Abstract:
The present invention discloses system and method for rehabilitation and enhancement of structural integrity of a reinforced concrete structures, comprising exposing beyond a deteriorated portion of a reinforcement where a non-deteriorated portion is visible, covering a surround of the exposed reinforcement by a tensile member that is coupled with an exterior surface of the reinforced concrete structure, and encapsulating the exposed reinforcement, with the encapsulation formed by the tensile member.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of priority of co-pending U.S. Utility Provisional Patent Application No. 62/010,356, filed 10 Jun. 2014, the entire disclosure of which is expressly incorporated by reference in its entirety herein. 
         [0002]    It should be noted that where a definition or use of a term in the incorporated patent application is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the incorporated patent application does not apply. 
     
    
     BACKGROUND OF THE INVENTION 
       [0003]    1. Field of the Invention 
         [0004]    One or more embodiments of the present invention relate to cost effective structural rehabilitation and enhancement. 
         [0005]    2. Description of Related Art 
         [0006]    Structural integrity of reinforced concrete structures is severely compromised due to spalling. In general, spalling is caused due to corrosion of the reinforcement, which is generally a reinforcing bar (or rebar for short) that is a metal or a metallic alloy most likely comprised of steel. When the reinforcement corrodes, it rusts (and crumbles) and therefore, expands in volume within the concrete structure, causing spalling. Additionally, loose pieces of rust particles (or crumbles) of the reinforcement also cause the concrete structure to lose its mechanical bond with the reinforcement, making the reinforcement ineffective. A further issue with corrosion of the reinforcement is that as the reinforcement corrodes into crumbling rust, the amount of reinforcement left is degraded, weakening the structural integrity of the reinforced concrete structure. 
         [0007]    Conventional methods for repairing of spalled reinforced concrete structures vary greatly dependent on the amount of spalling of the reinforced concrete structure, the amount of corrosion of the reinforcement, and overall budgeted cost for repair. In general, the conventional repairing processes of spalled reinforced concrete structures involved many labor-intensive steps that are complex and require skilled labor, which adds to the overall cost of the structural rehabilitation. 
         [0008]    In general, conventional methods of repair require excavation of the concrete structure to reach the corroded rebar. It should be noted that the size of the excavation (the cavity) should be sufficiently large to expose rebar beyond the corroded portion. That is, the excavation size should be large to reach the portion of the rebar where no corrosion is observed. Additionally, if the extent of the corrosion of the rebar observed is severe (e.g., where the integrity of the rebar is fully compromised, making it ineffective), the cavity should be further extended axially along the rebar to expose even more of the non-corroded portion thereof to enable augmentation of the rebar using well known splicing methodologies (detailed below). 
         [0009]    Once the appropriate axial length of rebar is fully exposed, the formed cavity is cleaned from debris such as loose concrete. Further, the rebar is also completely cleaned from debris, loose rust, and any visible corrosion. That is, the rebar must be completely cleaned from any corrosion until a non-corroded portion of the rebar (the actually clean, bare steel portion) is reached. Therefore, to completely clean the rebar from rust or any corrosion, excavated cavity must also be of sufficient depth to enable access and reach to the entire surface of the exposed rebar from all directions and not just the “front” viewable portion. It should be noted that completely cleaning of the rebar from corrosion and removal of all rust (e.g., by scraping) is very time consuming and labor intensive. If the rebar is fully compromised, the compromised portion must be cut out completely and augmented. 
         [0010]    The augmentation of a rebar is a complex, labor intensive, and time-consuming process that uses well known splicing methodologies, resulting in a lap spliced rebar. In general, the conventional methods for augmentation of a rebar require that the fully compromised portion of the rebar to be cut-off, and the remaining non-corroded exposed portions thereof be of sufficient axial length to allow for splicing (e.g., lap splicing). Therefore, the cavity itself must be enlarged to expose sufficient axial length of the non-corroded portion of the rebar to allow for proper lap splicing, resulting in continuous line of reinforcement that meet the required tensile strengths. 
         [0011]    After cleaning the rebar and cavity from loose debris (rust or loose concrete), and if required, augmenting the rebar, corrosion protection (anti-corrosion) is applied to the rebar (and the augmented rebar). Thereafter, a primer (sealant/adhesive bonding material) is applied to the surface of the excavated cavity to seal and provide a bonding surface, which facilitates bonding of mortar (detailed below) with the surface of the cavity. 
         [0012]    Thereafter, various methods are used to actually close off the cavity. For conventional methods, if the cavity is small, it is generally more cost effective to patch the cavity using well-known methodologies such as multi-lift patching, which itself is very time consuming, especially if the number of repairs is large. The quality of multi-lift patching process is generally poor due to potentially weak bonding properties between patched layers. Weak bonding properties are generally caused by variations in densities of the patching layers, temperature variation between a patched layer and a next layer, moisture variations, which affect viscosity of subsequent layers, etc. 
         [0013]    In conventional methods, if the cavity is large, it is generally more cost effective to pour mortar into a larger excavated cavity to close off the exposed rehabilitated rebar. However, prior to pouring of the mortar, forming structures are used for forming the poured mortar to fill the excavated cavity and allow the mortar to be cured flush with exterior surface of the concrete structure, which requires time and materials to construct. 
         [0014]    In general, the forming structures used to form (or shape) the mortar are comprised of structures that are built to fit over and cover the excavated cavity. Accordingly, if the forming structure is comprised of wood for example, the appropriate thickness and size of wood must first be selected. Thickness and size depend on the amount of load to be supported by the forming structure. In addition to selecting the correct thickness and size, the actual wooden forming structure constituting the wood form itself must be engineered and built to enable the correct forming or shaping of the mortar. This is especially difficult for non-flat surfaces such as reinforced concrete support columns that are generally cylindrical and hence, the wood forming structure must somehow be built to enable the mortar to be flush with the surface of the cylindrically or other odd-shaped structures. 
         [0015]    After selection of the thickness, size, and building of the forming structure, a means must be devised to actually securely position and place the wooden forming structure over the cavity opening. This phase of the overall conventional rehabilitations process becomes complex if the opening is oriented at a direction where the forming structure must be secured against gravity. For example, the excavated cavity opening may be under a bridge where the opening faces “down” below the bridge or it may be vertically oriented at the side of support column. Accordingly, the process of securing the forming structure over the opening must account for supporting it in a secure position. As importantly, the securing means must also support the loads of both the forming structure and the mortar when poured within the cavity (detailed below). Therefore, the securing means must take the weight of the mortar in addition to the forming structure to support both. 
         [0016]    Conventional methods of mounting and positioning forming structures depend on the type of material from which the forming structure is made (e.g., wood, steel, plastic, etc.). Normally, setting up a forming structure on a vertical or overhead surface requires support and mechanisms that include intricate bracing, wales, studs, stakes, pegs, screws, clamp supports, bars, etc. The work usually requires tying various pieces together, as well. 
         [0017]    After designing a forming structure for the cavity and installing or mounting it to cover over the cavity, a hole is made on the forming structure itself to allow mortar to be poured within the excavated cavity via the hole. This phase becomes complex when the opening of cavity and or the hole is overhead (i.e., oriented such that the pour is against the gravity). Thereafter, there is a wait time until the mortar is cured after which, the forming structure must be removed. The removal of the forming structure is not a simple task as it may require heavy machinery and skilled labor. 
         [0018]    It should be noted that in addition to the numerous labor-intensive operations to rehabilitate the reinforced concrete structure, additional care must be taken to ensure compatibility between materials used when rehabilitating the structure. For example, the type of corrosion protection material applied must be compatible with the type of mortar material used to fill the cavity or the type of primer used on the surface of the cavity. For example, the corrosion protection material used should not chemically interact with the mortar material, which may result in a degraded the integrity of both. 
         [0019]    Accordingly, in light of the current state of the art and the drawbacks to current rehabilitation methods mentioned above, a need exists for a rehabilitation process that is much simpler, requires much less labor-intensive/skilled operations, and uses compatible material for most rehabilitation projects. 
       BRIEF SUMMARY OF THE INVENTION 
       [0020]    A non-limiting, exemplary aspect of an embodiment of the present invention provides a method for rehabilitation and enhancement of structural integrity of a reinforced structures, comprising:
       exposing beyond a deteriorated portion of a reinforcement where a non-deteriorated portion is visible;       
 
         [0022]    covering a surround of the exposed reinforcement by a tensile member that is coupled with an exterior surface of the reinforced concrete structure; and
       encapsulating the exposed reinforcement, with the encapsulation formed by the tensile member.       
 
         [0024]    Another non-limiting, exemplary aspect of an embodiment of the present invention provides a system for rehabilitation and enhancement of structural integrity of a reinforced structures, comprising: 
         [0025]    a tensile member that functions as a forming structure for forming a filler within a substrate; 
         [0026]    the filler encapsulates a deterioriated reinforcement, binds to all surfaces with which the filler contacts, and provides compressive strength for the reinforced structure while the tensile member provides a tensile strength. 
         [0027]    These and other features and aspects of the invention will be apparent to those skilled in the art from the following detailed description of preferred non-limiting exemplary embodiments, taken together with the drawings and the claims that follow. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0028]    It is to be understood that the drawings are to be used for the purposes of exemplary illustration only and not as a definition of the limits of the invention. Throughout the disclosure, the word “exemplary” may be used to mean “serving as an example, instance, or illustration,” but the absence of the term “exemplary” does not denote a limiting embodiment. Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. In the drawings, like reference character(s) present corresponding part(s) throughout. 
           [0029]      FIG. 1  is non-limiting, exemplary illustration of a reinforced concrete structure with deteriorating reinforcement that is exhibiting spalling; 
           [0030]      FIG. 2  is non-limiting, exemplary illustration of a substrate of the reinforced concrete structure with exposed reinforcement in accordance with one or more embodiments of the present invention; 
           [0031]      FIG. 3A  is non-limiting, exemplary illustration of a substrate with exposed reinforcement and cavity prepared in accordance with one or more embodiments of the present invention; 
           [0032]      FIG. 3B  is a non-limiting, exemplary illustration of various marking methods for proper rehabilitation of reinforce concrete structure in accordance with one or more embodiments of the present invention; 
           [0033]      FIG. 4  is a non-limiting, exemplary illustration of substrate with an applied primer in accordance with one or more embodiments of the present invention; 
           [0034]      FIG. 5  is a non-limiting, exemplary illustration of substrate with an applied primer and adhesive material in accordance with one or more embodiments of the present invention; 
           [0035]      FIG. 6  is a non-limiting, exemplary illustration of substrate covered with tensile member in accordance with one or more embodiments of the present invention; 
           [0036]      FIGS. 7A to 7C  are non-limiting, exemplary illustration of vertically oriented substrate filled with filler in accordance with one or more embodiments of the present invention; 
           [0037]      FIGS. 8A and 8B  are non-limiting, exemplary illustration of overheard substrate filled with filler in accordance with one or more embodiments of the present invention; and 
           [0038]      FIGS. 9A to 9C  are non-limiting, exemplary illustrations of a method and system for full rehabilitation of reinforced concrete structures that exhibit extensive spalling in accordance with one or more embodiments of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0039]    The detailed description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed and or utilized. 
         [0040]    It is to be appreciated that certain features of the invention, which may, for clarity, be described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention that may, for brevity, be described in the context of a single embodiment may also be provided separately or in any suitable sub-combination or as suitable in any other described embodiment of the invention. Stated otherwise, although the invention is described below in terms of various exemplary embodiments and implementations, it should be understood that the various features and aspects described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they may be described, but instead can be applied, alone or in various combinations, to one or more of the other embodiments of the invention. 
         [0041]    One or more embodiments of the present invention provide method and system of rehabilitation processes for reinforced concrete structures that are much simpler, require much less labor-intensive/skilled operations, and use compatible materials for most rehabilitation projects. Non-limiting examples of reinforced concrete structures may include reinforced concrete structural members such as walls, slabs, beams, columns, etc. at various orientations (e.g., vertical, horizontal, inclined, etc.). 
         [0042]    One or more embodiments of the present invention provide method and system that simplify repairs and enhance structural integrity of reinforced concrete structures that have compromised tensile and compressive strengths. Compromised or loss of tensile strength of reinforced concrete structure may be generally due to compromised or deteriorated reinforcement because of corrosion. Further, the deterioration of the reinforcement due to corrosion may lead to delaminated and or spalling of the reinforced concrete structures, leading to weakening of compressive strength. 
         [0043]    One or more embodiments of the present invention provide method and system for strengthening and enhancement of a structure based on a combination of composite laminate forms constructed of a fiber reinforced polymer composite laminate and a corrosion resistant mortar. The strengthening and enhancement provided by the method and system of the one or more embodiments of the present invention include reinforcements that are less invasive than conventional reinforcement systems such as augmentation, replacement, splicing, or welding of reinforcing steel, or dowelling, at a fraction of complexity, space, and time taken to implement conventional systems. 
         [0044]    The repair system in accordance with one or more embodiments of the present invention includes preferred use of a pre-cured fiber reinforced polymer (FRP) laminate bonded by adhesive paste on a prepared surface surrounding a cavity created from removing rust, dust, and loose pieces of concrete resulting from corrosion/rusting of the reinforcement inside the structure. The repair method and system also includes the use of waterproof and generally chemical resistant polymer mortar introduced inside the cavity directly through a port/hole made in FRP laminate after it is fixed to a surface, to completely fill up the cavity and encapsulate the exposed reinforcement, including the corroded portion. The FRP laminate replaces or enhances missing/compromised tensile strength component of reinforced concrete structure and filler enhances compressive and tensile strength components thereof, including providing corrosion protection for the reinforcement. 
         [0045]      FIGS. 1 to 8B  are non-limiting, exemplary illustrations of method and system for structural rehabilitation and enhancement of structural integrity of a reinforced concrete structure, and progressively illustrate a non-limiting, exemplary method of systematic rehabilitation and enhancement operations in accordance with one or more embodiments of the present invention. In particular,  FIG. 1  is non-limiting, exemplary illustration of a reinforced concrete structure with deteriorating reinforcement that is exhibiting spalling, and  FIGS. 7 ,  8 A and  8 B are a non-limiting, exemplary illustration of a fully rehabilitated structure with an enhanced structural integrity in accordance with one or more embodiments of the present invention. 
         [0046]    As illustrated in  FIG. 1 , a method for rehabilitation and enhancement of structural integrity of a reinforced concrete structures commences with detecting a blemished surface  102  (e.g., spalling) of the reinforced concrete structure  104 , which as indicated above, may be a result of a corroded and rusting reinforcement  106 . As best illustrated in  FIG. 2 , to rehabilitate and enhance the structural integrity of a spalling reinforced concrete structures  104 , blemished surface  102  must be excavated until reinforcement  106  is reached. That is, method for rehabilitation and enhancement of structural integrity of reinforced concrete structures  104  includes excavating a portion of the reinforced concrete structure  104  at the blemished surface  102  to reach reinforcement  106  of the reinforced concrete structure  104 , with the excavation forming a cavity  108  on the reinforced concrete structure  104 . 
         [0047]    As illustrated in  FIG. 2 , cavity  108  may have sufficient size wherein the reinforcement  106  is exposed from all sides as illustrated and further, the exposed and visible portions of reinforcement  106  includes at least a deteriorated portion  110  of reinforcement  106  and a non-deteriorated portions  112 . Well-known and conventional mechanical means such as chisel, grinder, hammer, wire brush, etc. may be used to remove all debris and lose pieces of concrete from cavity  108  to reach a sound surface  114  thereof (e.g., a solid surface with no loose particles). All surfaces  114  of cavity  108  may be cleaned from oil, grease, dust, residue, paint, and any other material not part of the substrate  118 . 
         [0048]    As best illustrated in  FIG. 3A , once exposed, reinforcement  106  is preferably cleaned by removing the loosely corroded portions thereof using conventional mechanical abrasions. It should be noted that cleaning reinforcement  106  from corrosions is optional and is not required. However, as detailed below, cleaning reinforcement  106  from loosely corroded portions (for example, loose and crumbling rust) is required and would further enhance the overall compressive strength of the rehabilitated reinforced concrete structure in accordance with one or more embodiments of the present invention. That is, in general, loose, crumbling rust may potentially lower the overall compressive strength of filler that would be encapsulating the remaining reinforcement  106  (detailed below), if crumbling rust is not removed. In other words, the filler would be encapsulating loose, crumbling rust rather than the clean reinforcement  106 , with the crumbling rust positioned between filler and reinforcement  106 , which would obviously lower compressive strength of the filler in relation to the remaining reinforcement. It should be noted that although loose, crumbling rust is removed, unlike conventional methods, it is generally preferred to only remove the crumbling, dusty rust of the reinforcement and need not remove all visible corrosion. This substantially reduces time and labor to clean the reinforcement  106  compared with time and labor required using conventional methods described above, where cleaning reinforcement  106  was required to a point where non-corroded, clean reinforcement steel is reached. Further as detailed below, with one or more embodiments of the present invention, there is no need or requirement to apply anti-corrosion to the reinforcement  106  because the filler used (detailed below) is waterproof and fully encapsulates the reinforcement  106 , isolating it from potential moisture penetrations and further corrosions. 
         [0049]    In general, it is also preferred that cavity  108  and face area  116  be also cleaned from dust and loose particles. Dimensions of face area  116  are dictated by the dimensions of FRP laminate form required and used (as detailed below). To improve adhesion of Fiber reinforced Polymer (FRP) onto face area  116  as detailed below, surface defects of face area  116  may be reduced by reducing surface profile thereof to a maximum of about ⅛ inch or less (depending on application). Stated otherwise, visible protuberances in face area  116  may be smoothed by mechanical abrasion, and visible concave defects may be filled (or patched) with a material that has physical characteristics at least equal to that of substrate  118 . Other residues, oils, grease, coatings, sealers, and other contaminants may also be cleaned and if necessary, oil contamination may be removed using a degreaser, and the surface should in general be afterwards thoroughly rinsed free of degreaser and other chemicals such as etching material. 
         [0050]    After a thorough preparation of substrate  118 , an FRP laminate form may be selected with appropriate shape and dimensions (thickness, length, width) corresponding to the extent and geometry of the spalled area as well as size, spacing, and loss of strength of the reinforcement. That is, size of reinforcement  106  and the extent of loss of reinforcement  106  at portion  140  due to corrosion may be determined to determine correct dimensions and strength properties required for FRP laminate form, which would be used to determine the minimum size of face area  116  required. In general, the FRP laminate form must at minimum cover over the entire cavity  108  and also the entire face area  116  (which may be flat, curved, or other configurations) to provide sufficient strength to replace or supplement the amount of strength of reinforcement  106  lost due to corrosion, and also ensure to maintain filler within cavity. Accordingly, once the extent of loss of tensile strength of reinforcement  106  is determined, the appropriate FRP laminate form, including correct dimensions required to supplement or replace any tensile loss is selected and thereafter, based on the determined FRP laminate form dimensions, size of the face area  116  is determined. It should be noted that as is well known, the fibers of the FRP laminate form used must be oriented parallel to the tensile strength provided (or that would have been provided) by the reinforcement (unidirectional or multidirectional). 
         [0051]    As further illustrated in  FIG. 3A  and as part of continued preparation of substrate  118 , once cavity  108  is cleared, boundaries  120  for mounting and installation position of the FRP laminate form may be visibly marked on face areas  116 . Further, since cavity  108  would be covered by FRP laminate form prior to filling cavity  108  with the appropriate filler (detailed below), an additional marking  122  may be provided for one or more fill-point openings or holes (detailed below). 
         [0052]    As illustrated in  FIG. 3B , if face area  116  is horizontal and facing up, two perpendicular lines  301  and  305  may be drawn on the outside of the area that includes the cavity  108  and face area  116 . The lines  301  and  305  should be drawn in a manner that the intersection  313  of their traces is located generally over the deepest part of cavity  108 . If face area  116  is vertical or nearly vertical, crosswise lines  301  and  305  may be drawn outside of the area that includes cavity  108  and face area  116  such that the intersection of their traces  301  and  308  points to a spot immediately above a top extreme  307  of cavity  108 . If face area  116  is overhead and facing down, a first line  305  is drawn passing through one end of cavity of  108  and a projection of the deepest point of the cavity  108  onto plane of face area  116 , which (line  305 ) may be extended outside the face area  116 . Thereafter, a pair of crosswise lines  301   a  and  301   b  may be drawn on the outside of the area that includes cavity  108  and face area  116  such that an intersection  309   a  of the lines  305  and  301   a  points to a spot immediately under an end of cavity  108 . Further, the intersection  309   b  (of lines  305  and  301   b ) points to a spot immediately under the deepest point of cavity  108  (providing a crosshair for the projected deepest point). If a reinforcement component happens to lie directly between the intersection  309   b  and the deepest point of cavity  108 , the line  305  is redrawn to connect the end of cavity and a point over the deepest part of the cavity  108  and slightly away from of the rebar, so that the new path between intersection  309   b  and the deepest part of the cavity  108  is clear of any rebar. Alternatively, the original set of lines may be kept unchanged and the insertion point is marked and drilled slightly away from the side of the line  305  and long the line  301   b  so that the path between the insertion point and the deepest part of the cavity  108  is clear of any rebar obstruction. 
         [0053]    After preparing substrate  118  and as best illustrated in  FIG. 4 , a primer  124  is applied to coat the entire surface  114  inside cavity  108 , including the entire exposed portion of the reinforcement  106  and also the face area  116 . Primer  124  provides and enhances bonding between filler (detailed below) and cavity surface  114 , and also, reinforcement  106 . In addition, since the same primer  124  is used to prepare the adhesive material  126  (detailed below), application of primer  124  to face area  116  would further enhance bonding properties of the FRP laminate form with face area  116 . It should be noted that (as detailed below), given that filler itself has bonding capability and would fully pack inside cavity  108  and completely encapsulate reinforcement  106 , priming may not be necessary. However, since reinforcement  106  is inside cavity  108  and near surface  114 , it would not be disadvantageous to prime cavity  108 , reinforcement  106 , and surface area  116 , which would simply enhance bonding of the filler with all surfaces with which it contacts and encapsulates. 
         [0054]    Primer  124  is a polymer that may be an epoxy resin comprised of well known thermosetting polymers, non-limiting, non-exhaustive listing of examples of which may include primer RN075 epoxy system from FRP SOLUTION, INC., or the like. The polymer primer  124  may also optionally be polyurethane or polyester based and need not be epoxy-based resin. In general, primer  124  used should be able to bind to surface  114  with sufficient strength that when cured, primer  124  cannot be mechanically separated from surface  114  without causing cohesive or other damages to the surface  114 . That is, mechanically removal of primer  124  will induce or cause cohesive failure on the surface  114 . Cured primer  124  should be solid, chemically inert, and impervious to water. Primer  124  should also be sufficiently strong to not peel, crack, wrinkle, shrink or undergo any other deformation due to movements, contractions, expansions or other thermal or mechanical effects that are generally accepted as “normal” for surface  114 . Primer  124  should be sufficiently viscous to allow for it to be conveniently applied as a liquid without dripping or sagging down surface  114  after application. In other words, primer  124  has a sufficiently low viscosity to allow primer  124  to coat every surface (and groove, pores, or cracks) of the surface  114 , but unlike water, it has sufficiently high viscosity to allow it to remain within the cavity  108 . It should be noted that primer  124  is fully compatible with other materials that are used. In fact, primer  124  is the same binder material that is used in making the filler (detailed below) for the cavity  108 , FRP laminate forms, and the paste adhesive (detailed below). 
         [0055]    Primer  124  may be applied at a rate that it may coat the entire surface  114  uniformly and without blushing. Primer  124  may be applied by spraying or with roller/brush made of solid materials that are inert to primer  124 . Afterwards, there is a wait time until primer  124  is not fluid but still tacky before moving to the next operations, which includes operations related to installing the FRP laminate form. 
         [0056]    As illustrated in  FIG. 5 , as part of the installation operation of the FRP laminate form, after a thorough preparation of substrate  118 , a layer of prepared adhesive material  126  is applied on face areas  116  around cavity  108  that will be covered with FRP laminate form. Adhesive material  126  may be spread evenly and smoothly, and ensure that there are no voids, pinholes, bubbles, bumps or other surface irregularities present in the adhesive paste  126  applied to face areas  116 . Adequate amount of adhesive material  126  is applied to face areas  116  to ensure complete bonding between the FRP laminate (detailed below) and face areas  116 . 
         [0057]    Adhesive material (paste)  126  should bind to face areas  116  with sufficient strength that when cured, adhesive paste  126  cannot be mechanically separated from the substrate surface  116  without causing cohesive or other damages to the substrate. That is, mechanical removal of adhesive material  126  will induce or cause cohesive failure on the face areas  116 . The cured adhesive material  126  should be solid, generally chemically inert, and impervious to water. Adhesive material  126  should also be sufficiently strong to not peel, crack, wrinkle, shrink or undergo any other deformation due to movements, contractions, expansions or other thermal or mechanical effects that are generally accepted as “normal” for substrate  118 . Adhesive material  126  should be sufficiently viscous to allow for it to be conveniently applied as a paste without dripping or sagging down face areas  116  after application. During and after curing, adhesive paste  116  must firmly hold and fixedly maintain in place the FRP laminate form that is mounted over it. 
         [0058]    Adhesive material (paste)  126  used in accordance with one or more embodiments of the present invention is a well-known off the shelf product made of high strength polymers, for example, epoxy resin paste adhesive material comprised of thermosetting polymers in non-sag form that include added dry ingredients that increase a viscosity of the epoxy resin to form an epoxy resin paste. Non-limiting, non-exhaustive listing of examples of adhesive material  126  that may be used may include GS  100  epoxy from FRP SOLUTIONS, INC or the like. As with the primer  124 , adhesive material  126  is also fully compatible with other materials that are used immediately over or under it. 
         [0059]    As best illustrated in  FIG. 6 , thereafter, and within the working time of the applied adhesive  126 , FRP laminate form  130  is mounted on face areas  116  to entirely cover cavity  108 . That is, FRP laminate form  130  is placed over face areas  116  covered with adhesive paste  126  within the area markings  120  for application of FRP laminate form  130 , with fibers of the FRP  130  oriented in the proper direction. Preferably, fibers are oriented parallel to the direction of reinforcement  106  inside cavity  108 . FRP laminate  130  is pressed onto adhesive  126  and face areas  116  using adequate pressure to ensure an intimate contact between FRP laminate  130  and adhesive  126 . Using a hard roller, FRP laminate form  130  may be firmly pressed on to adhesive paste  126  to drive the excess adhesive  126  out and create an intimate contact and bond between FRP laminate form  130  and adhesive paste  126 . Using a spatula, paint knife or other similar tools, the oozed adhesive  126  from face area  116  may be removed to maintain a neat surface. Care should be taken not to disturb adhesive paste  126  by rotating, twisting, lifting FRP laminate form  130  or other actions that may introduce voids in the bond area or create variations in adhesive paste  126  thickness. In general, the assembled FRP laminate  130  is left intact until adhesive  126  is hardened. 
         [0060]    FRP laminate form  130  is a well-known off-the-shelf composite product constructed of fibers of carbon or glass, steel, or other high strength materials, which are impregnated and bonded together with a high strength impregnation polymer resin that is compatible with adhesive  126  and filler (detailed below). The FRP laminate form  130 , which constitutes the forming structure as well as the tensile member in accordance with the present invention, may comprise of material (composite material) made of polymer matrix reinforced with fibers. In other words, FRP laminate form  130  is comprised of well-known reinforcing fibers embedded and cured in well-known binder polymer matrix resin using well known methodologies. Non-limiting, non-exhaustive listing of examples of FRP laminate form  130  that may be used may include C-Clad, SC352, etc. from FRP SOLUTIONS, INC., or the like. It should be noted that the binder matrix used is comprised of a polymer matrix with a component thereof being the same material that is used for primer  124 . Non-limiting, non-exhaustive listing of examples of a polymer matrix resin used is RN075 epoxy from FRP SOLUTIONS, INC, or the like. Non-limiting, non-exhaustive listing of examples of fibers used for forming an FRP may include FC061 from FRP SOLUTIONS, INC, or the like. FRP and all its constituent components may be obtained from third party manufacturers such as FRP SOLUTIONS, INC. Further details related to FRP laminate form  130  (for example, use of unidirectional laminate forms versus multi-directional laminate forms, use dry versus wet layup, etc.) used is disclosed in U.S. Pat. No. 8,479,468 to Abbasi, the entire disclosure of which is expressly incorporated by reference in its entirety herein. FRP laminate form  130  may be prefabricated in various shapes, dimensions, and thicknesses suitable for most common situations. In general, the number of layers of fiber that are laid over one another (and cannot be physically reduced or removed once fabricated) may determine the thickness of FRP laminate form  130 . 
         [0061]    Depending on the manufacturing process, the fibers used in constructing the FRP laminate  130  can be either in the form of free strands or woven/bonded fabrics. In the case of using woven/bonded fabrics, a single or multiple layers of fabric may be needed for constructing the FRP laminate  130  to a desired thickness. Also, in the case of using woven/bonded fabrics, only one layer of lighter weight fabric may be placed in a general 90-degree fiber orientation to the main fibers to prevent the cured sheet from splitting and breakage during handling and installation. If required by the design and engineering, the fibers can also be laid in equal amounts in both 0- and 90-degree, or any other amount and directions. 
         [0062]    When permissible, the fibers—in fabric form—may be saturated with high strength impregnation polymer to form an uncured and unseeded form of FRP laminate  130 , which may be applied to surface  116  by the well-known wet layup method. In the case of using the wet layup method, after cavity  108  and reinforcement  106  are cleared and cleaned as previously stated, face areas  116  surrounding cavity  108  is cleaned and primed with the same high strength impregnation polymer matrix used in saturating the fibers of the FRP in the welt layup method (detailed in the incorporated U.S. Pat. No. 8,479,468 to Abbasi). While the primed face areas  116  are tacky and prior to being hardened, and while the fibers saturated with the high strength impregnation polymer matrix still in the wet state, the saturated fibers of fabric (the uncured form of the FRP laminate  130 ) may be pressed on face area  116  to form a cover over cavity  108 . The saturated fibers of fabric (in the uncured form of the FRP laminate  130 ) is placed on face areas  116  in a manner that it is bonded completely to face areas  116  all around cavity  108  to the extent determined by design and engineering requirements. In the case that the wet layup application requires using multiple layers of saturated fabrics in the uncured form of the FRP laminate  130 , the subsequent layers are applied in the manner that each new layer is in complete and intimate contact and bond with the previous layer. The final assembly is left to cure before proceeding to subsequent operations. 
         [0063]    In general, manufactured FRP laminate forms  130  are very hard, smooth and non-porous and hence, it is preferred if they are modified so that their smooth surfaces may adhere to structures and other finishes. Accordingly, in the non-limiting, exemplary instance illustrated in  FIG. 6 , prior to complete curing of adhesive paste  126 , FRP laminate  130  may be coated with an additional layer of the high strength impregnation polymer matrix resin used in its manufacture, non-limiting, non-exhaustive listing of examples of which may include the above mentioned polymer matrix resin RN075 epoxy, or the like. While the additionally applied resin is still liquid, one side of the FRP laminate  130  may be seeded by sprinkling of an adequate amount of clean and dry fine silica aggregate onto it. As indicated above, since the high strength polymer matrix resin applied to the surface of FRP laminate  130  becomes very hard, smooth and non-porous, the seeding process provides a suitable surface for other additional finishes to be applied over the installed system, such as paint, protective coating, plaster, other architectural or protective finishes, etc. The opposite, unseeded side of the cured FRP laminate  130  sheet may be lightly abraded to dull the surface for better bonding with the polymer adhesive paste  126 . It should be noted that FRP laminate  130  can be manufactured without being seeded. In such cases, both sides of the FRP laminate  130  can be lightly abraded (either at the manufacturing plant or installation site). 
         [0064]    Bonding FRP laminate form  130  with structure  104  using adhesive paste  126  enables the tensile properties of FRP to be transferred to structure  104 . Accordingly, FRP laminate form  130  functions as a forming structure for the filler (as detailed below) and adds tensile strength to compensate for loss in tensile strength due to deteriorated reinforcement  106 . 
         [0065]    In general, reinforcements  106  are positioned near periphery or edges  142  ( FIG. 1 ) of structures  104  and not at the center thereof. Accordingly, an FRP generally compensates for the reinforcement  106  closest thereto. That is, the tensile force that was supposed to have been absorbed and counter-acted by particular reinforcement  106  is now absorbed and counteracted by the installed or mounted and fixed FRP. In fact, FRP may completely replace the reinforcement and hence, no further need is required for augmentation of a reinforcement that is fully compromised (as was required by conventional systems). The number and orientations of reinforcement(s) determine FRP thickness and fiber orientations or tensile strength orientation direction of FRP. That is, if two or more reinforcements are used that are oriented crosswise, an FRP may be used that has fibers that are oriented crosswise to mimic tensile strength orientation directions of the original reinforcements. 
         [0066]    Upon curing adhesive  126 , or curing of all layers of FRP laminate  130  applied by wet layup (as detailed above), filling point mark(s) are placed on FRP laminate form  130  at the intersection of lines marked as detailed above. As best illustrated in  FIG. 7A , a hole  132  is made in FRP laminate form  130  (with care not to damage FRP laminate form  130 ) at the marked filling point  122 . The position of the hole  132  is chosen to be at the highest part of cavity  108  when face areas  116  is vertical. If FRP laminate form  130  is in vertical position, hole  132  is drilled at an angle such that drill travels slightly downward towards the inside of cavity  108 . The size of hole  132  is chosen to allow introducing filler  134  inside cavity  108  without compromising the strength and integrity of FRP laminate  130 . Thereafter, sufficient quantity of filler  134  is prepared and introduced inside cavity  108  through hole  132 . Non-limiting, exemplary methods of introducing filler  134  inside cavity  108  may include the use of injection or pumping with manual or automated devices such as hand operated pumps, caulking guns, injection pumps, grout pumps, and other similar devices. 
         [0067]    Filler  134  used is waterproof and generally chemical resistant polymer mortar introduced inside cavity  108  directly through a port/hole made in FRP laminate  130  after it is fixed to surface  116 , to completely fill up cavity  108  and encapsulate the exposed reinforcement  106 , including the corroded portion  110  and partially exposed non-corroded portions  112 . This prevents moisture from reaching reinforcement  106 , which prevents further corrosion and deterioration of reinforcement  106 . As indicated above, getting rid of corrosion is not important because reinforcement  106  is encapsulated within the waterproof filler  134 , which prevents further corrosion and also, any loss in tensile strength due to corrosion of reinforcement  106  is more than compensated by FRP laminate form  130 . However, waterproof filler  134  must fully cover any corroded portion  110 , including a small portion  112  of non-corroded reinforcement  106 . The depth of cavity  108  also need not be so deep to enable access for removing rust from reinforcement  106 , but must be sufficient to allow filler  134  to fully encapsulate reinforcement  106  from all sides. 
         [0068]    It should be noted that filler  134  used fully encapsulates reinforcement  106  and therefore, reinforcement  106  need not be rehabilitate to the level required by conventional processes where the cleaning of all corroded portion must be full to reach the clean steel part of the rebar. The reason for this is because reinforcement  106  will be prevented from further corrosion due to it being encapsulated by the waterproof mortar  134 . This also means that there is no need or requirement to apply anti-corrosion to existing rebar. In other words, waterproof filler  134  encapsulating reinforcement  106  would actually protect reinforcement against moisture and hence, future oxidation and corrosion. 
         [0069]    Filler  134  is a well-known off-the-shelf polymer-based mortar that is self-leveling and has high compressive and tensile strength properties, with compressive strength thereof at least equal to or greater than that of the substrate  108 . Non-limiting, non-exhaustive listing of examples of filler  134  that may be used may include HCM-25R from FRP SOLUTIONS, INC or the like. As with primer  124 , adhesive material  126 , and FRP constituents, filler  134  is also fully compatible with other materials that are used. 
         [0070]    In general, filler  134  used should be able to bind to primed surface  114  with sufficient strength that when cured, filler  134  cannot be mechanically separated from primed surface  114  without causing cohesive or other damages to primed surface  114 . That is, mechanically removal of filler  134  will induce or cause cohesive failure on primed surface  114 . Cured filler  134  should be solid, chemically inert, and impervious to water. Filler  134  should also be sufficiently strong to not peel, crack, wrinkle, shrink or undergo any other deformation due to movements, contractions, expansions or other thermal or mechanical effects that are generally accepted as “normal” for substrate  118 . Filler  134  should be sufficiently viscous to allow for it to be conveniently applied (introduced into cavity  108 ) and to allow filler  134  to fill every surface (and grooves or cracks) of the cavity  108  and reinforcement  106  (if any is left). In other words, filler  134  should be viscous enough to allow for it to be conveniently placed in cavity  108  and fill all empty spaces in the cavity and bind to all contacting surfaces. It should be noted that filler  134  is fully compatible with other materials that are used and with which it comes to contact. In fact, filler  134  uses the same binder material that is used in making the primer for the cavity  108 , FRP laminate forms, and the paste adhesive. the filler has a tensile strength that is greater than the tensile strength of the concrete structure, but less than the tensile strength of FRP. 
         [0071]    As illustrated in  FIG. 7B , if cavity  108  is to be filled by gravity filling, the tip of the manual or powered grout pump nozzle may be inserted inside cavity  108  thorough hole  132  and filler  134  is pumped until cavity  108  is filled completely, and the filler  134  is in complete, intimate contact with all surfaces  114  inside cavity  108 , including reinforcement  106 , and FRP laminate form  130 . Once cavity  108  is filled, nozzle tip may be removed and hole  132  in FRP laminate form  130  may optionally be plugged with a plastic cap  156 . The plug/cap  156  is a well-known off the shelf product, non-limiting examples of which may include rubber, plastic, wood, and other appropriate materials. The cap  156  may be optionally cut off after filler  134  is cured. 
         [0072]    As best illustrated in  FIG. 7C , if cavity  108  is to be filled by pressure grouting method, conventional injection port  150   a /b are inserted within respective opening  152   a /b and the prepared filler  134  is injected inside cavity  108  in well-known method using well known injection equipment, with port  150   b  being the ingress port and  150   a , the egress port. Ports  150   a /b are a well-known off the shelf product, non-limiting examples of which may include surface mounted ports, drill ports, weeping type, one way port, check valve types, and others. Once cavity  108  is filled and filler is  134  oozing out of the egress port  150   a , the injection may be stopped and ports  150   a /b closed and/or capped to allow filler  134  to cure. Once filler  134  is cured, injection ports  150   a /b may be cut off and removed without damaging FRP laminate form  130 . 
         [0073]    It should be noted that as an intermediate operation, as soon as cavity  108  is filled with filler  134 , a brief vibration may be applied to the outside surface of FRP laminate  130  to drive out any air entrapped inside filler  134 . Vibration also helps the filler  134  to settle, flow, and reach all surfaces  114  inside cavity  108 . When filler  134  is completely cured, the plug  132  or the port  150   a /b may be removed and the hollow area of the hole  132  and  152   a /b may be patched with an adequate amount of prepared and uncured adhesive  126  or other suitable material and left to cure before applying any finishes as needed. If needed, FRP laminate form  130  or a parts thereof may further be patched (e.g., due to uneven surfaces, voids, etc.) with compatible patching material, and apply finish as required. 
         [0074]    As best illustrated in  FIG. 8A , in the case of overhead cavities, a venting port  164  is inserted inside the hole  152   b  that is away from the end of the cavity  108  and bored into the FRP laminate from  130  through the point marked by intersection  309   b  ( FIG. 3B ). The venting port  164  has a tube  166  with sufficient length to reach the deepest point of cavity  108 . The tube  166  is placed in cavity  108  so that its tip barely touches surface  114  of cavity  108  thereby creating a minute gap between surface  114  of cavity  108  and the tip of tube  166 . The purpose of this port  164  is to prevent air entrapment and ensure that cavity  108  is completely filled with filler  134  as indicated by filler  134  oozing out of this port  166  (as indicated by the egress pointing arrow at the egress port  150   b ). When the cavity  108  is totally filled, both of the ports  150   a /b are closed and filler  134  is left to cure. 
         [0075]    With respect to  FIG. 8B  in particular, in this non-limiting, exemplary instance, a hole  160  is drilled into structure  104  so as to connect cavity  108  (spalled side) to opposite side surface  162  of structure  104 . Hole  160  is drilled either from inside cavity  108  or into surface  162  of structure  104  opposite to cavity  108  opening. Filler  134  is then introduced into cavity  108  via this hole  160  by either gravity feeding or pressure injection by hole  160  from surface  162 . 
         [0076]      FIGS. 9A to 9C  are non-limiting, exemplary illustrations of a method and system for full rehabilitation of reinforced concrete structures that exhibit extensive spalling in accordance with one or more embodiments of the present invention. The method and system illustrated in  FIGS. 9A to 9C  includes similar corresponding or equivalent components, interconnections, functional, operational, and or cooperative relationships as the method and system that is shown in  FIGS. 1 to 8B , and described above. Therefore, for the sake of brevity, clarity, convenience, and to avoid duplication, the general description of  FIGS. 9A to 9C  will not repeat every corresponding or equivalent component, interconnections, functional, operational, and or cooperative relationships that has already been described above in relation to method and system that is shown in  FIGS. 1 to 8B . 
         [0077]    As illustrated in  FIGS. 9A and 9B , there are instances where the reinforced concrete structure  104  is so severely damaged that the structure  104  does not have a sufficient surface area where it may be constituted as the face area  116  for secure connection of the FRP laminate form as described above. In fact, reinforcements  106  and any confinement rebars (or hoops, stirrups, etc.)  168  are generally exposed. Accordingly, a platform is created that serve the function of the above mentioned face area  116  to connect and secure an FRP laminate form  130  to such severely damaged structures. In this non-limiting, exemplary instance, the FRP laminate form  130  is a bidirectional FRP to supplement or replace bidirectional reinforcement (i.e., reinforcement  106  and confinement bars  168 ). Therefore, as illustrated in  FIG. 9C , a system and a method for rehabilitation and enhancement of structural integrity of a reinforced concrete structure is provided that includes studs  202  (that function support to form a platform to hold FRP laminate  130 ) with a first end  204  associated with surface  114  of cavity  108 . The studs  202  have sufficient height  206  wherein their second end  208  extends out of cavity  108 , providing an elevated surface (e.g., platform) that is generally in continuity (or aligned) with original substrate  222  (non-deteriorated, non-spalled) areas at the exterior of cavity  108  to enable connection of a FRP laminate form  130  to second end  208  of studs  202 . Finally, the FRP laminate forms  130  are fastened to second end  208  of stud  202  with the remaining processes the same as above. In this non-limiting, exemplary embodiment, the studs  202  are comprised of spacers (or bushings, sleeves, etc.)  210  within which are inserted fasteners (e.g., bolts, FRP anchors, etc.)  212  with a first end  214  of fasteners are secured into surface  114  of cavity  108 . FRP laminate form  130  includes connection holes that receive the free ends  216  of the fasteners, with a washer and nut  218  connecting or fixing the FRP laminate form  130  to the spacers  202  via the free ends  216  of the fasteners  212  (if fastener used is a bolt). It should be noted that the first end  214  of the fasteners are secured to surface  114  of cavity  108  by first providing an opening in the surface  114 , and doweling the fastener (placing the fastener in hole, and further securing it in the hole with use of adhesive material). Non-limiting example of FRP anchoring is disclosed in U.S. Pat. No. 8,479,468 to Abbasi. 
         [0078]    Although the invention has been described in considerable detail in language specific to structural features and or method acts, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as exemplary preferred forms of implementing the claimed invention. Stated otherwise, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. Further, the specification is not confined to the disclosed embodiments. Therefore, while exemplary illustrative embodiments of the invention have been described, numerous variations and alternative embodiments will occur to those skilled in the art. For example, different types of polymers may be used depending on engineering and design specifications. The thickness, length, width, types, and physical characteristics of FRP laminate  130  may vary according to engineering and design criteria. Non-limiting, non-exhaustive exemplary list of physical characteristics for filler  134  that may vary may include additive fiber type, polymer component, ratios of mix, manufacturer, etc. Filler  134  may be varied in accordance with engineering and designed to meet all specifications. Non-limiting, non-exhaustive exemplary list of physical characteristics for filler  134  that may vary may include the required compressive strength, required tensile strength, modulus of elasticity, use of fiber in the mix. Further, for horizontal applications ( FIG. 3B ), FRP laminate form  130  is first applied as described for the vertical and overhead applications, thereafter, an opening is made through the FRP laminate form  130  at intersection  313 , and filler  134  is filled via the opening until cavity  108  is completely filled in its entirety. Finally, if needed, FRP laminate form  130  or parts thereof may further be patched (e.g., due to uneven surfaces, voids, etc.) with compatible patching material, and apply finish as required. Such variations and alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention. 
         [0079]    It should further be noted that throughout the entire disclosure, the labels such as left, right, front, back, top, bottom, forward, reverse, clockwise, counter clockwise, up, down, or other similar terms such as upper, lower, aft, fore, vertical, horizontal, oblique, proximal, distal, parallel, perpendicular, transverse, longitudinal, etc. have been used for convenience purposes only and are not intended to imply any particular fixed direction or orientation. Instead, they are used to reflect relative locations and/or directions/orientations between various portions of an object. 
         [0080]    In addition, reference to “first,” “second,” “third,” and etc. members throughout the disclosure (and in particular, claims) is not used to show a serial or numerical limitation but instead is used to distinguish or identify the various members of the group. 
         [0081]    In addition, any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. Section 112, Paragraph 6. In particular, the use of “step of,” “act of,” “operation of,” or “operational act of” in the claims herein is not intended to invoke the provisions of 35 U.S.C. 112, Paragraph 6.