site handbook - repair to concrete

24
SITE HANDBOOK Repair of Concrete Structures - Patch Repair and Spray Applications A simple step by step guide to preparing and applying Sika Concrete Repair Systems

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Page 1: Site Handbook - Repair to Concrete

SITE HANDBOOK

Repair of Concrete Structures

- Patch Repair and Spray Applications

A simple step by step guide to preparing and applying Sika Concrete Repair Systems

Page 2: Site Handbook - Repair to Concrete

SITE HANDBOOK - Patch Repair and Spray Applications

Sikagard®- protective

coating layer

Sika® MonoTop®- pore sealer

and smoothing mortar

Sika® MonoTop® -repair and profi ling

mortar

Sika® MonoTop®/SikaTop® Armatec®-

reinforcementcorrosion protection

Page 3: Site Handbook - Repair to Concrete

Contents Page

Before Application

Health and Safety page 4Useful Documents page 5Bag Layout page 6Climate Conditions page 7Equipment page 8Do and Do Not page 9

Concrete Repair Procedure

1. Substrate Preparation page 103. Preparing Reinforcement page 124. Reinforcement Corrosion Protection page 135. Bonding Primer page 146a. Repair Application by Hand page 156b. Wet Spray Applcation page 167. Smoothing Mortar page 17

After Application

Curing Protection page 18Curing Methods page 18Cleaning Tools page 19Enviroment / Accidents page 19

Mixing page 20

Sika Repair Systems page 21

Hints and Advice

Over Head Application page 22Wet Spray Equipment page 23

Page 4: Site Handbook - Repair to Concrete

4

Health and Safety

Work Safely!

SITE HANDBOOK - Patch Repair and Spray Applications

Page 5: Site Handbook - Repair to Concrete

5

Product Data Sheet Edition 19/05/2009 Identification no: 02 03 02 04 001 0 000066 Sika® MonoTop®-412 NFG (Template for local translation, only for internal use)

1 1/5

Cons

truct

ion

Sika® MonoTop®-412 NFG

Sika® MonoTop®-412 NFG R4 Structural Repair Mortar with Corrosion Inhibitor

ProductDescription

Sika® MonoTop®-412 NFG is a 1-component, polymer modified, fibre reinforced, low shrinkage structural repair mortar with corrosion inhibitor meeting the requirement of class-R4 of EN 1504-3.

Uses Suitable for restoration work (Principle 3, method 3.1 & 3.3 of EN 1504-9). Repair of spalling and damaged concrete in buildings, bridges, infrastructure and superstructure works.

Suitable for structural strengthening (principle 4, method 4.4 of EN 1504-9). Increasing the bearing capacity of the concrete structure by adding mortar.

Suitable for preserving or restoring passivity (principle 7, method 7.1 and 7.2 of EN 1504-9). Increasing cover with additional mortar and replacing contaminated or carbonated concrete.

Characteristics / Advantages

Polymer modified for increased durability Superior workability and finishing Suitable for hand and machine application Can be applied up to 50 mm thick per application layer Class R4 of EN 1504-3 Structural repair Sulphate resistant Very low shrinkage behaviour Does not require a bonding primer even when manually applied Contains corrosion inhibitor Low chloride permeability

Tests

Approval / Standards LPM, Laboratory for Preparation and Methodology (Beinwil am See, Switzerland) – Initial Type Test report in accordance with EN 1504-3, Nr. 34,240-2E dated 9th April 2009.

Product Data

Form

Appearance / Colour Grey powder

Packaging 25 kg bag

Useful Documents

Method Statement Sika® MonoTop® Systems Detailed step by step guide to concrete repair

Product Data Sheet Product uses Substrate quality Substrate preparation Mixing Ratio Application conditions & tools Pot life Curing treatment

Material Safety Data Sheet Hazards First Aid Emergency Ecology

Page 6: Site Handbook - Repair to Concrete

6

SITE HANDBOOK - Patch Repair and Spray Applications

Bag LayoutExample: Sika® MonoTop®-412 N Main Description

Storage DetailsPerformance Classifi cation

Safety LabelApplication Information

Pot LifeCE MarkingProduct Characteristics

Page 7: Site Handbook - Repair to Concrete

7

Climate Conditions

Storage

Product storage:

Dry, cool conditions Undamaged original packaging

Application

Protect area from:

Direct sunlight Wind Rain Frost

Temperature

Check acceptable limits:

Ambient temperature Substrate temperature

12 months

Page 8: Site Handbook - Repair to Concrete

8

SITE HANDBOOK - Patch Repair and Spray Applications

Equipment

Mixing tools

Mixing bowel

Application tools

Sponge

Brushes

for machine applications see page 23

Hand tools

Page 9: Site Handbook - Repair to Concrete

9

Do and Do Not!

DO

Use only clean potable water

Make sure tools are clean and well maintained

Remove only concrete as instructed by supervising offi cer or qualifi ed engineer

Consult product data sheet before starting

DO NOT

Do not contaminate mixture with other chemicals

Do not mix powders from different products

Do not add more water than recommended

Do not mix and apply the product in direct sunlight

Page 10: Site Handbook - Repair to Concrete

10

SITE HANDBOOK - Patch Repair and Spray Applications

1. Substrate Preparation

Surface Preparation

Mark defective concrete

Concrete Removal

Using high pressure water jet, 1100 bar(large area)

or

With hammer drill(medium area)

or

Hammer and chisel (small patch repairs)

Remove tire wires, nails etc.Remove only defective concrete as instructed.Do not reduce structural integrity.

Page 11: Site Handbook - Repair to Concrete

11

2. Substrate Preparation

Extent of Concrete Removal

Remove concrete minimum 15 mm behind main bars

Correct Substrate Preparation

Roughen surface (2 mm minimum)

Cut sides minimum 90° to avoid undercutting and maximum 135° to reduce debonding around edges

Substrate shall be sound with no loose material

Inform supervisor immediatly if there are any cracks in the substrate

15 mm Minimum

Page 12: Site Handbook - Repair to Concrete

12

SITE HANDBOOK - Patch Repair and Spray Applications

3. Preparing Reinforcement

Cleaning Reinforcement

Remove all:

Tie wires Rust Mortar / Concrete Other loose material

Removal Techniques

Use steel wire brush

or

Abrasive blast cleaning techniques

or

High pressure water jetting(1100 bar minimum)

Inform supervisor immediatly of any badly damaged reinforcement

Page 13: Site Handbook - Repair to Concrete

13

4. Reinforcement Corrosion Protection

Application of Corrosion Protection

(if specifi ed)

Apply two 1 mm thick layers(total 2 mm minimum)

Application Techniques

Hopper spray for large applications

or

Inspect bars after to ensure full coverage

Allow time for the 1st coat to harden before applying 2nd coat.Allow application to dry before applying repair mortar.

Brush for small applications

Use two brushes simultaneously to ensure full application behind bars

Page 14: Site Handbook - Repair to Concrete

14

SITE HANDBOOK - Patch Repair and Spray Applications

5. Bonding Primer

Apply bonding primer (if specifi ed)

Wet the substrate

Wipe away excess water

Application Technique

For small patches brush fi rmly onto surface

For large areas spray on with hopper gun

Point gun at different angles on the surface to ensure even application behind the bars

small area: with sponge

large area: with air pressure

Page 15: Site Handbook - Repair to Concrete

15

6a Repair Application by hand

Surface Preparation

(if bonding primer not applied)

Wet the substrate

Wipe away excess water

Application Technique

Press fi rmly the repair mortar into the repair area using a trowel

Profi le surface and fi nish with trowel

Finish surface with wooden or PVC trowel for best results.Do not spray additional waterover the surface!

Apply 2nd layer when 1st layer is dry if application depth exceeds product’s max. layer thickness

small area: with sponge

large area: with air pressure

Page 16: Site Handbook - Repair to Concrete

16

Wipe away excess water

small area: with sponge

large area: with air pressure

SITE HANDBOOK - Patch Repair and Spray Applications

6b Wet Spray Application

Surface Preparation

Wet the substrate

Finish with PVC or wooden trowel

Make sure voids are fi lled behind bars.Point spray nozzle at different angles to the surface.If 2nd layer is required surface shall not be to smooth.

Application Technique

Point nozzle 200 mm to 500 mm from surface

Page 17: Site Handbook - Repair to Concrete

17

0,25 - 4 hrs.

7. Smoothing Mortar

Surface Preparation

Wet and clean surface with water (180 bar)

Smoothing or Levelling Mortar

Apply vertically using toothed trowel Apply with trowel approx. 45° to surface

When the 1st layer is hard, apply 2nd layer

Smooth surface using wooden trowel afterproduct has set

Use different size toothed trowel for required layer thickness

Page 18: Site Handbook - Repair to Concrete

18

SITE HANDBOOK - Patch Repair and Spray Applications

8. After Application

Curing Protection

Protect application from: Frost Wind Rain Sun

Curing Methods

Plastic sheeting Jute and water Other membranes

If no subsequent coating is to be applied on surface an approved curing agent could be used

Page 19: Site Handbook - Repair to Concrete

19

Enviroment

Dispose of waste responsibly

Separate recycling materials

Accidents

Seek immediate medical attention in the event of an injury

Additional Information

Cleaning Tools

Clean with water

Hardened material can only be removed mechanically

Page 20: Site Handbook - Repair to Concrete

20

SITE HANDBOOK - Patch Repair and Spray Applications

Mixing

One component System

(e.g. Sika® MonoTop®)

Add powder to water and mix for 3 minutes

Two component System

(e.g. Sika Top®)

Shake component A thoroughly and pour into clean container

Add in powder component C and mix for 3 minutes

Three component System

(e.g. Sika® EpoCem®)

Shake component A + B separately Mix components A + B together

Add (A + B) to powder component Cand mix for 3 minutes

Do not add extra water.

Adjust consistency to suit conditions using powder-component C.Refer to Product Data Sheet for more information.

Page 21: Site Handbook - Repair to Concrete

21

Sika Repair Systems

Prod

uct

Type

Appl

icat

ion

Desc

riptio

n

Sika

® M

onoT

op®-4

12 N

Repa

ir M

orta

rHa

ndw

et s

pray

R4 C

C No

rmal

Set

ting

Sika

® M

onoT

op®-4

12 S

R4 C

C Sl

ow S

ettin

g

Sika

® M

onoT

op®-4

12 N

FGRe

pair

Mor

tar

Hand

wet

spr

ayR4

PCC

Nor

mal

Set

ting

Sika

® M

onoT

op®-4

12 S

FGR4

PCC

Slo

w S

ettin

g

Sika

® M

onoT

op®-3

52 N

Repa

ir M

orta

rHa

ndw

et s

pray

R3 C

C No

rmal

Set

ting

Sika

® M

onoT

op®-3

52 S

R3 P

CC S

low

Set

ting

Sika

® M

onoT

op®-3

52 N

FGRe

pair

Mor

tar

Hand

wet

spr

ayR3

CC

Norm

al S

ettin

g

Sika

® M

onoT

op®-3

52 S

FGR3

PCC

Slo

w S

ettin

g

Sika

® M

onoT

op®-2

11 R

FGRe

pair

Mor

tar

Hand

R2 P

CC fa

st s

ettin

gSi

ka® M

onoT

op®-2

11 F

G

Sika

® M

onoT

op®-9

10 N

Bond

ing

prim

er a

nd

rein

forc

emen

t cor

rosi

on

prot

ectio

nHa

ndw

et s

pray

Norm

al u

se

Sika

® A

rmat

ec®-1

10 E

poCe

Bond

ing

prim

er a

nd

rein

forc

emen

t cor

rosi

on

prot

ectio

nHa

ndw

et s

pray

Dem

andi

ng u

se

Sika

® M

onoT

op®-7

23 N

Smoo

thin

g M

orta

rHa

ndw

et s

pray

R3 P

CC c

emen

titio

us

mor

tar

Sika

gard

®-7

20 E

poCe

Pore

Sea

ler

Hand

wet

spr

ayR4

Epo

xy c

emen

t

Page 22: Site Handbook - Repair to Concrete

22

SITE HANDBOOK - Patch Repair and Spray Applications

Hints and Advice -

Overhead Application

Apply mortar tightly behind reinforcement until bars are covered.

Press fi rmly to ensure pores in concrete substrate are fi lled.

From same end apply second layer in same direction as fi rst.

Repeat layers until void is fi lled

Smooth surface using wooden trowel

Page 23: Site Handbook - Repair to Concrete

23

Hin

ts a

nd

Ad

vice -

Wet

Sp

ray

Eq

uip

men

t

1

2

3

4

5

1 2

Hop

per c

onte

nt: 6

ltr

Wei

ght (

empt

y): 1

.5 k

g A

ir re

quire

men

t: 22

0 l/m

in R

equi

red

air p

ress

ure:

2 to

3 b

ar A

djus

tabl

e ap

ertu

re

Pro

cess

: Wet

spr

ay a

pplic

atio

n C

onve

ying

vol

ume:

0.4

– 2

.4 m

3 /h C

onve

ying

dis

tanc

e:

horiz

onta

l up

to 7

0 m

Pum

p pr

essu

re: m

ax. 2

5 ba

r D

imen

sion

s: L

×W

×H

(mm

): 22

90×

680×

1150

Mot

or: 4

00 V

/50

Hz C

apac

ity o

f the

ves

sel:

100

ltr W

eigh

t: 40

0 kg

(ink

l. M

ixer

)

Hop

per

Gu

n

Mort

ar

Pu

mp

for

“W

et”

Sp

ray

Ap

plicati

on

, e.g

. Pu

tzm

eis

ter

S5 E

VTM

wit

h M

ixer

TM

100

1 N

ozzl

e fo

r mor

tar ø

1 to

8 m

m2

Noz

zle

for fi

nis

hing

coa

t ø 0

.5 to

1.0

mm

1 Gu

n w

ith a

djus

tabl

e ap

ertu

re2

Hopp

er3

Quic

k di

scon

nect

4 Ho

se ø

13

mm

, 10

m lo

ng5

45°

Adap

tor f

or a

pplic

atio

n ov

er h

ead

(In

depe

nden

t air

com

pres

sor

is

nee

ded)

Page 24: Site Handbook - Repair to Concrete

The information contained herein and any other advice are given in good faith based on Sika’s current knowledge and experience of the products when properly stored, handled and applied under normal conditions in accordance with Sika’s recommendations. The information only applies to the application(s) and product(s) expressly referred to herein and is based on laboratory tests which do not replace practical tests. 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 products. The information contained herein does not relieve the user of the products from testing them for the intended application and purpose. All orders are accepted subject to our current terms of sale and delivery. Users must always refer to the most recent issue of the local Product Data Sheet for the product concerned, copies of which will be supplied on request.

Sika Services AGBusiness Unit ContractorsSpeckstrasse 22CH-8330 PfäffikonSwitzerlandPhone +41 58 436 23 80Fax +41 58 436 23 77www.sika.com ©

Sik

a Se

rvice

s AG

/ BU

Cont

ract

ors

/ Con

cret

e Re

pair

/ Site

Han

dBoo

k Re

pair

of C

oncr

ete

Stru

ctur

es/ C

MS

/ DT

/ 10.

2009

s i n c e1 9 1 0

Innovat ion & Consistency