Building Pathology Flashcards
(310 cards)
During a defects inspection spalled bricks are identified. What are the common causes?
- Use of incorrect mortar on historic buildings – modern cement mortars, rather than lime.
- Moisture in the brick during a freeze thaw cycle
- Rainwater hitting the surface, poor drainage or water consistently running down the brick.
- Non-breathable coatings such as sealants – unable to dispel water through its pores.
- High pressure cleaning
What problems are associated with vegetation growth to damp/shaded brickwork?
- They cause erosion of the mortar joints, hold and attract moisture, storing it within the brickwork, causing problems of water penetration.
What is meant by the term concrete cancer?
- Alkali Silica Reaction (ASR), the most common form of alkali-aggregate reaction (AAR)
What is ASR?
- It occurs when, given the correct combination of conditions, the highly alkaline pore water can react with certain types of aggregate to produce gel. It needs critical silica in the aggregate, sufficient moisture and high alkalinity from the cement or other sources to occur.
- The gel absorbs water to expand and can cause the concrete to crack or disrupt, including map cracking and small pop outs. A white gel can also be seen oozing out of the concrete.
- The durability of the concrete can be compromised and in some cases the tensile strength of the concrete component can be reduced. It is very damaging, sometimes resulting in structural failure and the need to demolish a building.
- Infrequent in the UK since the introduction of BS 8500 – British standard for concrete.
Explain carbonation.
- It is the reaction of atmospheric carbon dioxide with the calcium hydroxide within the cement mix. The reaction produces calcium carbonate and lowers the PH to around 9 (from 12). This reduction starts on the surface, but can ultimately reach the depth of the steel reinforcement via capillary action. If the alkalinity reduces the passive resistive layer to the surface of the steel reinforcement, it will start to corrode and expand, causing cracking and spalling to the concrete. This allows further water ingress, accelerating the deterioration of the concrete. Particularly an issue if the reinforcement has insufficient concrete cover. The quality of the concrete will also have an effect, as the more porous the concrete, the quicker the process will occur.
How does sulphate attack affect concrete?
How does sulphate attack affect concrete?
- Sulphates/ salts of e.g gypsum are water soluble and are readily transported into the cement mortar/concrete where they react with the tricalcium aluminate in cement to form crystals, generating high expansive forces in the mortar/concrete.
- To occur there must be sufficient sulphate and sufficient long term water.
What are the key indicators of cavity wall tie failure?
- Horizontal cracking along the mortar joint the ties are embedded in, occurring at regular intervals (5/6 and 7/8 courses) with displacement of adjacent bricks.
- May also be stepped cracking where mortar joints are thin and hard.
- Corroding tiles expand so the bed joints widen and the outer leaf grows in height, which causes the outer leaf to bow (deflect). Also leads to gaps around windows.
- Can lead to pagoda effect at exposed gables.
- Vertical cracks may be evident external/internal wall junctions and horizontal cracks appear at junctions of wall and ceiling.
- Exposed elevations within industrial and marine environments are more prone, especially where exposed to driving rain and salt laden air.
- Inadequate protection of ties prior to 1930, often left untreated. Substandard galvanising between 1964-1981.
How can stonework be repaired?
- Minor repointing of eroded joints (lime or earth based mortar)
- Rebedding loose stones
- Filling of cavities by a skilled mason using coloured mortar, reinforced with non-ferrous armatures for deeper patches.
- De-frassing to lightly brush off loose material
- Stones can sometimes be removed and reversed to hide the deterioration.
- Fractured or delaminating stone might be grouted and pinned.
- Only stones that are severely defective and be unable to fulfil their structural or weathering function should be replaced.
How would you rectify the issue of wall tie failure?
- Cast and wrought iron wall ties (1850-1920) sometimes protected by bitumen – tend to snap, rather than corrode and a significant number need to fail before serious collapse is imminent.
- 1970s – galvanised wire ‘butterfly’ wall ties had too thin coating of zinc and are particularly prone to failure.
- Principle remedy to remove the old wall ties and either stitch in new or drill in new ones and fix them with resin or expanding anchors.
- Products such as Helix spiral replacement wall ties and Triton wall tiles are used.
- Type of remedy and tie must be matched to the type of failure that has occurred.
- If the wall has failed due to expansion of the tie within the brickwork, or if both leaves are cracked, a structural engineer may have to be consulted to assess the best remedial action.
- Refer to BRE Digest 329.
- Locate ties with a metal detector
- Remove, crop or encapsulate existing/failed wall ties.
- New ties can be fixed by:
o Resin fix
o Mechanical fix
o Cementitious wall anchors - Holes are drilled, ties installed and tightened to required torque,
- Cracked brickwork and mortar can be replaced.
A white powdery substance has appeared on the surface of some new brickwork. What might it be and what can you do about it?
- Soluble salt crystallisation – unsightly efflorescence on the surface.
- Can lead to delaminating brickwork
- Common in new brickwork
- Recurrent efflorescence is common with faulty detailing.
- Salts can be contained in the bricks or surrounding atmosphere
- The salt solution passes through the pores or dry material and leaves a deposit within the pores upon evaporation.
- Deposited salts accumulate at depth of wetting and create back pressure which delaminates the brick – this exposes pores behind and the process is repeated.
- If left, it will progress as frost attack causing delamination and friable bricks.
- Clean off the efflorescence with a stiff bristled brush followed by a wet sponging with a mild solution.
- If it persists remove the source of wetting and replace bricks if appropriate.
The reinforcement bars on a concrete building are exposed and corroding. What are the causes and remedial work strategies?
- Carbonation – occurs due to ingress of atmospheric carbon dioxide reacting with water within the concrete, which forms carbonic acid that neutralises the concrete’s alkalinity. This breaks down the passive layer around the reinforcement causing it to corrode due to the presence of water and oxygen at a slowly progressing rate. It s more of a concern when there is poor cover over the steel reinforcement or the concrete is poorly compacted. It is more rapid in porous concrete with low cement content and concrete with a high water: cement ratio. It can lead to a loss of strength and in extreme cases structural failure.
- Chloride attack – calcium chloride may be present in reinforced concrete as a result of its inclusion as an accelerator, by contamination from de-icing salts or from the use of unwashed or poorly washed marine aggregates. Sufficient levels of chloride may result in chloride induced corrosion, which can be more difficult to deal with than corrosion caused purely by carbonation. Its effects can be wide ranging, including a reduction in structural capacity. Passive film forms on steel and remains intact providing concrete remains highly alkaline (12.6+ PH). Use of calcium chloride accelerators popular in 50s and 60, but was banned in 1977. Corrosion may occur in concrete that contains sufficient chlorides, even if its not carbonated or showing visible signs of deterioration. Free chloride ions and combined chloride ions in concrete – free chloride ions within pore structure of concrete interferes with passive protective film on steel. Chloride induced corrosion in localised breakdown of passive film, rather than widespread deterioration that occurs with carbonation. Result is rapid corrosion of metal at anode, leading to formation of a pit in the bar surface and significant loss of cross-sectional area (pitting corrosion). Occasionally the bar may be completely eaten through, but can occur without any visual sign of cracking/spalling. Exaggerated by presence of deep carbonation – additional free chloride ions increases likelihood of corrosion.
- ASR (concrete cancer) occurs when pore water reacts with certain aggregates to produce a gel, which absorbs water, expands and causes cracking. 3 factors must be present – critical silica in the aggregate (troublesome aggregates in the SW), sufficient moisture, high alkalinity from cement/external sources. Can result in structural failure and need to demolish building if tensile strength of concrete is reduced.
- Repairs include:
o Carbonation:
Removing defective concrete and cut out the reinforcement to damaged members. New reinforcement fixed butt-welding to existing and new concrete cast.
Guniting – (proprietary process) fine concrete sprayed to concrete surface under repair at high velocity.
Coating/sealants/membranes can reduce carbonation progress, but if chlorides are present as rebar depth coating will not prevent carbonation.
Electrochemical re-alkalinisation – cathodic reactions around rebar produce hydroxyl ions
• steel cathodes attract alkali metal ions towards its surface, so high alkalinity is restored around rebar.
• Temporary anode (steel mesh) attached to concrete. The electrolyte penetrates concrete and raises alkalinity at cover. Anti-carbonation coating then applied.
Cathodic protection – permanent and very expensive technique. Anode system (coating or mesh) sprayed/fixed to whole surface of concrete. Current applied which passes to reinforcement, which is then made cathode, preventing corrosion of reinforcement.
o Calcium chloride:
Assess extent of chloride by sampling/testing and assess extent of corrosion and depth of rebar.
Either shore up or demolish if building structurally affected.
Difficult to repair as new corrosion cells forms on boundary of repair – use of zinc anodes embedded in repair and attached to rebar can reduce effect.
Cathodic protection available for high levels of chlorides.
Could apply corrosion inhibitors to surface.
o ASR
Replacing spalled concrete and reinforcement often the most suitable repair. Remove spalled concrete and corroded rebar and replace. Clean and treat surrounding areas, and repair using cement mortar, epoxy mortar or concrete.
What tests are available to detect carbonation?
- The extent and depth can be confirmed using manganese hydroxide or phenolpthalin solution.
- Phenolpthalin indicator – phenolpthalin solution reacts with uncarbonated cement by leaving a pink indicator.
- Electromagnetic device can detect reinforcement positions, cover depths and diameters.
- Samples can be sent to a lab for testing.
How would you specify repairs to concrete affected by carbonation?
o Removing defective concrete and cut out the reinforcement to damaged members. New reinforcement fixed butt-welding to existing and new concrete cast.
o Guniting – (proprietary process) fine concrete sprayed to concrete surface under repair at high velocity.
o Coating/sealants/membranes can reduce carbonation progress, but if chlorides are present as rebar depth coating will not prevent carbonation.
o Electrochemical re-alkalinisation – cathodic reactions around rebar produce hydroxyl ions
– steel cathodes attract alkali metal ions towards its surface, so high alkalinity is restored around rebar.
Temporary anode (steel mesh) attached to concrete. The electrolyte penetrates concrete and raises alkalinity at cover. Anti-carbonation coating then applied.
o Cathodic protection – permanent and very expensive technique. Anode system (coating or mesh) sprayed/fixed to whole surface of concrete. Current applied which passes to reinforcement, which is then made cathode, preventing corrosion of reinforcement.
Explain how you would deal with a case of sulphate attack on concrete
- Must be high levels of water-soluble sulphates within the adjacent ground. To affect concrete buried in the ground, concrete must be of low density and must be a large amount of moisture movement through the concrete. Common cause is contaminated hardcore beneath concrete floor slab – sulphates become mobile due to a broken drain/high water table. Sulphate enters concrete (solution form), water evaporates leaving the sulphates, they react with calcium hydroxide and calcium aluminates causing expansion and the concrete deteriorates – cracking and heave.
- Concrete should be removed along with contaminated hardcore.
Explain how you would deal with a case of ASR.
- Occurs when pore water reacts with certain aggregates to produce a gel, which absorbs water, expands and causes cracking. 3 factors must be present – critical silica in the aggregate (troublesome aggregates in the SW), sufficient moisture, high alkalinity from cement/external sources. Can result in structural failure and need to demolish building if tensile strength of concrete is reduced.
- Repair by replacing spalled concrete and reinforcement often the most suitable repair. Remove spalled concrete and corroded rebar and replace. Clean and treat surrounding areas, and repair using cement mortar, epoxy mortar or concrete.
Can you list some common defects which occur in masonry?
- Cavity wall tie corrosion
- Lack of movement joints
- Frost attack
- Soluble salt crystallisation (efflorescence)
- Calcium silicate brickwork
What are the signs of cavity wall tie failure?
- Horizontal cracking to mortar joints at regular intervals
- Expansion of the outer leaf of brickwork
- Wall bulges at 900mm horizontally and 450mm vertically.
What causes cavity wall tie failure?
- Corrosion of the ties due to poorly galvanised ties between 1960s and early 1980s
- Corrosion of embedded tie in black ash mortar due to chemical action (sulphates)
- Wall ties may have been incorrectly or be insufficient in number
What are the ways in which wall tie corrosion can be remedied?
- Resin fixed
- Mechanically fixed
- Cementitious wall anchors
How are cementitious wall anchors installed to a cavity wall?
- Holes are drilled, ties installed and tightened to the required torque.
- Cracked brickwork and mortar can be replaced.
Where would you expect to find movement joints in masonry and how frequently should they be installed?
- In long stretches of masonry, such as terraced houses
- Boundary walls
- Should be placed every 12-15m
What are the issues that are caused without having movement joints?
- Thermal movement occurs in the brickwork
- The book end effect takes place
- Movement results from the expansion of the brickwork due to a rise of moisture content
How would you remedy defects caused by a lack of expansion joints in masonry walls?
- Cur new 16mm movement joints every 12-15m in the brickwork.
What is frost attack and how would you recognise it and where does it take place in masonry walls?
- It is the spalling of brickwork owing to the effects of water ingress, which can lead to the total disintegration of the brickwork.
- It takes place to exposed brickwork such as a parapet wall or exposed elevations.