponding loading .

If these masonry joints are not filled in with an appropriate grout again (pointing), then the result can be leaks, the falling out of one or more sewer bricks from the walls up to collapse of the arching. In this type of damage in the wetted …

Removing loose jointing material

The butt and bed joints in the region of the springing line are cleaned out up to a hard underground but not more than 5 cm deep due to the fact that the joint mortar can soften and parts of it can be scratched out and thus have no real strength properties. This is carried out by means of a pneumatic angle grinder (Flex). Very uneven or small masonry joints are additionally cleaned out.

(Image: Compressed air-driven …

Cleaning of cleared joints

Then follows the removal of the waste material using the high-pressure jet again.

(Image: Cleared and cleaned joints of masonry) (Image: Cleared and cleaned joints of masonry)

Re-jointing the previously cleaned-out joints

Ground and cleaned joints are re-filled up to the joint underground cavity with the Sewament 40 corrosion-resistant cement mortar of the Mapei Company making sure that there are no bad parts. The material used is first processed with a manually filled hand cartridge filler. The joints are filled-in from a corrosion depth of 1 cm (after cleaning).

(Image: Applying the new jointing material with the hand …

Aug 01, 2006

Modules

Manholes perform a variety of functions, they are used to connect pipelines, to change direction and/or elevation, to provide access for personnel and/or equipment, and to provide aeration and ventilation to the drain and sewer system. Like sewers and pipes, defective manholes need to be repaired.

This module covers the repair of climbing aids, the repair of defects, the construction and materials of concrete repair systems and joint repair.

After completion of this module, you will have a sound knowledge of:

  • methods of repairing climbing aids; defects and joints; and
  • requirements and application limitations of the methods.
(Image: 55125 - Titelbild Dokumentation)

Proess: Re-jointing corroded masonry joints, crack injection, repair of damaged laterals

Title: Repair of masonry sewage collectors and manholes while retaining the original masonry by rehabilitation of the joints and crack injections.

Location: Position in the road cross section of a German main road

Limiting values:

  • System: Combined wastewater sewer, wastewater sewer
  • Material: Masonry
  • Cross sectional shapes:

The rehabilitation of the masonry collectors is achieved by injection of the existing cracks and re-jointing the corroded masonry joints. With this method the corrosion protection of the collectors and their partly insufficient stability as shown by the calculations is again established.

In order to determine the quality standards in the execution of the masonry rehabilitation as regards materials and procedures, three reference fields were carried …

Sewer cleaning

Corroded or loose jointing material, blooms, bulges, foreign matter (e.g. greases or oils) growths, dust and other dirt are removed by means of high-pressure jets with a flushing pressure of maximum 150 bar.

Removing loose jointing material

The butt and bed joints in the region of the springing line are cleaned out up to a hard underground but not more than 5 cm deep due to the fact that the joint mortar can soften and parts of it can …

Re-jointing the previously cleaned-out joints

Ground and cleaned joints are re-filled up to the joint underground cavity with the Sewament 40 corrosion-resistant cement mortar of the Mapei Company making sure that there are no bad parts. The material used is first processed with a manually filled hand cartridge filler. The joints are filled-in from a corrosion depth of 1 cm (after cleaning).

Creating the fresh mortar

For creating the repair mortar, …

Injection of cracks in the crown

The cement-bound ERGELIT Kombina I injection mortar is mixed using a drilling machine with a stirrer attachment by continuously adding dry mortar and make-up water. After filling the fresh mortar into the pressure vessel, this is sealed and attached to the compressor.

(Image: Pressure vessel for transporting the injection mortar) (Image: Pressure vessel for transporting the injection mortar) (Image: Pressure vessel …

A final high-pressure flushing is carried out in order to clean the rehabilitated section before acceptance.

The sewer is only optically tested for leaks, i.e. it is optically inspected for infiltrating groundwater.

The last working step is the cleaning of the construction site.

Repair of an accessible brick sewers and manholes while preserving the exposed masonry by joint rehabilitation and crack injection.

(Image: 49785 - Titelbild Dokumentation)

Process: Manhole rehabilitation

Title: Replacement of a defective manhole top and repair of the surrounding road surface

Location: Industrial area

Limiting conditions:

  • System: Man accessible manhole with bricked manhole base and top portion of prefabricated concrete components
  • Material: Concrete (part to be rehabilitated)
  • Nominal size: Manhole top DN 625
  • Manhole depth: 1.5 - 2.0 m
  • Position of manhole: Road area…

Machines and equipment:

  • 1 HGV with crane
  • 1 Jackhammer
  • 1 Compressor
  • 1 Gas burner
  • 1 Melting pot

Tools

  • Rule
  • Trowel
  • Shovel
  • Hammer
  • Cement bucket
  • Pouring bucket

Materials

Following is a summary of the most important materials and components used in this process:

  • 1 concrete support ring
  • 1 manhole frame
  • 1 manhole cover
  • Mortar and pouring cement
  • Bituminous material for surface pouring

Work safety:

Within the scope of the site documentation, there is no explicit …

Replacement of a defective manhole top by breaking open the asphalt surface

For removing the manhole top, first the road surface is chiselled up with a jackhammer around the manhole frame to a width of approximately 20 cm around the frame. The width of the working space is meant to make a professional replacement of the manhole top possible and to allow the placing of paving stones after the replacement of the top thus allowing it to be integrated …

Installing the support ring

The mortar required for the new support ring is mixed on site in the cement bucket with the shovel. A layer of mortar is applied with the trowel on the top surface of the manhole taper. The support ring is placed on the mortar and the height is controlled by means of a rule and a string. If necessary, the height is adjusted by means of light taps with a hammer on the edge of a piece of wood placed on the support ring to …

The last working step is the cleaning of the site. The road surface can be used again approximately 1 hour after the installation of the manhole top.

(Image: Loading the defective manhole top onto the truck using the crane) (Image: Loading the truck using the crane) (Image: Loading the melting equipment onto the truck using the crane)

Replacement of a defective manhole top and repair of the surrounding road surface.