After cleaning the corroded area and cutting back the corroded edges, you weld the reinforcing bars to the flanges and the web. A form is then placed around the corroded section and filled with concrete. Figure 7-18 shows this procedure for a steel H-pile. The same system can be used for other structural members.

Sheetpiling Repair

Sheetpiling usually serves as a bulkhead to retain earth or other fill. Holes in the bulkhead will result in loss of materials and settlement behind the bulkhead. Local damage or holes can be repaired by welding on plates or more sections of steel sheetpiling. If the holes are small, wooden plugs can be used to fill the holes. Usually, it is necessary to install new sheetpiling in the deteriorated areas; however, it may be economically feasible to protect the damaged sheetpiling with a concrete facing, as shown in figure 7-19. Remove all rust, scale, and marine growth before placing concrete. Concrete covers, when applied to the exposed exterior face of the piling, should be at least 6 inches in thickness and extend well beyond the area of corrosion, damage, or deterioration. Formwork should be of wood, supported in place by stud bolts that are welded to the sheetpiling. Use heavy zinc-coated bolts and nuts. It is preferable that the wood forms be left in place because they will provide protection against damage from floating debris and erosion for some time. Where the back of the bulkhead can be easily exposed, it may be advisable to encase the sheetpiling completely in concrete. Minimum thickness of concrete facing where the piling is completely encased in concrete should be 3 inches. Care must be taken in replacing the backfill when the sheet pile has been encased. GRANULAR materials are preferable. Fill should be placed in layers and well compacted.

Tie Rod Repair

Deteriorated tie rods will allow the top of a bulkhead to move outward. Remove the fill to expose the tie rods and turnbuckles by starting the excavation at the back face of the bulkhead, and progress to the shore in as narrow a trench as possible along the tie

Figure 7-19. - Concrete encasement of steel sheet pile.

Figure 7-18. - Concrete encasement of steel pile.