Problem
Severe corrosion caused by moisture intrusion from the top deck.
Conditions
The moisture intrusion and ponding issues were so severe that the owners were boring holes in the surface of the top deck to drain the standing water.
Solution
The custom-engineered design solution was based on ACI and ICRI code requirements for strengthening the flexural and compressive characteristics of damaged concrete. First, all damaged areas of the concrete substrate were removed and sound aggregate was exposed. On the top side of the concrete deck, an epoxy mortar was then applied to not only resurface the concrete, but also to create a slight grade in the roof, which would allow water to drain. While this mortar was wet, the crew applied two layers of 12” Engineered Composite strips with a 1/2” overlap between the strips for added strength. On the T-beams on the underside of the concrete deck, the crew applied the concrete mortar onto the beams, as well as on the damaged flat sections of concrete in between the beams. While wet, they applied two layers of Composite in a “U wrap” along the beam
lengths and overlapping strips on the flat concrete. Whether working on the deck above or on the beams below, the crew ran the Composite Wraps through the patented saturation machine to ensure correct fiber-to-resin coverage.
Result
The composite installation was performed without incident and the harbor-side structure returned to service within days. The asset owner was extremely pleased with the outcome, the re-graded deck no longer experiences ponding issues and the moisture intrusion has stopped.
