SPECIFICATION

FOR CONCRETE
PATCH REPAIR

JKR 20601-0254-19

BAHAGIAN PERKHIDMATAN FORENSIK STRUKTUR

CAWANGAN KEJURUTERAAN AWAM DAN STRUKTUR
IBU PEJABAT JKR MALAYSIA
KUALA LUMPUR www.jkr.gov.my
 TABLE OF CONTENT

PAGE

1.0 GENERAL .................................................................................................................. 1

1.1 Scope ............................................................................................................... 1

1.2 Submission of Documents ............................................................................ 1

1.2.1 Repair Mortar ....................................................................................... 1
1.2.2 Steel Reinforcement ............................................................................ 1
1.2.3 Cement Based Reinforcement Primer ................................................. 1

2.0 MATERIALS .............................................................................................................. 1

2.1 General............................................................................................................. 1

2.2 Patch Repair Mortar........................................................................................ 2

2.3 Reinforcement Corrosion Inhibiting Product .............................................. 2

2.4 Curing .............................................................................................................. 3

3.0 WORKMANSHIP ....................................................................................................... 3

3.1 Removal of Concrete ...................................................................................... 3

3.1.1 Identification and Marking Out ............................................................. 3
3.1.2 Extent and Depth of Concrete Breakout .............................................. 3
3.1.3 Breaking Out of Concrete .................................................................... 3
3.1.4 Additional Concrete Breakout .............................................................. 4

3.2 Steel Reinforcement Surface Preparation.................................................... 4

3.3 Additional or Replacement of Steel Reinforcement .................................... 4

3.4 Concrete Surface Preparation ....................................................................... 4

3.5 Repair Mortar Patching .................................................................................. 5

3.5.1 Method of Placing ................................................................................ 5

3.6 Repair Mortar Application – Quality Control Testing ................................. 5

Appendix 1 .............................................................................................................................. 7
Appendix 2 .............................................................................................................................. 8
Appendix 3 .............................................................................................................................. 9

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 SPECIFICATION FOR CONCETE PATCH REPAIR

1.0 GENERAL

1.1 Scope

i. This specification shall be used for concrete spalling not exceeding the main
reinforcement depth.

ii. The works shall include the removal of concrete on beam, slab, wall and
column. The S.O. shall inspect the concrete to identify any cracks, spalling,
delamination or corroding reinforcement. Remedial works for the reinforced
concrete shall be determined by the S.O. after his inspection.

1.2 Submission of Documents

1.2.1 Repair Mortar

The Contractor shall submit for the S.O.’s approval prior to commencement of work:

i. Name and generic type of the proposed repair mortar material.

ii. Name and address of supplier and manufacturer of repair mortar.

iii. Product data sheets showing compliance with the specification requirements
as per Section 2 of this specification. The S.O. will require documentation
from an accredited independent testing laboratory to confirm the
performance criteria stated on product data sheets.

iv. Detailed proposal of concrete removal, application and curing techniques to

be used.

1.2.2 Steel Reinforcement

The Contractor shall submit details as per Clause 3.3. of this Specification.

1.2.3 Cement Based Reinforcement Primer

The Contractor shall submit details as per Clause 3.5. of this Specification.

2.0 MATERIALS

2.1 General

i. The repair mortar shall be an approved repair mortar supplied in pre-

measured units of dry components.

ii. The materials shall remain in their original sealed containers until the time of
use and shall be stored in strict accordance with the manufacturer’s
specification.

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 iii. Each consignment of materials shall be accompanied by a manufacturer’s
certificate of date of manufacture. Material stored beyond the manufacturer’s
recommended shelf life shall not be used.

2.2 Patch Repair Mortar

The mortar shall have the following properties, determined in general accordance with BS EN
1504 “Products and System for Protection and Repair of Concrete Structures”.

i. Compressive strength shall be equal or more than 45 N/mm2 at 28 days as

per EN 12190;

ii. Adhesion strength shall be more than 2 N/mm2 at 28 days as per EN1542;

iii. Bond strength for restrained shrinkage/expansion shall be more than 2

N/mm2 as per EN 12617-4;

iv. Chloride ion content shall be less than 0.05 % as per EN 1015-17; and

v. Carbonation resistance: dk < control concrete (MC (0, 45)) as per EN 13295.

Details of Performance Characteristics, Identification Requirements and Performance

Requirements for Repair Products are specified in BS EN 1504 as shown in Appendix 1, 2
and 3 of this document.

2.3 Reinforcement Corrosion Inhibiting Product

The material shall be corrosion inhibiting product and in compliance to EN 1504-7 (Products
and Systems for the protection and repair of concrete structural, Part 7: Reinforcement
corrosion protection) as follows:

Table 1.0: Performance Requirements (adopted from Table 3 of BS EN 1504-7:2006)

Performance Requirements Intended Test Method
Characteristic Usage
Corrosion The test is considered to have been All EN 15183
protection passed if the coated zones of the
steels are free of corrosion and if rust
creep at the ground plate edge < 1 mm.

Shear adhesion Assessment criterion is the bond stress As specified EN 15184

(coated steel to at a displacement of 0.1 mm.
concrete)
The test is considered to have passed
if the bond stress determined with the
coated bars is in each case at least 80
% of the reference bond stress
determined for the uncoated bars.

The mortar materials shall be mixed, applied and cured in strict accordance with the
manufacturer’s specifications.

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2.4 Curing

The repair material shall be protected against premature surface drying and rainfall for at least
72 hours. The manufacturer’s recommendation for curing shall be followed. Curing and
protection shall start immediately after compaction of the concrete.

3.0 WORKMANSHIP

3.1 Removal of Concrete

3.1.1 Identification and Marking Out

i. The areas of concrete to be broken out are identified as having:

a. Spalled and delaminated concrete; or

b. Corroded reinforcement. The criterion will be for areas where the

electrochemical potential of the reinforcement is less than -150
millivolts Cu/CuSO4.

ii. All areas shall be re-inspected by the Contractor and verified by the S.O.
before work commenced;

iii. The concrete to be broken out will be marked out by the contractor. The
breakout area shall be entered into record sheets in duplicate and signed by
the S.O. The original shall be kept by the S.O. and the duplicate kept by the
Contractor and shall be used as a record for measuring the work. Breakout
work shall not proceed until approval of the S.O. is obtained.

3.1.2 Extent and Depth of Concrete Breakout

i. The perimeter of the repair shall be delineated by cutting at 90 degrees to the

surface with a grinding disk to avoid feather edges.

ii. The depth of cut shall be a minimum of 10mm. Care shall be taken to ensure
that no steel reinforcement is cut e.g. by use of a cover meter. The Contractor
shall report to the S.O. any reinforcement which has been damaged by the
work. The Contractor shall propose a remedial method for approval of the
S.O. before carrying out the repair works at his own cost.

3.1.3 Breaking Out of Concrete

i. The Contractor shall submit propping details and installation procedure for
the structural elements requiring concrete breakout to the S.O. for approval,
signed by a Professional Engineer (P.E.) registered with Board of Engineers
(BEM) Malaysia. The Contractor shall not commence any concrete breakout
works before receiving the S.O.’s written approval of propping details and
procedures. The Contractor shall remain responsible for all propping details
and procedures irrespective of the S.O.’s approval.

ii. Concrete within marked out areas shall be removed using light mechanical
breakers or hammers and chisel, cutting to expose the reinforcement and a

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 sound concrete substrate to the satisfaction of the S.O., without breaking out
behind the reinforcement.

3.1.4 Additional Concrete Breakout

i. Where the breakout indicates that the exposed reinforcement is further

corroded, it should be broken out to a minimum of 150mm along the length
of the bar, or in the case of the surrounding concrete being unsound, the S.O.
shall be informed and an enlarged area agreed to the satisfaction of the S.O.
If the concrete spalling exceeds the reinforcement depth, the method of repair
shall then follow the Specification for Formwork Pressure Grouting.

ii. The Contractor shall mark out the enlarged breakout area for the S.O.’s
approval. Upon approval, the additional breakout area shall be photographed
and entered into record sheets in duplicate and signed by the S.O. The
original shall be kept by the S.O. and the duplicate by the Contractor and
shall be used as a record for the purpose of measuring the work. Breakout
work shall not proceed until approval of the S.O. is obtained.

3.2 Steel Reinforcement Surface Preparation

All exposed reinforcement surfaces shall be thoroughly cleaned to the satisfaction of the S.O.

3.3 Additional or Replacement of Steel Reinforcement

The Contractor shall report to the S.O. any reinforcement which has lost 10% or more of its
nominal diameter as a result of corrosion. These reinforcements shall be replaced. Additional
or replacement reinforcement shall be of the same size and type with the original
reinforcement. Method of repair shall then follow the Specification for Formwork Pressure
Grouting.

3.4 Concrete Surface Preparation

i. Smooth off form concrete surface shall be roughened by mechanical

scabbling to the S.O.’s satisfaction to provide a good adhesion surface for
application of the repair mortar. Care shall be taken to ensure that vibration
from the method of preparation does not cause delamination of adjacent
render or concrete.

ii. All concrete surface receiving the repair mortar shall be prepared by
mechanical scabbling to remove loose render, surface laitance, organic
contaminants e.g. moss, algae growth, etc and other contaminants. Care
shall be taken to ensure that vibration from the method of preparation does
not cause delamination of adjacent render or concrete.

iii. On completion of all mechanical preparation, adjacent areas of render shall

be tapped with a lightweight hammer or more preferably a 25mm ball bearing
on a 1m long flexing handle. If a delamination is not detected at a crack, the
crack shall be repaired as per Specification for Crack Repair. Any hollow
sounding areas shall be brought to the attention of the S.O.

iv. Water dampening of the concrete shall be carried out by the Contractor to
Saturated Surface Dry (SSD) condition.

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3.5 Repair Mortar Patching

3.5.1 Method of Placing

i. The repair mortar shall be applied to a surface prepared in accordance with

Clause 3.4.

ii. The repair mortar shall be mixed using equipment of a type approved by the
S.O. and shall normally be a force action mixer. The mixing liquid shall be
added to the dry components and thoroughly mixed to achieve a uniform
consistency.

iii. The mortar shall then be applied to the prepared surface using hand packing
and trowelled to the satisfaction of the S.O.

iv. The finishing texture of the final repair mortar layer shall match the finishing
on the existing interior surface.

3.6 Repair Mortar Application – Quality Control Testing

i. Routine quality control tests and inspection shall be performed by the

Contractor in accordance with his approved Quality Control and Testing
programme. Approval of a repair mortar area by the S.O. will require
acceptable results from a visual inspection to check for cracking and
delamination and adhesion bond strength tests.

ii. The Contractor shall inform the S.O. of all completed repair mortar areas one
(1) day after final application for the S.O.’s inspection and approval.

iii. The S.O. shall inspect all repaired areas approximately seven (7) days after
final application for cracks by visual inspection and delamination by tapping
with a lightweight hammer or a 25mm ball bearing on a 1m long flexing
handle. If a crack or delamination is detected by the S.O. then the Contractor
shall breakout the repaired area and repeat the repair mortar application at
this own cost.

iv. The bond strength of the applied mortar to the substrate, and any repair
mortar inter-coat layers, will be tested by S.O. approximately seven (7) days
after final application using a Limpet pull-off tester, at the minimum rate of 3
per 100m2 of applied area or 1 per 10 patch repair areas, whichever is the
greater number of tests. The Contractor shall carry out site trials on the
applied render to establish the 7 to 28 days adhesion strength relationship,
to the satisfaction of the S.O., to enable testing at 7 days to achieve the
specified 2 N/mm2 at 28 days. The Contractor shall provide access as
required for testing and shall repair any damage to the repair mortar and
concrete resulting from the pull-off tests, at his own cost.

v. The bond adhesion strength of the applied repair mortar shall be greater than
the tensile strength of the substrate as determined by the failure occurring
100% in the substrate or a minimum value of 2 N/mm2.

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 vi. Areas where bond adhesion strength is found to be deficient shall be
removed and replaced as instructed by the S.O. at the Contractor’s own cost.

vii. Upon approval that no cracks nor delamination nor deficient adhesion bond
areas exist in the repair area, the location and result of the crack,
delamination and bond checks shall be recorded in duplicate copies and
signed by the S.O. The original shall be kept by the S.O. and the duplicate
by the Contractor and shall be used as a record for the purpose of approving
the work.

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Appendix 1

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 Appendix 2

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Appendix 3

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 ACKNOWLEDGEMENT

We would like to thank all committee members below for their invaluable support and assistance rendered
during the entire review process:

Committee Members
Ir. Hj. Mohd Noor Azudin bin Hj. Mansor Pengarah Kejuruteraan Pakar (Struktur)
Ir. Mohd Shaifuddin bin Abdul Razak Bahagian Perkhidmatan Forensik Struktur
Ir. Hanizah binti Argadan Bahagian Perkhidmatan Forensik Struktur
Ir. Emmy Sherina binti Ismail Hashim Bahagian Perkhidmatan Forensik Struktur
Ir. Bernard Toides Bahagian Perkhidmatan Forensik Struktur
Ir. Mohd Firdaus bin Mohd Bahagian Perkhidmatan Forensik Struktur
Ir. Amirul Haikal bin Azizan Bahagian Perkhidmatan Forensik Struktur
Ir. Mohd Hairul Nizam bin Shukor Bahagian Perkhidmatan Forensik Struktur
Mohd Fairoze Mazly bin Zulkifli Bahagian Perkhidmatan Forensik Struktur
Nur Naemah binti Esa Bahagian Perkhidmatan Forensik Struktur
Benny Anak Andrew Esing Bahagian Perkhidmatan Forensik Struktur
Ir. Norhayati binti Khairudin Bahagian Kejuruteraan Awam
Ir. Hafizah binti Zakaria Bahagian Rehabilitasi dan Konservasi
Ir. Amisah binti Ahwang Bahagian Rehabilitasi dan Konservasi
Ir. Lee Choon Siang Bahagian Rehabilitasi dan Konservasi
Ezuan bin Jamadon Bahagian Rehabilitasi dan Konservasi

Reviewers
Ir. Dr. Lim Char Ching Pengarah Kejuruteraan, Cawangan Jalan
Dr. Maziah binti Mohammad Pengarah, Pusat Kecemerlangan Kejuruteraan &
Teknologi JKR (Cre@te)
Mr. Steven Ng Sika Kimia Sdn. Bhd
Mr. Rafiq Rashid Sika Kimia Sdn. Bhd
Mr. Tengku Mohd Khairi Tengku Khalid Mapei Malaysia Sdn. Bhd
Mrs Chan Swee Fun Mapei Malaysia Sdn. Bhd

Cover and Illustration

Othman bin Mohd Joned Bahagian Perkhidmatan Forensik Struktur

Secretariat
Ir. Bernard Toides Bahagian Perkhidmatan Forensik Struktur
Othman bin Mohd Joned Bahagian Perkhidmatan Forensik Struktur
 BAHAGIAN PERKHIDMATAN FORENSIK STRUKTUR
CAWANGAN KEJURUTERAAN AWAM DAN STRUKTUR
TINGKAT 4-10, MENARA KERJA RAYA BLOK G
IBU PEJABAT JKR MALAYSIA
50480 KUALA LUMPUR