Only thin spalls may be repaired. The Engineer will determine what constitutes an acceptable spall, but in general the limits are 1-inch in depth and 6 square inches in area. If either of those limits is exceeded, or if the damage exposes any reinforcing steel or prestressing strand, the damage will render the piling unacceptable unless specifically deemed otherwise by the Engineer.

Smooth out the perimeter of the damaged area to eliminate jagged edges.

Minor spalls deemed acceptable for repair should be cleaned and coated with neat epoxy in accordance with Section 1 of Chapter 3 of this manual.

Do not build up the spalled areas with repair material other than neat epoxy since it is likely to debond during driving operations.

The Engineer may allow for repair when damage is deeper than 1 inch but does not progress beyond the outer layer of steel reinforcement. In those cases the damaged areas should be built up with epoxy mortar and confined by CFRP wrapped completely around the piling for a distance not less than six inches beyond the damaged area.

If one end of a piling is damaged beyond the limits outlined above, but the damage extends less than 6 inches from the end, then the fabricator or contractor may remove (cut) up to 6 inches from the end to eliminate the damaged portion.

Clearly mark the altered side as the “Tip End.”

After cutting, recess the prestressing strands 3/8-inch minimum and fill the voids with epoxy mortar (typical strand end treatment).

Re-form the chamfers after completing the cutting and

repairing

operations.

There are no standard criteria for acceptance or rejection when both ends of a piling are damaged, but generally the member will be rejected since it would not be possible to avoid hammering a damaged end.

Engineer must approve any repairs when damage occurs on both ends of a piling.