Concrete Repair and Rehabilitation: 5-Day Professional Training Course

Course Overview

This intensive 5-day specialized training program provides comprehensive knowledge of concrete assessment, repair techniques, and rehabilitation strategies for deteriorating structures. Designed for structural engineers, repair contractors, facility managers, construction professionals, and inspectors, this course covers damage evaluation, repair material selection, application methods, quality control, and structural strengthening to extend service life and restore concrete infrastructure performance.

Target Audience: Structural engineers, repair contractors, building inspectors, facility managers, maintenance engineers, construction managers, consultants, and professionals involved in concrete structure assessment and restoration.

Day 1: Concrete Deterioration Mechanisms & Assessment

Morning Session: Understanding Concrete Deterioration (9:00 AM - 12:00 PM)

Root Causes of Concrete Damage:
Identifying and understanding deterioration mechanisms including physical damage, chemical attack, corrosion, and environmental factors that compromise concrete structures.

Deterioration Mechanisms:

• Physical deterioration: freeze-thaw damage, thermal cycling, abrasion, erosion

• Chemical attack: sulfate attack, acid attack, alkali-aggregate reaction (AAR)

• Corrosion of reinforcement: carbonation-induced and chloride-induced

• Biological deterioration: microbial attack, vegetation damage

• Structural overloading and fatigue

• Poor construction practices and material defects

• Fire damage and elevated temperature effects

• Delamination and spalling mechanisms

• Efflorescence and leaching

• Scaling and surface degradation

• Cracking types: structural, shrinkage, thermal, settlement

• Service life factors and degradation modeling

Afternoon Session: Condition Assessment & Investigation (1:00 PM - 5:00 PM)

Diagnostic Techniques:
Implementing systematic investigation procedures using visual inspection, non-destructive testing (NDT), and destructive testing to accurately assess concrete condition and deterioration extent.

Assessment Methods:

• Visual inspection protocols and damage mapping

• Core drilling and sampling (ASTM C42)

• Petrographic examination (ASTM C856)

• Compressive strength testing of cores

• Carbonation depth measurement (phenolphthalein test)

• Chloride content testing and profiling (ASTM C1152)

• Half-cell potential surveys for corrosion assessment

• Concrete resistivity measurements

• Ultrasonic pulse velocity testing (ASTM C597)

• Rebound hammer testing (ASTM C805)

• Ground-penetrating radar (GPR) for embedded features

• Infrared thermography for delamination detection

• Cover meter for reinforcement location and depth

• Corrosion rate measurement techniques

• Load testing and structural evaluation

• Laboratory analysis and reporting

Hands-On Session: NDT equipment demonstrations and data interpretation exercises

Day 2: Repair Materials & Selection Criteria

Morning Session: Repair Material Types & Properties (9:00 AM - 12:00 PM)

Material Science for Repair:
Understanding repair material categories, properties, and performance characteristics essential for durable, compatible repairs that match or exceed original concrete performance.

Repair Materials:

• Portland cement-based mortars and concretes

• Polymer-modified cementitious materials

• Epoxy resin systems: adhesives, mortars, grouts

• Polyester and vinyl ester resins

• Polyurethane systems for crack injection

• Shotcrete: dry-mix and wet-mix processes

• Self-consolidating repair concrete

• Rapid-setting and rapid-strength materials

• Shrinkage-compensating materials

• Fiber-reinforced repair mortars

• Pre-bagged proprietary repair products

• Corrosion inhibitors and migration technologies

• Protective coatings and sealers

• Material compatibility requirements (ICRI guidelines)

• Performance testing: bond strength, shrinkage, durability

Afternoon Session: Material Selection & Specification (1:00 PM - 5:00 PM)

Engineering the Right Solution:
Developing systematic approaches to selecting appropriate repair materials based on deterioration type, exposure conditions, structural requirements, and compatibility considerations.

Selection Criteria:

• Substrate preparation requirements

• Bond strength and adhesion properties

• Thermal expansion compatibility

• Elastic modulus matching considerations

• Permeability and moisture transmission

• Chemical resistance requirements

• Structural vs. non-structural applications

• Traffic and service loading conditions

• Temperature extremes and environmental exposure

• Application method constraints

• Cure time and return-to-service requirements

• Cost-effectiveness and life-cycle analysis

• ASTM and ACI material standards

• Performance specifications vs. prescriptive specifications

• Quality control testing requirements

Workshop: Material selection matrix development for various repair scenarios

Day 3: Surface Preparation & Repair Techniques

Morning Session: Surface Preparation Methods (9:00 AM - 12:00 PM)

Foundation for Successful Repairs:
Mastering critical surface preparation techniques that ensure proper adhesion, long-term performance, and durability of concrete repairs.

Preparation Techniques:

• Importance of surface preparation (ICRI CSP profiles)

• Concrete Surface Profile (CSP) requirements for different materials

• Mechanical preparation: scarifying, milling, grinding, sandblasting

• Water jetting: low, high, and ultra-high pressure

• Hydrodemolition advantages and applications

• Saw cutting and chipping procedures

• Deteriorated concrete removal criteria

• Reinforcement cleaning and preparation

• Chloride contamination removal verification

• Surface cleanliness standards

• Moisture content evaluation and control

• Priming and bonding agents application

• Environmental conditions for surface prep

• Dust control and containment measures

• Safety considerations and personal protection

Afternoon Session: Concrete Repair Application Methods (1:00 PM - 5:00 PM)

Proven Repair Techniques:
Implementing various application methods including hand-applied repairs, form-and-pour, shotcrete, and grouting techniques for different repair situations.

Application Methods:

• Hand-applied trowel repairs: vertical and overhead

• Form-and-pour concrete replacement

• Shotcrete application: dry-mix and wet-mix procedures

• Pre-placed aggregate method

• Pressure grouting and gravity grouting

• Injection techniques for crack repair

• Dry-pack method for deep narrow repairs

• Overlay systems: bonded and unbonded

• Preplaced aggregate concrete

• Flowable fill and self-leveling materials

• Patch configuration and geometry optimization

• Featheredge vs. square-cut edges

• Multi-layer application strategies

• Consolidation and finishing techniques

• Quality control during application

• Common application errors and prevention

Practical Demonstration: Repair application techniques on sample concrete elements

Day 4: Crack Repair & Structural Strengthening

Morning Session: Crack Repair Technologies (9:00 AM - 12:00 PM)

Addressing Concrete Cracking:
Diagnosing crack causes, evaluating structural significance, and selecting appropriate repair methods including epoxy injection, routing and sealing, and stitching techniques.

Crack Repair Methods:

• Crack classification: active vs. dormant, structural vs. non-structural

• Crack width measurement and monitoring

• Epoxy injection procedures (ACI 224.1R)

• Equipment: injection ports, packers, pumps

• Gravity feed vs. pressure injection

• Surface sealing and crack chasing

• Routing and sealing techniques

• Flexible sealants for active cracks

• Mechanical stitching with staples

• Drilled and grouted dowels across cracks

• Carbon fiber staples and reinforcement

• Crack evaluation for structural impact

• Repair material selection for crack types

• Quality assurance and testing

• Long-term monitoring requirements

Afternoon Session: Structural Strengthening & Rehabilitation (1:00 PM - 5:00 PM)

Enhancing Load Capacity:
Implementing advanced strengthening techniques including fiber-reinforced polymer (FRP) systems, external post-tensioning, and structural overlays to increase capacity and extend service life.

Strengthening Systems:

• Fiber-Reinforced Polymer (FRP) composites: carbon, glass, aramid

• FRP application methods: wet layup, pre-cured systems

• Surface preparation for FRP installation

• Structural steel plate bonding

• External post-tensioning systems

• Concrete jacketing and section enlargement

• Structural overlays and toppings

• Shear strengthening techniques

• Flexural strengthening design considerations

• Column wrapping and confinement

• Seismic retrofitting strategies

• Load transfer mechanisms

• Quality control and acceptance testing

• Long-term monitoring and inspection

• Design standards: ACI 440, ACI 562

Case Studies: Successful strengthening projects and lessons learned

Day 5: Corrosion Protection & Quality Assurance

Morning Session: Corrosion Prevention & Control (9:00 AM - 12:00 PM)

Protecting Reinforcement:
Implementing comprehensive corrosion protection strategies including cathodic protection, corrosion inhibitors, coatings, and electrochemical treatments for existing structures.

Corrosion Mitigation:

• Reinforcement corrosion fundamentals

• Cathodic protection systems: impressed current and sacrificial anode

• System design, installation, and monitoring

• Corrosion inhibitor technologies: surface-applied and migrating

• Electrochemical chloride extraction (ECE)

• Electrochemical re-alkalization

• Barrier coatings and sealers

• Hydrophobic impregnations and water repellents

• Epoxy-coated reinforcement replacement

• Stainless steel reinforcement options

• Galvanized reinforcement considerations

• Cover restoration and thickness requirements

• Moisture control and drainage improvements

• Joint sealing and waterproofing systems

• Performance monitoring and maintenance

Afternoon Session: Quality Assurance & Project Management (1:00 PM - 3:30 PM)

Ensuring Repair Success:
Establishing comprehensive quality control programs, testing protocols, and project management procedures that ensure repairs meet performance specifications and durability requirements.

Quality Management:

• Quality control plan development

• Pre-repair mockup and testing requirements

• Material testing: batch testing, field sampling

• Bond strength testing: pull-off tests (ASTM C1583)

• Core testing of completed repairs

• Surface preparation verification

• Application inspection and documentation

• Curing requirements and monitoring

• Acceptance criteria and performance standards

• Non-conformance management

• Warranty considerations and requirements

• Contractor qualification and certification

• Safety management on repair projects

• Environmental compliance and containment

• Documentation and record-keeping

• Post-repair monitoring programs

Closing Session: Standards, Codes & Best Practices (3:30 PM - 5:00 PM)

Professional Practice:
Understanding applicable standards, codes, guidelines, and industry best practices governing concrete repair and rehabilitation projects.

Standards & Guidelines:

• ACI 562: Code Requirements for Assessment, Repair, and Rehabilitation

• ACI 546R: Concrete Repair Guide

• ICRI Technical Guidelines and Guideline Specifications

• ASTM standards for repair materials and testing

• Local building codes and structural requirements

• Specification writing for repair projects

• Bid evaluation and contractor selection

• Cost estimating for repair work

• Project scheduling and phasing

• Risk management and contingencies

• Sustainability in repair and rehabilitation

• Life-cycle cost analysis

Capstone Project:
Teams assess hypothetical deteriorated structure scenario, develop investigation program, recommend repair strategy, specify materials and methods, and prepare quality control plan with technical justification.

Final Assessment:

• Written examination covering course content

• Certificate of Completion presentation (35 PDH/CEU credits)

• Professional resources and continuing education pathways

• Q&A panel with repair industry experts

Learning Outcomes

Participants will be able to:

• Diagnose deterioration mechanisms through systematic investigation

• Conduct comprehensive condition assessments using NDT and laboratory testing

• Select appropriate repair materials based on technical and performance criteria

• Specify and oversee proper surface preparation procedures

• Implement various repair techniques and application methods

• Design strengthening systems for structural enhancement

• Apply corrosion protection technologies effectively

• Develop quality control programs ensuring repair durability

• Prepare specifications compliant with industry standards

• Manage repair projects from assessment through completion

Course Materials Included

• Comprehensive concrete repair manual with technical data

• ACI and ICRI standards and guideline excerpts

• Repair material selection charts and decision matrices

• NDT equipment operation guides

• Quality control checklists and inspection forms

• Case study compilation with photographic documentation

• Certificate of Completion (35 PDH/CEU credits)

Course Delivery Methods

• Technical lectures with visual documentation

• Hands-on demonstrations and practical exercises

• NDT equipment operation training

• Video case studies of repair projects

• Group problem-solving workshops

• Real-world project analysis

Prerequisites

Bachelor’s degree in civil/structural engineering or related field, OR minimum 3 years experience in concrete construction, inspection, or repair. Basic understanding of concrete technology recommended.

Keywords: concrete repair training, concrete rehabilitation, structural repair, concrete restoration, deterioration assessment, NDT testing concrete, epoxy injection, FRP strengthening, corrosion protection, concrete damage, repair materials, surface preparation, crack repair, structural strengthening, ACI 562, concrete maintenance, building restoration, infrastructure repair, shotcrete repair, concrete patching, cathodic protection, concrete inspection course