CRS

Concrete
Repair
Systems

MATERIAL & METHOD STATEMENT

Type of Defect : Honeycomb

(larger voids, aggregate loss, perimeter flaking, loss particles, active corrosion
particles, depth exceeding 40 mm).

Repair Technique : Grouting

Material Used : Sika Grout- 212, a non-shrink, self-leveling, cementitious grout.

Sikadur - 732, a thixotropic, epoxy - bonding agent for old to new concrete.

Epoxy Bonding
(Sikadur-732)

Repair Mortar
(Sika Grout – 212)
CRS
Concrete
Repair
Systems

GROUTING

A. Substrate and Formwork Preparation:

A.1 Mark clearly the area of substrate surface where damage or defect concrete is to be
removed.

A.2 Take out the defective concrete by chipping with a mechanical chipping hammer. If
rebar is exposed more than half of its diameter chip to sound concrete by at least 25
mm behind rebar. If it is impossible to clear the concrete behind rebar due to
overcrowded reinforcements, chip only down to undoubtedly sound concrete provided
that an epoxy bonding agent is used, and prior thorough cleaning by wire brush and
compressed air have been done to the reinforcement and chipped concrete surfaces.

A.3 Cut surface edges of the boundaries activities formed from chipping with a hand-held
mechanical concrete cutter/grinder to square edges of about 10 mm minimum depth
perpendicular to the concrete surface to avoid any feather edge.
 A.4 Remove all loose chippings, rust and dusts from the concrete cavity surfaces and
exposed rebar surfaces by power steel brush, compressed air blowing and/ or water
blastcleaning.

A.5 Prepare a custom or tailor fit formwork to cover the formed cavity at the wall with a
grout entry opening (letter box technique or funnel) on its top immediately above the
cavity.

A.6 Assemble the formwork and carry out a trial installation ensuring a tight fitting bottom
and side contacts with the concrete wall surface, by providing a two-face adhesive
foam in between and a strong shoring supports.

A.7 Take out the pre-assembled formwork and prepare for the epoxy bonding and grout
application.

B. Epoxy Bonding Agent and Grout Mixing and Applications:

B.1 Prepare the epoxy bonding agent, Sikadur-732, mix by using low speed drill (500 rpm)
with fabricated mixing paddle, mix or agitate Sikadur-732 Part A, then decant all Part B
into A, and mix together thoroughly until a uniform colour is achieved (typical mixing
time: 3 mins.).

B.2 Apply the bonding agent forcefully into the substrate and rebar surfaces with a firm
short-bristled brush and allow the coat to get tacky (about after 35 mins. from
application). Apply as thin as possible, but do not leave any part of the surface
uncovered.

B.3 Just after completing the brushing application of epoxy bonding agent, fix immediately
the pre-assembled formwork together with its supports. Make sure that the supporting
formwork are strongly anchored and ably shored inorder to counter the considerable
bursting force of the flowable concrete (grout).

B.4 Prepare and mix constituent materials in a mixer, Sika Grout 212 (Mix Design = SG
212 : Water = 25 : 4.0 by wt.) then the Sika Grout 212. Consistency for optimum flow
without segregation, maybe adjusted by the addition of some small quantities of water.
Mix for at least 3 minutes or until a smooth and even consistency is achieved.

B.5 Once the formwork is fixed in place, and while the epoxy bonding agent still tacky
(about after 35 mins. from application), pour the Sika Grout 212 into the formwork.

B.6 Consolidate the grout while filling, by tapping slightly the formwork with a wood stick or
a rubber mallet.

B.7 Fill the formworks with the grout up to the top level of the opening making sure that the
cavity is entirely filled.

B.8 Leave the grout to harden till next day (at Least 24 hours).

C. Formworks Stripping and Curing:

C.1 Remove the fomworks by slowly dismantling the supports and fixtures.
C.2 Patch any surface depression found with lean mix of Sika Grout 212.

C.3 Curing must be done after the removal of formworks and continue curing until 7 days.

C.4 For additional curing a wet burlap covering the repair area maybe installed.

Client Name: _______________________

__________________________________

CRS
Job Name: _________________________
Concrete
Repair __________________________________
Systems

Important Note:
This report has been prepared based on Sika’s current knowledge and experience of Sika’s products when properly stored,
handled and applied under normal conditions. It only applies to the application and product referred to in this report. In case of
changes in the parameters of the application, such as changes in substrates etc., or in case of a different application, consult
Sika’s Technical Service prior to using Sika’s products. The user of the product must test the product’s suitability for the intended
application and purpose. Consult the current technical data sheet. Except as expressly stated in writing, Sika’s warranty is
governed exclusively by our current sales conditions. In particular, Sika does not warrant the correct application of its product.