Construction

Repair and Restoration Using Sika Materials

Sika Egypt

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Concrete Repair

Before

After

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Introduction :
Definitions
.Repair:
To replace or correct deteriorated, damaged, or faulty materials, components, or elements of a concrete structure.

.Repair systems:
The materials and techniques used for repair.

.Protection:
The process of maintaining a concrete structure in its present or restored condition by minimizing the potential for deterioration or damage in the future.

.Strengthening:
The process of restoring the capacity of weakened components or elements to their original design capacity, or increasing the strength of components or elements of a concrete structure.

ACI 546R

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Repair Methodology :
.Evaluation. .Relating observations to causes. .Selecting methods and materials. .Preparation of drawings and specifications. .Selection of a contractor. .Execution of the work. .Quality control.

ACI 546R

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Concrete Damage and Defects

Mechanical

Chemical

Physical

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2.Concrete Damage due to reinforcement corrosion

Carbonation

Chlorides

Stray/Electrical Current
Chemicals (Acids, solvents...)

Chlorides Water

Carbonation

Concrete under attack

Impact

Alkali Silica Reaction

Abrasion Temperature

+ Errors made during design or Construction

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The Procedures for Repairing Concrete

Surface Preparation :

.Concrete surfaces should be sound, clean and free from oils, grease or
surface contaminants.

. Remove all loosely adhering particles.

Steel Protection and Bonding Agent :

. Steel reinforcement is to be cleaned using steel brush to remove all

adhering particles .

.Protect the Steel from corrosion using Sika Steel Protection materials. .Use a bonding agent to bond the old concrete with the repairing mortar
(concrete).

. Could use a material with a combination between both actions .

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Using Cement-based Anti-Corrosive Rebar Coating :

Used in repairing Existing constructions

Using Sika Top Armatec -108:

Cement-based, Synthetic modified 2- component coating for corrosion protection. Used in reinforced corroded bars resulting from carbonation. Used against the action of Calcium Chlorides and de-icing salts. Excellent adhesion to steel . Good bonding coat for subsequent cement and epoxy-based repair mortar. Contains Corrosion inhibitors. Colour : Grey-Green

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Using Cement-based Epoxy modified Anti-Corrosive Rebar Coating and bonding agent :
Used in repairing Existing constructions

Using Sika Top Armatec -110 EpoCem : Cement-based epoxy modified three-component anti-corrosive coating and bonding agent. As an anti-corrosion coating for reinforcement steel : Used in repairing of concrete where there is corrosion in the reinforcement steel. Act as an effective barrier against penetration of water and chlorides . As a bonding agent for use on concrete mortar or steel : For bonding new concrete to old . For repairs to concrete using SikaTop and Sika Rep patching and repair mortars .

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Sika Top Armatec -110 EpoCem:

Coverage: As a bonding slurry not less than 1.5 2.0 Kg /m2 (depending on substrate conditions). As an anti-corrosion coating approx. 2 kg/m2/2 coats (depending on method of application) .

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Using Epoxy Primer for steel :

Used in new constructions

Using Sika Zinc Rich EG : To provide excellent protection against corrosion for iron , re-bars and steel structure . Theoretical layer thickness with a consumption of 100 g/m2 is 25 microns . Surface preparation is the most important step in the coating system:

.Oil or grease contamination should be totally removed. .Blast cleaning

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Using Corrosion Inhibiting Impregnation :

Used in new and Existing constructions Using Sika Ferrogard -903:

Sika Ferrogard -903 is a corrosion inhibiting , emulsion-type impregnation for concrete . Sika Ferrogard -903 penetrates the concrete by liquid and vapour diffusion. Sika Ferrogard -903 has a high affinity to steel and forms a protective film on the steel surface . Sika Ferrogard -903 suitable for treatment of reinforcing steel which is corroding or in danger of being corroded in areas without any visible concrete defects .

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Sika Ferrogard -903:

Total consumption : 0.3-0.5 kg/m2 Number of coats : 3-5 coats are required ( depend on the absorbency of the substrate . Penetration rate : Sika Ferrogard-903 can penetrate at a speed of 2.5 mm to 20 mm per day . Protective layer : Sika Ferrogard-903 forms an adsorbed protective layer on the reinforcement . The process of forming this protective layer takes place even in carbonated concrete and with the presence of chlorides in the concrete.

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SURFACE PREPARATION
<45 degree

90 degree 45 degree

CLEARLY DEFINED EDGES AT ANGLE > 45 DEGREE

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Sika Repairing Materials

1. Repairing concrete: The quality depends on : - Mix design - Quality of the components - Application practices To improve properties of fresh and hardened concrete : Use the Concrete admixtures: Water Reducer, High Range Water Reducer (Plastiment and Sikament). Silica fume (Sika Fume ). Corrosion inhibitor => new generation of non-toxic mixed inhibitor - Modified Amino Alcohol (Ferrogard Technology Ferrogard 901).

Use Sika Micro-Concrete System Sika Crete 114

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2. Repairing mortars
Cementitious mortars: Polymer modified blended mortars Cement + Sand + polymers (Sika Latex & Sika Bond DV & Sika Bond LA) The polymer : . Acts as water-reducer . Improves bond strength . Improves flexural strength . Reduces permeability

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3.Pre-blended Repair mortars

3.1. Ordinary Repair mortars
Cement based, multi-purpose patching and repair mortar, incorporating the use of micro-fibers. (Sika Rep & Sika Rep Fine)

3.2. Polymer modified repair mortars.

is a cement based, polymer modified, (Always two component) repair mortar with added polyamide fibers. (Sika Top 121 & 122)

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REPLACING DAMAGED CONCRETE

Sika Rep & Sika Latex mortar Sika Top 122

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Epoxy Repair Mortar

(Sika Dur 41 ) -Three component mortars -High early mechanical performances -High chemical resistance but with physical characteristics quite different than the concrete substrate characteristics : - Thermal coefficient expansion - Modulus of elasticity - Temperature resistance

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Concrete Cracks :
Structural and non-structural cracks. Static and live cracks. Dry Cracks or running water Cracks. Crack width.

Rebar Cracks

Shrinkage Cracks

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Measuring Crack width

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Surface Structural Cracks:

Crack Filler SIKADUR 31

Cap Seal SIKADUR 52

Surface Injection by SIKADUR 52 For Cracks of 0.5 - 5 mm

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Deep Structural Cracks:

Cap Seal SIKADUR 52

Injection Holes

Deep Injection by SIKADUR 52

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Methods of Repair:
First Solution :
Small repair thickness for concrete
Bonding Agent:

Using Sika Bond or Sika Latex S.B.R (modified styrene butadiene rubber emulsion) Sika Latex : Water 1:1 + (Cement : Sand, 1:1). The first mortar coat must then be applied while the bonding grout is still wet.
Repair Mortar :

Using Sika Bond or Sika Latex as a waterproofing admixture with Ratio Sika Latex : Mix. Water 1: 3
Repair Mortar : Sika Latex : Mixing water = 1:3

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Methods of Repair:
Second Solution :
Large repair thickness for concrete
Bonding Agent:

Using Sika Latex . Sika Top 121 (Polymer Modified Patching and Adhesive Mortar). Sika Top Armatec -110 EpoCem.
Repair Mortar :

Sika Top 122 (Fiber Reinforced Polymer Modified Repair Mortar) Sika Rep (Multi-Purpose Patching and Repair Mortar) Repair mortar with Sika Latex.
Repair Mortar

Bonding Agent

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Methods of Repair:
Third Solution :
Steel Protection: Sika Top Armatec -108 Sika Top Armatec-110 EpoCem. Sika Zinc Rich Bonding Agent: Using Sika Latex . Sika Top 121 (Polymer Modified Patching and Adhesive Mortar). Sika Top Armatec -110 EpoCem. Repair Mortar : Sika Top 122 (Fiber Reinforced Polymer Modified Repair Mortar) Sika Rep (Multi-Purpose Patching and Repair Mortar) Repair mortar with Sika Latex.

Large repair thickness with Steel Corrosion

Use Sika Protective Coating Sika Seal 105 Sika Top Seal 107 Sika gard 550 W

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Methods of Repair:
Fourth Solution :
Large Vertical repair thickness with Steel Corrosion
Steel Protection: Sika Top Armatec -108 Sika Top Armatec-110 EpoCem. Sika Zinc Rich Bonding Agent: (Optional) Using Sika Latex . Sikadur 32 Repair Mortar : Sika grout 200/214 Sika Crete 114

Use Sika Protective Coating Sika Seal 105 Sika Top Seal 107 Sika gard 550 W

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Methods of Repair:
Fifth Solution :
Large Vertical repair thickness with Steel Corrosion
Steel Protection: Sika Top Armatec -108 Sika Top Armatec-110 EpoCem. Sika Zinc Rich Bonding Agent: (Optional) Using Sika Latex . Sikadur 32 Shotcrete Mortar : Using Sigunit Powder. SikaCem Gunit -133 Plaster Mortar : Ordinary Repair mortar + Sika Latex.

Use Sika Protective Coating Sika Seal 105 Sika Top Seal 107 Sika gard 550 W

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Fixation of dowels and starter bars.

Sika Dur 31 CF (V/H) Sika Dur 42 (V) Sika Grout 200/214 (V)

Horizontal Tie H Vertical Tie V

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Anchoring Fixation:
Tie depth (Ld) : (10-12 ) s Tie Diameter : For Sikadur 31 (s + (2-4 mm)) For Sikadur 42 (s + 7 mm)

For Sika grout 200/214 (s + 18 mm)

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Grouting
Sikadur-42 ( Grout Epoxy )

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Sikadur-42 ( Grout Epoxy )

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Sikadur-42 ( Grout Epoxy )

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Repairing techniques
HORIZONTAL APPLICATION

Pouring grout through openings Pencil vibrator For Cement Grout Sika Grout 200 & 214 & 295

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Methods of Repair:
Sixth Solution : Strengthening of structures with Carbon Fiber Reinforced polymer Strips

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CONCLUSION
The Repair Process seems easy but the quality and therefore the durability of the work is influenced by numerous factors. Sika is helping the customers for the selection of the material the most suitable for his application. This selection should take into consideration : - causes of the damages - quality of the substrate ( preparation...) - qualification of the applicator - atmospheric conditions - cost of the repair

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