Site Hand Book

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

SITE HANDBOOK - Patch Repair and Spray Applications

Sikagard®- protective

coating layer

Sika Top ® pore sealer

and smoothing mortar

Sika Top® - repair and profiling

mortar

SikaTop® Armatec®-

reinforcement corrosion protection

Contents Page

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

Concrete Repair Procedure1. 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 ApplicationCuring Protection page 18Curing Methods page 18Cleaning Tools page 19Enviroment / Accidents page 19

Mixing page 20

Sika Repair Systems page 21

Hints and AdviceOver Head Application page 22Wet Spray Equipment page 23

4

Health and Safety

Work Safely!

SITE HANDBOOK - Patch Repair and Spray Applications

5

Useful Documents

Method Statementn Sika® Top Systemsn Detailed step by step guide to concrete

repair

Product Data Sheetn Product usesn Substrate qualityn Substrate preparationn Mixing Ration Application conditions & toolsn Pot lifen Curing treatment

Material Safety Data Sheetn Hazardsn First Aidn Emergencyn Ecology

6

SITE HANDBOOK - Patch Repair and Spray Applications

Bag LayoutExample: Sika® Top-122 Main Description

Storage Details

Safety LabelApplication Information

Product Characteristics

7

Climate Conditions

StorageProduct storage:

n Dry, cool conditionsn Undamaged original packaging

ApplicationProtect area from:

n Direct sunlightn Windn Rainn Frost

TemperatureCheck acceptable limits:

n Ambient temperaturen Substrate temperature

12 months

8

SITE HANDBOOK - Patch Repair and Spray Applications

Equipment

n Mixing tools

n Mixing bowel

n Application tools

n Sponge

n Brushes

for machine applications see page 23

Hand tools

9

Do and Do Not!

DOUse only clean potable water

Make sure tools are clean and well maintained

Remove only concrete as instructed by supervising officer or qualified engineer

Consult product data sheet before starting

DO NOTDo 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

10

SITE HANDBOOK - Patch Repair and Spray Applications

1. Substrate Preparation

Surface Preparationn Mark defective concrete

Concrete Removaln Using high pressure water jet, 1100 bar

(large area)

or

n With hammer drill (medium area)

or

n Hammer and chisel (small patch repairs)

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

11

2. Substrate Preparation

Extent of Concrete Removaln Remove concrete minimum 15 mm behind

main bars

Correct Substrate Preparationn Roughen surface (2 mm minimum)

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

n Substrate shall be sound with no loose material

Inform supervisor immediatly if there are any cracks in the substrate

15 mm Minimum

12

SITE HANDBOOK - Patch Repair and Spray Applications

3. Preparing Reinforcement

Cleaning ReinforcementRemove all:

n Tie wires n Rustn Mortar / Concrete n Other loose material

Removal Techniquesn Use steel wire brush

or

n Abrasive blast cleaning techniques

or

n High pressure water jetting (1100 bar minimum)

Inform supervisor immediatly of any badly damaged reinforcement

13

4. Reinforcement Corrosion Protection

Application of Corrosion Protection (if specified)n Apply two 1 mm thick layers

(total 2 mm minimum)

Application Techniquesn Hopper spray for large applications

or

n 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.

n Brush for small applications

Use two brushes simultaneously to ensure full application behind bars

14

SITE HANDBOOK - Patch Repair and Spray Applications

5. Bonding Primer

Apply bonding primer (if specified)n Wet the substrate

n Wipe away excess water

Application Techniquen For small patches brush firmly onto

surface

n 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

15

6a Repair Application by hand

Surface Preparation (if bonding primer not applied)n Wet the substrate

n Wipe away excess water

Application Techniquen Press firmly the repair mortar into the

repair area using a trowel

n Profile surface and finish with trowel

Finish surface with wooden or PVC trowel for best results. Do not spray additional water over 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

16

n 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 Preparationn Wet the substrate

n Finish with PVC or wooden trowel

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

Application Techniquen Point nozzle 200 mm to 500 mm from

surface

17

0,25 - 4 hrs.

7. Smoothing Mortar

Surface Preparationn Wet and clean surface with water (180 bar)

Smoothing or Levelling Mortarn Apply vertically using toothed troweln Apply with trowel approx. 45° to surface

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

n Smooth surface using wooden trowel after product has set

Use different size toothed trowel for required layer thickness

18

SITE HANDBOOK - Patch Repair and Spray Applications

8. After Application

Curing ProtectionProtect application from:n Frostn Windn Rainn Sun

Curing Methodsn Plastic sheetingn Jute and watern Other membranes

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

19

Enviromentn Dispose of waste responsibly

n Separate recycling materials

Accidentsn Seek immediate medical attention in the

event of an injury

Additional Information

Cleaning Toolsn Clean with water

Hardened material can only be removed mechanically

20

SITE HANDBOOK - Patch Repair and Spray Applications

MixingOne component System (e.g. Sika® MonoTop®)n Add powder to water and mix for 3 minutes

Two component System (e.g. Sika Top®)n Shake component A thoroughly and pour

into clean containern Add in powder component C and mix for 3

minutes

Three component System (e.g. Sika® EpoCem®)n Shake component A + B separatelyn Mix components A + B together

n Add (A + B) to powder component C and 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.

21

Sika Repair Systems

22

SITE HANDBOOK - Patch Repair and Spray Applications

Hints and Advice - Overhead Application

n Apply mortar tightly behind reinforcement until bars are covered.

n Press firmly to ensure pores in concrete substrate are filled.

n From same end apply second layer in same direction as first.

n Repeat layers until void is filled

n Smooth surface using wooden trowel

23

Hint

s an

d Ad

vice

- W

et S

pray

Equ

ipm

ent

1

2

3

4

5

1 2

n H

oppe

r con

tent

: 6 lt

rn

Wei

ght (

empt

y): 1

.5 k

gn

Air

requ

irem

ent:

220

l/min

n R

equi

red

air p

ress

ure:

2 to

3 b

arn

Adj

usta

ble

aper

ture

n P

roce

ss: W

et s

pray

app

licat

ion

n C

onve

ying

vol

ume:

0.4

– 2

.4 m

3 /hn

Con

veyi

ng d

ista

nce:

ho

rizon

tal u

p to

70

mn

Pum

p pr

essu

re: m

ax. 2

5 ba

rn

Dim

ensi

ons:

L×

W×

H (m

m):

22

90×

680×

1150

n M

otor

: 400

V/5

0 Hz

n C

apac

ity o

f the

ves

sel:

100

ltrn

Wei

ght:

400

kg (i

nkl.

Mix

er)

Hopp

er G

un

Mor

tar P

ump

for “

Wet

” Sp

ray

Appl

icat

ion,

e.g

. Put

zmei

ster

S5

EVTM

with

Mix

er T

M 1

00

1 N

ozzl

e fo

r mor

tar ø

1 to

8 m

m2

Noz

zle

for fi

nish

ing

coat

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)

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.

Obour Factory:1st industrial Zone (A)Elobour City, Egypt.Tel : +202-46100714 (8 lines)Fax : +202-46100759Mob : + 2012-3908822 / 55

Alex Office:4 Mohamed Masoud st,Behind Olmby ClubAlexandria, Egypt.Tel : +203-4244601Fax : +203-4244604Mob: +2012-3909922

www.sika.com.eg