3-K2M Harvey Building Spalling Detail Sheet S1.0.pdf

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CLEANING OF REINFORCING STEEL

1.

2.

3.

4.

LIGHT/MEDIUM CORROSION IS DEFINED AS PORTIONS OF THE REINFORCEMENT WITH

SURFACE CORROSION AND LOCAL PITTING THAT RESULTS IN LESS THAN 20% OF

SECTION LOSS OF THE STEEL. HEAVY CORROSION IS ANY CORROSION RESULTING IN

SECTION LOSS GREATER THAN 20%

CLEAN ALL EXISTING REINFORCEMENT WITH LIGHT/MEDIUM OR HEAVY CORROSION TO

REMOVE ALL CORROSION SCALE AND EXPOSE BARE STEEL. ALL SURFACES OF THE

REINFORCEMENT SHALL BE CLEANED. DETERMINE SECTION LOSS AFTER

REINFORCEMENT IS CLEANED TO DETERMINE IF SUPPLEMENTAL REINFORCEMENT IS

REQUIRED.

FOLLOW THE BONDING AGENT MANUFACTURER CLEANING RECOMMENDATIONS FOR

ALL REPAIRS. ALL SCALE SHOULD BE REMOVED FROM THE BAR AS NECESSARY TO

PROMOTE MAXIMUM BOND OF REPLACEMENT MATERIAL. OIL-FREE ABRASIVE BLAST IS

THE PREFERRED METHOD. A TIGHTLY BONDED LIGHT OXIDE BUILD-UP ON THE SURFACE

MAY RESULT FROM HIGH-PRESSURE WATERBLASTING, WITH OR WITHOUT ABRASIVE.

THIS IS USUALLY NOT DETRIMENTAL TO BOND, UNLESS A PROTECTIVE COATING IS

BEING APPLIED TO THE BAR SURFACE, IN WHICH CASE THE COATING MANUFACTURER'S

RECOMMENDATIONS FOR SURFACE PREPARATION SHOULD BE FOLLOWED.

REINFORCEMENT SHOULD BE CLEANED AND DRY BEFORE COATING WITH CORROSION

INHIBITOR AND BONDING AGENT.

NO CORROSION

ORIGINAL MILL SCALE

CORROSION

LIGHT/MEDIUM

CORROSION

HEAVY

CLEANING REQUIRED

CLEANING UNDERSIDE OF BAR

CONCRETE

PATH OF

ABRASIVES

CAREFULLY REMOVE EXIST.

CONC. AROUND BAR TO REACH

UNDAMAGED PORTION OF BAR

EXIST. BOTTOM

OXIDIZED BAR

PROVIDE NEW HORIZONTAL BAR.

IF LOSS OF SECTION IS 25% OR

MORE MATCH EXIST. (TYP.)

ELEVATED SLAB DETAIL

BAR

UNOXIDIZED OXIDIZED BAR

BAR

UNOXIDIZED

REPAIR OF REINFORCING STEEL

DUE TO SECTION LOSS

IF REBAR HAS LOST MORE THAN 25% OF ITS CROSS SECTION (20% IF 2 OR MORE CONSECUTIVE PARALLEL BARS ARE AFFECTED)

CONSULT THE ENGINEER.

IF REPAIRS ARE REQUIRED TO THE STEEL REINFORCEMENT THE FOLLOWING METHODS SHOULD BE USED:

1. COMPLETE BAR REPLACEMENT ADDITION OF SUPPLEMENTAL BAR OVER AFFECTED SECTION.

2. NEW BAR MAY BE MECHANICALLY SPLICED TO OLD BAR OR PLACED PARALLEL TO AND APPROXIMATELY 3/4" FROM EXISTING BAR.

3. LAP LENGTH SHALL BE DETERMINED IN ACCORDANCE WITH ACI 318, AND STRUCTURAL GENERAL NOTES.

EXIST.

REBAR

NEW SPLICED

REBAR

CORROSION

LIGHT/MEDIUM

CORROSION

HEAVY

SEE NOTES

ACI REQUIRED LAP

CLEANED REINFORCEMENT RECOMMENDED CLEARANCE

�3/4" MAX.

CORROSION

LIGHT/MEDIUM

SEE NOTES

ACI REQUIRED LAP

TYPE II REPAIR

(COSMETIC COATING) ELEVATION VIEW

SURFACE OF CONCRETE

CLEAN EXPOSED REINF. STEEL AND

COAT EXPOSED BARS WITH

REINFORCEMENT PROTECTION

MATERIAL MIN 20 MIL DFT COATING

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TYPICAL CONCRETE REPAIR

ELEVATION AT COLUMN

CLEAN OXIDIZED, EXPOSED

EXIST. REINFORCING AS

REQUIRED (TYP.)(FIELD VERIFY)

DO NOT CUT OR DAMAGE

EXISTING REINFORCING.

EXIST. CONCRETE BEAM

EXIST. COLUMN

FIELD VERIFY AND PREPARE

REPAIR AREA AS REQUIRED.

PROVIDE NEW COLUMN

VERTICAL, IF LOSS OF SECTION

IS 25% OR MORE. MATCH EXIST.

(TYP.)(FIELD VERIFY)

PROVIDE #4 BENT BAR IF LOSS

OF SECTION IS 25% OR MORE

AS REQUIRED

SECTION A-A

EXIST. COLUMN

VERTICAL (TYP.)

NEW VERTICAL

AS REQUIRED

EXIST. CONCRETE

COLUMN

DRILL AND INSTALL NEW #4 TIES w/

EPOXY ADHESIVE SYSTEM TO

ANCHOR BAR INTO EXIST. COLUMN

6"

�3"

APPLY SIKA TOP 123 PLUS

MORTAR (FOLLOW

MANUFACTURER'S INSTRUCTIONS)

SEE NOTE 4 BELOW

UNDAMAGED CONCRETE

EXIST. UNCORRODED REBAR

TIGHTLY BONDED TO CONCRETE

EXIST. CONCRETE SURFACES PREPARED

TO RECEIVE REPAIR MATERIAL

EXIST. CORRODED REBAR, TYP.

TYPICAL EXPOSING AND UNDERCUTTING

REINFORCING STEEL DETAIL

SECTION THROUGH CONCRETE MEMBER

APPLICABLE TO HYDRODEMOLITION, HYDROMILLING, AND PNEUMATIC, HYDRAULIC

AND ELECTRIC BREAKERS

CAUTION! BEFORE STARTING REMOVALS, REVIEW EFFECT OF REMOVALS ON

STRUCTURAL INTEGRITY. PROVIDE SHORING OF MEMBER AS NECESSARY.

PARTICULAR CARE SHALL BE EXERCISED AT SLAB/BEAM CONNECTIONS TO COLUMNS.

1.

2.

3.

4.

5.

REMOVE LOOSE OR DELAMINATED CONCRETE ABOVE CORRODED REBAR.

ONCE INITIAL REMOVALS ARE MADE, PROCEED WITH UNDERCUTTING OF

ALL EXPOSED CORRODED REBAR. UNDERCUTTING WILL PROVIDE

CLEARANCE FOR UNDER BAR CLEANING, FULL BAR CIRCUMFERENCE

BONDING TO SURROUNDING CONCRETE, AND WILL SECURE THE PATCH

STRUCTURALLY.

UNDERCUTTING OF EXISTING REBAR: PROVIDE MINIMUM 3/4" CLEARANCE

BETWEEN EXPOSED BARS AND SURROUNDING CONCRETE OR 1/4" MORE

THAN THE LARGEST AGGREGATE IN CONCRETE REPAIR MATERIAL,

WHICHEVER IS GREATER.

CONCRETE REMOVALS SHALL EXTEND ALONG THE REBAR TO LOCATIONS

THAT ARE FREE OF BOND INHIBITING CORROSION, AND WHERE THE BAR IS

WELL BONDED TO SURROUNDING CONCRETE.

IF UNCORRODED REBAR IS EXPOSED DURING THE UNDERCUTTING

PROCESS, CARE SHALL BE TAKEN NOT TO DAMAGE THE BAR'S BOND TO

SURROUNDING CONCRETE. IF BOND BETWEEN BAR AND CONCRETE IS

BROKEN, UNDERCUTTING OF THE BAR WILL BE REQUIRED.

ANY REINFORCEMENT WHICH IS LOOSE SHALL BE SECURED IN PLACE BY

TYING TO OTHER SECURED BARS OR BY OTHER APPROVED METHODS.

DESIGN CRITERIA

APPLICABLE BUILDING CODE: 2023 FLORIDA BUILDING CODE, BUILDING (2023 FBC)

SPALLING REPAIR GUIDELINES :

THE FOLLOWING IS OFFERED FOR GENERAL INFORMATION AND GUIDANCE TO THE

CONTRACTOR AND BUILDING OWNER(S). DURING REPAIRS, CONDITIONS MAY BE EXPOSED

WHICH REQUIRE FURTHER INSPECTION BY THE ENGINEER AND MORE SPECIFIC INSTRUCTIONS

FOR PROPER REPAIR.

1) ALL WORK SHALL COMPLY WITH APPLICABLE CODES INCLUDING, BUT NOT LIMITED TO FBC

2023 PLUS SUPPLEMENTS, ASCE 7-22, AND ACI 318.

2) THE CONTRACTOR MAKING THE REPAIRS SHALL BE RESPONSIBLE FOR THE MEANS,

METHODS, TECHNIQUES, SEQUENCE, PROCEDURES, AND ALL SAFETY ASPECTS OF THE

CONSTRUCTION.

3) THE CONTRACTOR SHALL PROTECT ALL UTILITIES, BUILDING COMPONENTS, AND

PROPERTY ADJACENT TO THE REPAIR AREAS. THE CONTRACTOR SHALL BE RESPONSIBLE

TO REPAIR OR REPLACE ANY DAMAGE AT THEIR EXPENSE.

4) REMOVE ALL NON-STRUCTURAL ITEMS ATTACHED TO THE AREA OF REPAIR TO ALLOW

FULL ACCESS TO THE REPAIR.

5) TEMPORARY SHORING SHALL BE INSTALLED, IF REQUIRED, TO SUPPORT LOADS

SUPPORTED BY THE STRUCTURAL ELEMENT BEING REPAIRED. EACH POST SHORE SHALL

BE CAPABLE OF SUPPORTING AT LEAST FIVE THOUSAND POUNDS INDEFINITELY AND SHALL

BE PLACED IN A PROPER MANNER. TEMPORARY SHORING IS THE CONTRACTOR'S

RESPONSIBILITY. THE CONTRACTOR SHALL ENGAGE A LICENSED PROFESSIONAL

ENGINEER TO DESIGN TEMPORARY SHORING. PROVIDE SHORING PLAN, SHORING

SEQUENCE, AND CALCULATIONS SUBMITTAL SIGNED AND SEALED BY A LICENSED

ENGINEER IN THE PROJECT LOCATION.

6) REPAIR PROCEDURE IS AS FOLLOWS:

(a) SOUND CONCRETE SURFACES TO LOCATE CONCEALED SPALLING AND DELAMINATION.

(b) REMOVE ALL SPALLED AND CRACKED CONCRETE FROM ALL SURFACES OF THE

STRUCTURAL COMPONENT DOWN TO UNDAMAGED CONCRETE AND REMOVE ALL

CONCRETE IN CONTACT WITH CORRODED STEEL REINFORCEMENT (REBAR) AND

UNDERCUT BELOW THE EXISTING REBAR AS REQUIRED. REMOVE CONCRETE BY

CHIPPING. ALL HORIZONTAL STRUCTURAL (BEAMS AND SLABS) SHOULD BE SHORED

PRIOR TO SELECTIVE DEMOLITION UNLESS DEEMED NOT REQUIRED BY THE

ENGINEER.

(c) CLEAN EXPOSED STEEL REINFORCEMENT TO REMOVE ALL CORROSION AND SCALE

AND CLEAN THE NEWLY EXPOSED CONCRETE SURFACES. REMOVE ALL LOOSE

MATERIAL, WET CONCRETE, TRACES OF OIL, GREASE, LAITANCE, FORM TREATMENTS,

ETC.

(d) COMPLETELY COAT THE EXPOSED STEEL REINFORCEMENT WITH A CORROSION

INHIBITOR SUCH AS CORROSEAL TO ISOLATE THE BARS FROM THE NEW REPAIR

CONCRETE MATERIAL THAT WILL BE USED.

(e) ADD ANCHORS, STIRRUPS, ETC., AS NECESSARY TO PROVIDE FOR PROPER

ATTACHMENTS OF THE REPAIR MATERIAL AS DETAILED IN THE SPECIFIC REPAIR

INSTRUCTIONS OR DESIGN.

(f) USE APPROVED BONDING AGENT TO IMPROVE COLD JOINT BOND BETWEEN ALL

EXPOSED OLD SURFACES AND THE NEW CONCRETE OR PATCHING MATERIAL.

(g) APPLY PATCHING MATERIAL TO MATCH THE EXISTING CONCRETE.

7) THE BONDING AND PATCHING AGENT SHALL BE SPEED CRETE REDLINE OR EQUIVALENT

AND SHALL BE APPLIED ACCORDING TO THE MANUFACTURER ’S RECOMMENDATIONS.

8) ALL CRACKS LESS THAN 1/16" WIDE, NOT IDENTIFIED BY THE ENGINEER ARE CONSIDERED

NONSTRUCTURAL MINOR CRACKS. NONSTRUCTURAL MINOR CRACKS SHOULD BE OPENED

TO REMOVE LOOSE MATERIAL AND MAY BE EPOXY INJECTED WITH A HIGH MODULUS

EPOXY RESIN CONFORMING TO ASTM C881.

9) IF ANY STEEL REINFORCEMENT IS FOUND TO BE DEGRADED BY MORE THAN 30% OF ITS

ORIGINAL DIAMETER, NEW STEEL REINFORCEMENT SHALL BE SPLICED TO REPLACE THE

COMPROMISED BAR. SEE REPAIR OF REINFORCING STEEL DUE TO SECTION LOSS DETAIL.

10) FORMS SHALL BE CONSTRUCTED TO MATCH THE EXISTING FINISHED SHAPE UNLESS

SPECIFIED OTHERWISE.

11) ANY CONCRETE REPAIR MATERIAL USED IN THE REPAIR SHALL HAVE A 28-DAY

COMPRESSIVE STRENGTH OF 5,000 PSI MINIMUM AND SHALL CONTAIN OR BE

PREMANUFACTURED WITH CORROSION INHIBITOR ADMIXTURE.

12) THE CONTRACTOR SHALL CONTACT THE ENGINEER FOR FURTHER DESIGN DETAIL IF

THERE IS BELIEVED TO BE ANY NEED FOR A SPECIAL ADMIXTURE OR PROCEDURE DURING

THE REPAIR.

13) CONTACT K2M DESIGN, INC. FOR FURTHER GUIDANCE IF THE ABOVE INSTRUCTIONS

CANNOT BE ACHIEVED OR RESULT IN A CONFLICT.

APPLICABLE TO PROJECT VERIFICATION AND INSPECTION TASK CONTINUOUS DURING TASK LISTED PERIODICALLY DURING TASK LISTED REFERENCED STANDARD (a) APPLICABLE CODE REFERENCE

X 1. INSPECTION OF REINFORCING STEEL, INCLUDING PRE-STRESSING TENDONS

AND PLACEMENT -- X ACI 318: 20, 25.2, 25.3, 26.6.1-26.6.3

X

2. REINFORCING BAR WELDING

a. VERIFY WELDABILITY OF REINFORCING BARS OTHER THAN ASTM A706;

b. INSPECT SINGLE PASS FILLET WELDS MAXIMUM 5/16”: AND c INSPECT ALL OTHER WELDS

-- X AWS D1.4

ACI 318:26.6.4 --

3. INSPECTION OF ANCHORS CAST IN CONCRETE ACI 318: 17.8.2

ACI 318: 17.8.2.4 --

X 5. VERIFYING USE OF REQUIRED DESIGN MIX -- X ACI 318: 19, 26.4.3, 26.4.4 1904.1, 1904.2

X

6. PRIOR TO CONCRETE PLACEMENT, FABRICATE SPECIMENS FOR

STRENGTH TESTS, PERFORM SLUMP AND AIR CONTENT TEST, AND

DETERMINE THE TEMPERATURE OF THE CONCRETE

X --

ASTM C 31

ASTM C 172

ACI 318: 26.5, 26.12

X 7. INSPECT CONCRETE AND SHOTCRETE PLACEMENT FOR PROPER APPLICATION TECHNIQUES X -- ACI 318: 26.5 --

X 8. INSPECTION FOR MAINTENANCE OF SPECIFIED CURING TEMPERATURE AND

TECHNIQUES -- X ACI 318: 26.5.3 -26.5.5

X -- ACI 318: 26.10 --

X --

10. INSPECT ERECTION OF PRECAST CONCRETE MEMBERS -- X ACI 318: 26.9 --

13. VERIFICATION OF IN-SITU CONCRETE STRENGTH, PRIOR TO STRESSING OF

TENDONS IN POST-TENSIONED CONCRETE AND PRIOR TO REMOVAL OF SHORES

AND FORMS FROM BEAMS AND STRUCTURAL SLABS

-- X ACI 318: 26.11.2 --

14. INSPECT FORMWORK FOR SHAPE, LOCATION, AND DIMENSIONS OF

CONCRETE MEMBER BEING FORMED -- X ACI 318: 26.11.1.2 (b) --

(a) WHERE APPLICABLE, SEE SECTION 1705.13.

(b) SPECIFIC REQUIREMENTS FOR SPECIAL INSPECTION SHALL BE INCLUDED IN THE RESEARCH REPORT FOR THE ANCHOR ISSUED BY AN APPROVED SOURCE IN ACCORDANCE WITH 17.8.2 ACI 318, OR OTHER QUALIFICATION PROCEDURES. WHERE SPECIFIC REQUIREMENTS ARE NOT PROVIDED, SPECIAL INSPECTION REQUIREMENTS SHALL BE SPECIFIED BY THE REGISTERED DESIGN PROFESSIONAL AND SHALL BE

APPROVED BY THE BUILDING OFFICIAL PRIOR TO THE COMMENCEMENT OF THE WORK.

TABLE 3: REQUIRED VERIFICATION AND INSPECTION OF CONCRETE CONSTRUCTION

X --

-- X

X

X

-- X --

4. INSPECTION OF ANCHORS POST INSTALLED IN HARDENED CONCRETE MEMBERS

a. ADHESIVE ANCHORS INSTALLED IN HORIZONTALLY OR UPWARDLY INCLINED

ORIENTATION TO RESIST SUSTAINED TENSION LOADS.

b. MECHANICAL ANCHORS OR ADHESIVE ANCHORS NOT DEFINED IN 4.a.

9. INSPECTION OF PRESTRESSED CONCRETE FOR:

a. APPLICATION OF PRESTRESSING FORCES AND

b. GROUTING OF BONDED PRESTRESSING TENDONS

ACI 318: 17.8.2

11. FOR PRECAST CONCRETE DIAPHRAGM CONNECTIONS OR REINFORCEMENT AT JOINTS

CLASSIFIED AS MODERATE OR HIGH DEFORMABILITY ELEMENTS (MDE OR HDE) IN

STRUCTURES ASSIGNED TO SEISMIC DESIGN CATEGORY C, D, E, OR F, INSPECT SUCH

CONNECTIONS AND REINFORCEMENT IN THE FIELD FOR:

a. INSTALLATION OF THE EMBEDDED PARTS

b. COMPLETION OF THE CONTINUITY OF REINFORCEMENT ACROSS JOINTS c COMPLETION OF CONNECTIONS IN THE FIELD

X

X X

ACI 318: 26.13.1.3

ACI 550.5

12. INSPECT INSTALLATION TOLERANCES OF PRECAST CONCRETE DIAPHRAGM CONNECTIONS

FOR COMPLIANCE WITH ACI 550.5 -- X ACI 318: 26.13.1.3 --

X www.k2mdesign.com

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SPALLING REPAIR

DETAILS

TKP Checker

25810

S1.0 7/30/2025

S im on to n St

, K ey

W es t, FL

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S1.0 - SPALLING REPAIR DETAILS