Building Pathology Flashcards
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.
How is frost attack caused in a brickwork wall?
- It can occur in older bricks and those under burnt during firing
- It occurs near the surface of the bricks as moisture gains easy access
- Frost attack then takes place which requires regular freeze and thaw cycles when the material is wet. The expansion caused by the freezing of the trapped water causes the brick to break/spall off.
How would you remedy sections of spalled brickwork?
- Remove the source of wetting i.e. repair leaking rainwater goods etc
- Cut out and replace the defective sections of brick in isolated locations
What is soluble crystallisation and how is it caused?
- Unsightly salt deposits, efflorescence, are deposited on the surface of the brickwork and display white staining
- It is caused by salts contained within the brickwork passing through the pores of dry material and leave the salts on the surface upon evaporation
- Deposited salts gather at the depth of wetting and create back pressure which delaminates the brick
- This exposes pores and the process repeats
What are the issues with calcium silicate brickwork?
- Unrestrained thermal expansion takes place
- There is generally poor resistance to frost when brickwork is contaminated by chloride due to sea water (not used near coast)
- Diagonal cracking often takes place which then allows moisture ingress to occur.
What are the remedial measures available for defects due to calcium silicate brickwork?
- Re-point in a sulphate resisting mortar if ground water contains sulphate
- Allow for adequate movement joints at 12-15m centres.
How might you identify that calcium chloride has affected a concrete structure?
- Corrosion of the steel reinforcement has taken place and caused the concrete to spall off.
- Visible rust staining to the steel reinforcement.
What causes concrete to suffer from calcium chloride?
- Calcium chloride was used as an accelerator for setting concrete in the 1950s and 60s.
- De-icing salts can also be a problem in concrete car parks
- When chlorides are present in the concrete, the steel reinforcement corrodes when through it is in an alkaline environment.
Can you tell me how you would know that calcium chloride was the cause of the corrosion to concrete and subsequent delamination of the cover rather than carbonation?
- Unlike carbonation, calcium chloride corrosion is localised and is known as pitting.
- If left, the steel reinforcement can completely be destroyed by the corrosion which is darker in colour than corrosion by carbonation.
Can you tell me some factors that might affect the resistance of concrete to chloride penetration?
- Depth of the concrete cover
- Mix design
- Use of admixtures
- Degree of curing
What remedial repair options would you advise your client to take when dealing with a building suffering from calcium chloride?
- In the first instance, assessment of the extent of the chloride should be undertaken by sampling and chemical testing.
- Assess the depth of the rebar and extent of corrosion
- Then take appropriate action, such as shoring or, in extreme cases, demolition.
- Use of zinc anodes embedded in a repair and attached to the rebar can reduce the effect of the calcium chloride, but it is not a permanent cure.
- Cathodic protection can be used but it is expensive and complex
What is ASR and how might you identify it on site?
- Alkali Silica Reaction produces a map pattern cracking effect with small concrete pop outs.
- Uncommon to building structures and is seen more in civil structures.
What causes ASR?
- It occurs when water in the concrete pores reacts with certain aggregates to create a gel.
- The gel absorbs water, expands and causes the concrete to crack
- For ASR to occur it is depended on 3 factors – 1. Silica in the aggregate 2. Sufficient moisture 3. High alkalinity.
What is the difference between AAR and ASR?
- Alkali Aggregate Reaction is the main concrete deterioration risk associated with aggregates, but ASR is the most common form of AAR.
How do you remedy ASR?
- Take a risk based approach i.e. is the consequence severe, such as failure of the structure?
- Replacing a reinforcement and the spalled section of concrete is often the most suitable, relatively short term repair.
What is plastic cracking in concrete?
- Segregation or obstructions within the concrete i.e. reinforcement spaces.
- The concrete is normally horizontal and may combine to honeycomb effect.
- Result of rapid drying out of the concrete
Can you name some typical stone defects?
- Pollution
- Thermal stress
- Wearing by wind borne solids
How does pollution cause damage to stonework?
- Sulphur dioxide and water can make the surface of stones rough and cause surface crazing
- In coastal areas the wind can carry and deposit sea spray on the stones which will deposit chlorides on the stone’s surface.
How is thermal stress caused to stonework?
- The day time sun warms the surface of the stonework and at night this is reversed causing differential thermal stress and fatigue of material.
- The wetting depth of the material/susceptibility to water ingress becomes greater.
How does wearing by wind borne solids affect stonework?
- In coastal areas some solids, such as sand grains, may be carried considerable distances by strong winds, which will slowly erode the surface of the stonework
- This will affect the stone’s ability to resist the passage of moisture.
What are the typical defects associated with a 1960s high rise office block?
- Condensation
- Failure of external cladding and structural components
- Deteriorated DPCs
- Floor slab settlement
- Lack of a DPM
- Deteriorated plastic plumbing goods
- Brittle sarking felt
- Rotted softwood timbers
- Failing flat roofs
- Wall tie corrosion
- Spalling concrete
- Corrosion of metal frames.
- Deleterious materials – HAC, asbestos, woodwool slabs, concrete carbonation, calcium chloride accelerators, corrosion of reinforcement and metal structures (fire escape), fixing failure (external wall panels, parapet walls).
- Low performance for dampness and insulation.
Your client has just bought a concrete framed office block, built in the 1960s. Explain to him the issues that will need to be considered when refurbishing the building from a pathology point of view.
- Whether HAC, hollow clay pot or wood wool slabs were used in the construction of the property.
- Whether the concrete frame suffers from carbonation, chloride attack, ASR or sulphate attack and will require remedial works.
- There may be low floor loading which may not accommodate current loads without strengthening.
- The building may be poorly insulated with high air infiltration rates.
Your client has a concrete clad building that is suffering from carbonation. You have repaired the current defective areas. How can you prevent further problems occurring?
- You can treat the surface of the concrete to stop the concrete alkalining, but must be crack proof coatings to be effective.
- Alternatively could install cathodic protection, but this is expensive.
Your client’s building is known to have been built using HAC concrete. Is this a problem? What would you recommend that he does about it?
- Often there are no implications if left, but it would depend on situations and conditions. Most structures have sufficient reserve strength even when converted.
- In order to ensure that there are no issues, I would recommend that my client undertakes an investigation consisting of sample testing to assess the HAC’s strength, extent of conversion, and durability, determining what materials were used from the Local Authorities’ records of HAC buildings.
- If the strength has been reduced, the live loads will either need to be reduced or strengthening will be required.
- Localised repairs of any reinforcement corrosion.
Can you tell me some typical defects to a 1960s concrete portal frame building?
- Leak to asbestos cement roof sheets
- Carbonation to the concrete frame
- Cavity wall tie failure
- Cracking and delamination to the ground bearing slab.
What was the primary type of asbestos used in asbestos cement roof sheets and how long should they last for?
- Chrysotile
- Between 40-60 years
How might you identify if the asbestos cement roof sheets are leaking/defective?
- Cracking parallel with the long edge
- Cracking across the width of the sheet
- Corrosion of the fixings
- Moss growth and surface deterioration
How are the cracks to the width of the sheet caused?
- Structural movement
- Overloading/foot traffic
- Wind loads coupled with defective fixings
How does corrosion of the fixings lead to a defective roof sheet?
- The expansion of the fixings leads to the cracking of the sheets and then subsequent water ingress.
How does moss growth cause defects and leaking to the sheets?
- Carbonation increases porosity and in damp conditions the surface is suitable for moss and algae growth.
- The algae produces acidic run off which damages other components
What remedial works can you undertake to asbestos cement roof sheets?
- Encapsulation
- Overlaying
- Full replacement
Describe how you would replace an asbestos cement roof.
- Consult HSE guidance note A14 and A12 which relates to the handling of asbestos and the cleaning of it during removal.
- Protect nearby surfaces with sheeting
- Dampen and remove fasteners and place in a waste container
- Double wrap large pieces in bags and seal
- Dispose of waste at a licensed disposal centre.
How would you identify carbonation to a concrete frame?
- Cracking along the line of the reinforcement bars
- Spalling and delamination of whole areas of concrete cover
How is carbonation caused?
- Atmospheric carbon dioxide reacts with water in the concrete which forms a carbonic acid that neutralises concrete’s natural alkalinity
- Alkalinity of concrete is reduced, passivity lost and the steel reinforcement eventually corrodes.
- Corrosion makes the steel expand which eventually makes the concrete cover crack and spall off.
How do you identify that carbonation has occurred?
- Visual inspection
- Hammer test to discover unsound concrete
- The depth of the carbonation can be ascertained by phenolpthalein, which is a pink dye that indicates where no carbonation has occurred.
What repair options can be undertaken to address carbonated concrete?
- Isolated replacement
- Electrochemical re-alkalisation
- Cathodic protection
Tell me how you would undertake isolated repairs to carbonated concrete?
- Cut out the concrete surrounding the rebar and over the fully corroded length.
- Clean the steel reinforcement bar and apply corrosion inhibitor i.e. Sika/Fosroc product
- If badly corroded replace the steel bar by welding new piece to existing
- Replace the concrete cover with proprietary product to restore alkalinity
- Apply anti-carbonation product to external surface.
How does cathodic protection work?
- In corrosion cells anodes attract oxides which causes the deterioration whilst cathodes do not.
- If an electrical current can be applied to metal it can be made into a cathode.
- An anode system, coating or mesh is sprayed or fixed to the whole surface of the concrete and a current is applied which then passes into the reinforcement.
What are the signs of cavity wall failure?
- Horizontal cracks 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 placed or be insufficient in number.
What are the ways wall tie corrosion can be remedied?
- Resin fixed
- Mechanically fixed
- Cementitious wall anchors
How are cementitious wall anchors installed?
- Holes are drilled, ties installed and tightened to required torque.
- Cracked brickwork and mortar can be replaced.
What are the causes of cracking to the ground bearing floor slab?
- If soil contains high sulphates level and no DPM is installed
- Hardcore could be contaminated with high sulphates
- Sulphate may become mobile due to a broken drain or high water table.
Can you describe the process of sulphate attack to the slab?
- Soluble sulphate enters the concrete
- Water evaporates leaving the sulphates
- Water then reacts with calcium hydroxide causing expansion
- Concrete cracks due to expansion
How would you address a concrete slab that is cracking and delaminating?
- Remove the source of soluble sulphates and repair the drain
- Break up the concrete slab and the hardcore and replace, installed with new DPM.
Can you name some typical defects to 1960s concrete high rise buildings?
- Failed asphalt roof coverings
- Carbonation
- High chloride content to frame
- Condensation
What defects can occur to mastic asphalt roof coverings?
- Crazing
- Cracking
- Blisters
- Ponding
How is crazing caused to asphalt roof coverings?
- By a lack of solar reflective treatment and ponding through the expansion of the material in hot weather and contraction in cold weather.
How is cracking of the covering caused to asphalt roof coverings?
- Differential settlement and movement between asphalt and the substrate often due to the absence of an isolating membrane.
How are blisters caused to asphalt roof coverings?
- By trapped moisture as some concrete roofs are asphalted before they are completely dry.
How is ponding caused to asphalt roof coverings?
- Inadequate falls and poor workmanship.
What options are available to address defects to asphalt flat roofs?
- Isolated repairs
- Encapsulation (application of a liquid applied membranes)
- Total replacement
Can you talk me through the process of undertaking isolated repairs to mastic asphalt?
- Hot poultice repairs are carried out by first covering the defective area with molten asphalt so that underlying material is softened.
- The existing defective, now softened, mastic is then removed to a depth of 10mm and a width of approximately 75mm.
- New molten asphalt is then poured in its place and a lap joint is formed with the surrounding existing asphalt.
How would you identify carbonation to a concrete frame?
- Cracking along the line of the reinforcement bars.
- Spalling and delamination of whole areas of concrete cover.
How is carbonation caused?
- Atmospheric carbon dioxide reacts with the water in concrete which forms a carbonic acid which neutralises concrete’s natural alkalinity.
- Alkalinity of concrete is reduced, passivity is lost and the steel reinforcement eventually corrodes.
- Corrosion makes the steel expand, which eventually makes the concrete cover crack and spall off.
How do you identify that carbonation has occurred?
- Visual inspection
- Hammer test to discover unsound concrete
- The depth of carbonation is ascertained by phenolthalein which is pink dye which indicates where no carbonation has occurred.
What repair options can be undertaken to address carbonated concrete?
- Isolated replacement
- Electrochemical re-alkalisation
- Cathodic protection
Tell me how you would undertake isolated repairs to carbonated concrete?
- Cut out the concrete surrounding the rebar and over the full corroded length
- Clean the steel reinforcement bar and apply corrosion inhibitor i.e. Sika/Fosroc product.
- If badly corroded, replace the steel bar by welding new piece to existing.
- Replace the concrete cover with proprietary product to restore alkalinity.
- Apply anti-carbonation product to external surface.
How does cathodic protection work?
- In corrosion cells anodes attracts oxides which causes the deterioration whilst cathodes do not.
- If an electric current can be applied to metal it can be made into a cathode.
- An anode system, coating or mesh is sprayed or fixed to the whole surface of the concrete.
- A current is applied which then passes to the reinforcement.
How can you identify that chloride is present in the concrete?
- Localised cracking due to how the steel corrodes.
- Rust staining
- Localised delamination of cover due to the expansion of the rebar.
What are the causes of chloride introduction to concrete in a high rise building?
- Introduced as an accelerator during the mixing process
- Naturally occurring through unwashed marine aggregates
- External contamination through de-icing salts
- Chloride ions can break down the passive layer of alkalinity around the rebar.
How can you tell the difference between concrete that is affected by carbonation and concrete that has been affected by calcium chloride?
- Calcium chloride causes the rebar to corrode at a darker colour than carbonation
- The effects of calcium chloride to steel reinforcement are localised and as such is termed ‘pitting corrosion’.
How would you advise your client to remedy concrete affected by high chloride content?
- Undertake patch repairs similar to carbonation i.e. clean/replace corroded sections of rebar
- Adopt a cathodic protection system to prevent further effects by the chloride ions.
What is condensation?
- Condensation is when warm moisture vapour comes into contact with a cold surface and cools to the dew point.
- At the dew point, the water vapour turns into a liquid on the cold surface
What is the dew point in relation to condensation?
- The atmospheric temperature which varies according to pressure and humidity, below which water droplets begin to condensate and dew forms.
What are the symptoms of condensation?
- Surfaces become misty with stains running down the walls
- Damp patches with no definitive edges occur along with mould growth.
What are the typical causes of condensation?
- Human activity such as washing, cooking etc.
- Cold bridges in well insulated buildings.
- Poor ventilation.
How do you repair condensation?
- Reduce dampness in the building surfaces by:
o Improving ventilation
o Improving insulation
o Increasing heating levels
o Alter the living habits of the occupants.
What is cold bridging?
- Localised areas in buildings with a higher thermal conductivity than in adjacent areas, resulting in an overall reduction in the thermal insulation of the building.
What causes cold bridging?
- Differences in construction such as a break in the continuity or a penetration of the insulation.
- Lintels over doors and windows in the 1960s and 70s were plagued by this problem.
What remedies are available to a property suffering from areas of cold bridging?
- Ensuring that there is adequate ventilation
- During construction, ensuring that cavities are closed and that vertical/horizontal dpcs are incorporated into construction.
Can you name some typical defects to 1980s steel framed buildings?
- Cut edge corrosion to profiled metal roof sheets
- UV deterioratin of roof lights
- Failed metal cladding coatings
- Composite cladding panels
What are the symptoms of cut edge corrosion?
- The protective coating starts to peel back at the lap joints – approximately 10mm is considered defective.
What are the causes of cut edge corrosion?
- When the roof sheets are cut in the factory the coating is damaged and micro-cracking occurs which allows the admission of moisture and leads to corrosion.
- Water also get trapped at the lap joints and the coating lifting exacerbates.
How do you remedy cut edge corrosion?
- Clean the affected area and remove the defective coatings.
- Gun apply a sealant to bridge the gap (25mm either side of joint)
- Brush apply one coat of seamsil (37mm) either side of the joint.
How do you identify that UV deterioration has taken place to GRP rooflights?
- The exterior gel coat to the rooflights deteriorated and the glass fibres are exposed due to UV exposure.
- The sheets become brittle and hard and are easily damaged.
- Leaks become more likely as does moss growth.
- Light transmission is reduced.
How would you remedy a UV deteriorated rooflight?
- Replace the rooflight.
- Or apply a translucent resin coating such as HD Sharmans’ Delglaze once the surface has been suitably cleaned and dried.
What are the signs of failed metal cladding coating?
- Plastisol, PVF2 etc. coating starts to peel back and flake away in places.
- Corrosion could be evident to exposed cladding below.
What are the causes of failed metal cladding coating?
- Coating may have lost adhesion due to poorly prepared substrate
- The coating may have broken down due to UV and temperature change
- The recommended repaint guidelines are often ignored (every ten years)
What would you advise to do to address failed cladding coatings?
- Thoroughly prepare the substrates and spray apply a new coating such as Girocoat or steel seal.
Why are composite cladding panels classed as a defect?
- The combustability and fire spread is the main concern as there is a risk of collapse due to instability.
- Expanded polystyrene is the worst infill material as it promotes rapid fire spread.
What are the other types of infill material and when did the LPCB become aware of the dangers?
- EPS – Expanded polystyrene
- PUR – polyurethane foam
- PIR – polyisocyanurate foam
- PF – phenolic foam
- Pre-2000 are likely to have a PUR foam
What remedy would you suggest to your client in the event of discovering non-LPCB compliant composite cladding?
- Send a sample to the lab for testing to ascertain the material being dealt with.
- PIR can be engineered to comply.
What are the typical life spans for flat roof coverings asphalt/built up felts?
- Asphalt – 25 years
- Built up felt – 10-20 years
- GRP (Fibreglass) – 20-30 years
- Green roof – 40-50 years
- EPDM – 50 years
Explain the difference between warm and cold deck roof construction
- Cold roof – the thermal insulation layer is located immediately above or between the ceiling joists with the vapour control layer below the insulation, so everything above the insulation including rafters, roof space etc. will be colder than the living space beneath it. When warm/damp air permeates up through the ceiling and reaches the cold roof space, the change in temperature can result in condensation forming so adequate roof space ventilation must be provided to remove this air
- Warm roof – the insulation layer is laid on top of the roof structure with the structural deck and its supports being at a temperature closer to that of the building’s interior. The vapour control layer is placed below the insulation and the plywood/osb board sits on top.
What are the common defects associated with sheet lead coverings?
- Lead is extremely sensitive to changes in temperature – in temperature fluctuations the lead will expand/contract in cycles. Where bay sizes exceed maximum recommended sizes there will be rippling and cracking.
- The junction along the length of each bay is normally formed with a roll or welted upstand. Inappropriate fixing will result in buckling and cracking of the sheet, often along the roll.
- Foot damage causing sharp debris to pierce the lead
- Corrosion pinholes caused by acid run off from algae, moss and types of wood
- Condensation dampness due to poor ventilation under the lead
- Inadequate overlaps at lead joints or joints are poorly made
- Puddles caused by inadequate falls/slopes on roofs and large gutters.
What do the lead codes refer to?
- The thickness of the lead that should be used to best suit a project
- Ranging from Code 3 to Code 8 separating lead into different thickness and weight, equating to a specific weight measured in kilograms per square meter.
- Each code has been specifically classified for different purposes to ensure lead functions to a high quality standard and is installed correctly.
What is a tingle?
- Slate straps that are commonly used for repairing broken or slipped slate roof tiles by fixing it to the batten and turning the end up to hold the repaired slate in place.
- More temporary measure to keep the slates in place until repairs can be carried out.
- Usually formed from lead and nailed to the roofing battens, taken underneath the loose tiles and then neatly folded around the tail of the slate.
Name the common defects associated with slate roof coverings?
- Nail sickness (original fixings made of iron/poor quality galvanised steel and will corrode over time, which can cause nails to snap allowing the slate to slip).
- Broken slates – absorb water over time and eventually start to fracture/break.
- Slipped slates – nail breakage or enlargement of the nail hole as a result of natural decay.
- Delamination – texture is layered and when it starts to reach the end of its life, the layers might begin to split apart, which can lead to breakages and leaks.
- Flashing damage.
What problems can arise from using two different metals next to each other?
- When a dissimilar metals contact each other in the presence of moisture, galvanic corrosion may result. The wet metals behave like a battery and produce an electrical current and the surface of one or both metals becomes pitted and corrode as the exchange of electrons takes place. Galvanic corrosion can seriously weaken metal parts, which eventually will fail. Structures could collapse and piping could break/develop leaks if materials are incompatible.
- The most common dissimilar metal combinations are carbon steel/aluminium and carbon steel/copper. When in contact they should be coated with nonconductive material, such as epoxy or phenolic paint. Gaskets can also be used to separate metals.
How are rainwater goods sized and what section of the building regulations relates to this?
- Part H (Drainage and Water Disposal)
- The size of guttering should be determined by the area of the roof and the anticipated rainfall intensity ( amount of water anticipated in a 2 minute rainstorm). There are a number of calculators that can be used to size gutters and downpipes based on this information.
What problems are likely to be associated with a leaking flat roof with woodwool slab decking and what remedial works should be considered?
- During the 1950s-70s woodwool was used as a permanent formwork as a convenient means of providing thermal insulation properties to exposed floor slabs.
- Because of the permanent shuttering conceals the steel reinforcement it is difficult to know whether full compaction and coverage of the steel reinforcement has been achieved and whether it was placed properly and was properly embedded in concrete. The spacers may have been displaced and the steel could rest directly on the top of the surface of the slab and as a result strength and fireproofing would be compromised.
- This could lead to a poor or failed bond between the woodwool and the hardened concrete, excessive penetration of the grout/mortar into the woodwool leading to the impairment of the concrete and honeycombing/voiding of the concrete beneath the reinforcement.
- This would leave the steel reinforcement exposed to any roof leaks and could lead to corrosion and the weakening of the reinforcement.
- Non-destructive testing can be undertaken to identify whether any issues exist, although physical sampling is likely to be more reliable. Removal of the shuttering and repairs using hand placed mortars/sprayed concrete may be necessary if defects are found.
What problems are associated with replacing slated roof coverings with new concrete tiles?
- Sagging, as concrete tiles are heavier than slates, and this can occur if the roof timbers have not been strengthened.
- Roof spread where rafters have pushed the walls outwards and sunk in the middle. In severe cases, structural work may be needed and a structural engineer should be consulted.
What are the main defects caused to flat roofs?
- Excessive movement
- Entrapped moisture
- Solar degradation
- User negligence
What causes excessive movement to flat roofs?
- Drying shrinkage (moisture movement of timber and concrete)
- Deflection of the decking under the load of the covering etc.
- Structural failure of the decking
- Thermal changes in the deck and coverings
What are some of the results of excessive movement in flat roofs?
- Roof sagging
- Localised ponding
- Splitting/tearing of the roof coverings
- Water ingress at pipe and vent junctions
What causes moisture to become entrapped in a flat roof?
- Lack of effective ventilation to remove vapour
- Inadequate or missing moisture barrier
- Laying covering directly on to wet decking or snow or not allowing free water to evaporate from concrete.
From an inspection of a flat roof how could you tell moisture was entrapped?
- Blistering/bubbling of the surface as a result of hot weather.
How would you identify if solar degradation had occurred to a flat roof?
- Blistering and cracking would appear on the surface.
- Crazing through the surface.
- Asphalt in particular becomes brittle.
What are the causes of solar degradation in flat roofs?
- Inadequate solar protection using chippings/paint/tiles.
- Wind scouring of the chippings.
What are the causes of user negligence to flat roofs?
- Impact damage to surface
- Specifying an inadequate number of movement joints
- Designing ineffective ventilation
- Short life of materials and incorrect falls
- Overheating of asphalt during laying
- Poorly laid reflective chippings