You are on page 1of 37

Construction

Repair and Restoration


Using Sika Materials

Sika Egypt

Construction

Concrete Repair

Before

After

Construction

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

Construction

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

Construction

Concrete Damage and Defects

Mechanical

Chemical

Physical

Construction

2.Concrete Damage due to reinforcement corrosion

Chlorides

Carbonation

Chlorides
Water

Carbonation

Alkali Silica
Reaction

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

Concrete under
attack

Impact

Abrasion
Temperature

+ Errors made during design or Construction

Construction

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 .

Construction

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

Construction

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 .

Construction

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) .

Construction

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

Construction

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 .

Construction

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.

Construction

SURFACE PREPARATION
<45 degree

90 degree
45 degree

CLEARLY DEFINED EDGES


AT ANGLE > 45 DEGREE

Construction

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

Construction

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

Construction

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)

Construction

REPLACING DAMAGED CONCRETE

Sika Rep & Sika Latex mortar


Sika Top 122

Construction

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

Construction

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

Rebar Cracks

Shrinkage Cracks

Construction

Measuring Crack width

Construction

Surface Structural Cracks:

Crack Filler
SIKADUR 31

Cap Seal
SIKADUR 52

Surface Injection by SIKADUR 52


For Cracks of 0.5 - 5 mm

Construction

Deep Structural Cracks:

Cap Seal
SIKADUR 52

Injection Holes

Deep Injection by SIKADUR 52

Construction

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

Construction

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

Construction

Methods of Repair:
Third Solution :

Large repair thickness with Steel Corrosion

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.

Use Sika Protective Coating


Sika Seal 105 Sika Top Seal 107 Sika gard 550 W

Construction

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

Construction

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

Construction

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

Construction

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)

Construction

Grouting
Sikadur-42 ( Grout Epoxy )

Construction

Sikadur-42 ( Grout Epoxy )

Construction

Sikadur-42 ( Grout Epoxy )

Construction

Repairing techniques
HORIZONTAL
APPLICATION

Pouring grout through openings


Pencil vibrator For Cement Grout
Sika Grout 200 & 214 & 295

Construction

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

Construction

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

Construction

You might also like