How to Repair a Damaged Steel Column (with video)

There are both traditional and new innovative ways to repair steel columns, below we give you the exact steps that we take to bring damaged or corroded columns back to full capacity.

Surface Prep

• Start with basic surface preparation on the install area to ensure a clean and suitable surface for the repair materials to adhere to.

Rebar Installation

• Per design, determine the allocation and placement of rebar. For this jacket, use four number 7 rebars.
• Drill holes for the rebar, inject anchoring resin into the holes, and then insert the rebar to size.

Sheer Clamps

• Install sheer clamps to help the concrete encasement lock onto the piles more effectively. Adjust and apply the clamps to the recommended torque, which in this case is 80 foot-pounds.

Spacers

• Install spacers to ensure a quality jacket radius. The number of spacers used can vary depending on the installation requirements; use four spacers, positioning one at every corner.
• Depending on the type of install, you may need different types of spacers, different size spacers, and different amounts of spacers. Adjustments might be necessary.

Jacket Preparation

• Cut the PileMedic jackets to size according to the install. Mark a line at the desired width and cut along it. For example, cut from a standard 48-inch width down to 38 inches.

Resin Application

• Mix the resin (two 20 TC) following the specific ratio (for every 100 grams of part A, use 43 grams of Part B).
• Apply the resin to at least half the length of the overall jacket, ensuring there is no color separation for a consistent application. Aim for a clean process to minimize mess and ensure a good bond.

Wrapping the Jacket

• Position the non-resined end to be the inside of the jacket, with the resin side being the outside layer of the wrap. Wrap the jacket around the column, securing a tight radius and ensuring it’s nicely locked around.

Securing with Zip Ties

• Once a basic radius is set, use zip ties to secure the jacket at intervals, recommending at least three sets per height of the jacket to distribute the load evenly.

Final Adjustments and Curing

• After securing the jacket with zip ties, use meter sticks or similar tools to ensure the edges sit flat as the resin cures.
• You may use screws along the seam to ensure each layer of the jacket is locked in place.
• Allow the setup to cure for about 12 hours before proceeding with grout filling.

Grout Filling

• Seal the bottom of the jacket to prevent grout leakage, using duct tape or other suitable materials. Apply several layers extending from the jacket onto the ground.
• Begin filling the pile with grout, starting with a base layer of one to two inches to ensure it does not push out the bottom. Fill slowly, monitoring for leaks.
• Once the initial grout layer has cured, continue to fill the jacket, occasionally tapping the pile gently to settle the grout and avoid shifting.

Final Touches

• After the grout has sufficiently cured, remove the zip ties and any additional materials used for the installation.
• Apply a seam sealant on any overlaps or exposed areas for added protection.
• Finish off the pile with a coat of paint or topcoat as desired.

This comprehensive guide provides the necessary steps to repair damaged or corroded steel columns using PileMedic, ensuring a durable and effective restoration.

Frequently Asked Questions