Upload
phamkien
View
221
Download
2
Embed Size (px)
Citation preview
Presentation of
Selection, Application and Pricing of Concrete Repair and Tile Bonding System
to
Hong Kong Institute of Surveyors
on
28th April 2015
Concrete Repair – Crack Repair
Method Description
1 Simply seal the crack with waterproofing coatings
2 Fill the crack by brushing dry cement and moistening
3 Seal the crack with cement grout
4 Cut V-groove and fill up with concrete repair mortar
5 Fill the crack with polymer resin by gravity or injection
6 Inject epoxy resin
7 Inject epoxy resin and seal the crack with waterproof coatings
Concrete Repair – Crack RepairElement Crack Width Through/Non-through Crack Repair Method
Underground ≤ 0.3mm Through and Non-through 1
Underground > 0.3mm Through and Non-through 7
Slabs ≤ 0.3mm Non-through 2
Slabs ≤ 0.3mm Through 5
Slabs (Soffit Only) ≤ 0.3mm Non-through 3
Slabs > 0.3mm Non-through 3
Slabs > 0.3mm Through 5 or 6
Beams ≤ 0.3mm Non-through 3
Beams ≤ 0.3mm Through 5
Beams > 0.3mm Non-through 4
Beams > 0.3mm Through 5 or 6
Wall/Columns ≤ 0.3mm Non-through 3
Wall/Columns ≤ 0.3mm Through 5
Wall/Columns > 0.3mm Non-through 4
Wall/Columns > 0.3mm Through 5 or 6
Concrete Repair – Crack Injection Method
• Clearly identify the full length of crack• Surface seal the crack with epoxy paste• Drill holes along the crack at interval equivalent to the
thickness of concrete• Insert injection packers into the holes• Starting at the lowest position (for vertical wall) and keep
injecting resin until some resin being emitted from the next injection packer
• Move to the next injection packer and repeat the same step until the full length of crack is injected
Concrete Repair – Crack Injection Materials
For Water Seepage Repair – Polyurethane Resin
• Single Component – Flexible Foam• Two Component – Rigid Foam, Fast Water Cut-off
For Structural Repair – Epoxy Resin
• Two Component – Rigid Plastic• Two Component – Flexible Plastic
Concrete Repair – Crack Injection Pricing
Chemical Polyurethane Polyurethane Epoxy Epoxy
No. of Component Two One Two Two
Form after dry Rigid Foam Flexible Foam Rigid Plastic Flexible Plastic
Leaking Cracks Suitable Suitable Not Suitable Not Suitable
Materials Cost/m(1mm X 150mm) $ 20 $ 25 $ 20 $ 25
Labour and Materials Cost/m $ 500 $ 500 $ 500 $ 500
Concrete Repair – Specification for Repair Mortars
Test Technical Performance Class 25 Class 40TM 1 Compressive Strength at 28 days 20-40 MPa 30-60 MPa
TM 2 Minimum Tensile Strength at 7 days 1.5 MPa 2.0 MPa
TM 3 Elastic Modulus at 28 days 9-15 GPa 15-25 GPa
TM 4 Minimum Bond Strength at 7 days 1.5 MPa 2.0 MPa
TM 5 Cracking in Coutinho Ring at 28 days Nil Nil
TM 6 Minimum Figg Air Permeability 150 seconds 200 seconds
Site Minimum Pull-off Strength at 7 days 0.375 MPa 0.5 MPa
HD 002 Polymer Content by Mass of Cement > 5% > 5%
HD 002 Aggregate Cement Ratio (A/C Ratio) 2/1 to 4.5/1 2/1 to 4.5/1
Concrete Repair – “PCCS – RM” (Product ConformityCertification Scheme for Repair Mortars)
Hong Kong Accreditation Service (HKAS)
Hong Kong Concrete Institute (HKCI)
Hong Kong Certification Body Accreditation Scheme (HKCAS)
Hong Kong Laboratory Accreditation Scheme (HOKLAS)
Concrete Repair – Quality Control from HKHA Valid Product Certificate for “PCCS-RM”
Local Test ( 1 set per 100m3 or 6 months )• Compressive Strength• Bond Strength• Coutinho Ring• Polymer Content
Full Test ( 1 set per 500m3 or 18 months ) • Compressive Strength• Bond Strength• Tensile Strength• Elastic Modulus• Coutinho Ring• Air Permeability• Polymer Content
Concrete Repair – Quality Control from HKHA
Pull-off Test – Test for Every 25 m2 Patch Repairs
Inspection Core Test – Test for Every 25 m2 Patch Repairs
Test by Void Detector – Test for All Patch Repairs
Visual Inspection – Test for All Patch Repairs
Concrete Repair – Patch Repair Method
• Saw-cut the perimeter of the repair area to a minimum depth 6 mm to avoid feather edges
• Remove all defective concrete until sound substrates are exposed• Concrete around exposed reinforcement steel should be hacked back
by minimum 13 mm• Remove any rust appeared on the reinforcement steel• Immediately apply corrosion protection primer to the reinforcement
steel and allow to dry• Dampen concrete substrates with water and apply surface bond coat to
the concrete surface and reinforcement steel• Apply the repair mortar while the surface bond coat is still tacky• Build-up the thickness by multi-layers if required. Intermediate layers
should be keyed and primed before the next layer is applied• Cure the surface properly with curing compound
Concrete Repair – Patch Repair Pricing
Class 25 Pre-bagged Class 40 Pre-bagged
Max. thickness per layer/mm 50 40
Elastic Modulus/GPa 9-15 15-25
Materials Cost/m3 $10,000 $11,500
Materials Cost/m2 (25mm thick) $250 $288
Labour and Materials Cost/m2 (25mm thick) $1,200 $1,400
Concrete Repair – Case Studies
Polyurethane Injection to Ceiling of Carpark
Water seepage on ceiling.Inject flexible PU resin
Use hand injection pump to pump resin into the crack through the non-return packers
Cured PU foam cut-off water
Concrete Repair – Case Studies
Epoxy Injection to Wall
Remove tiles to expose the crack. Drill holes to insert injection packers
Mix the two components of epoxy resin
Inject mixed epoxy resin to crack through non-return injection packers
Concrete Repair – Case Studies
Patch Repair to Ceilings
Spalled concrete on the ceiling of a open corridor.
Patch repair the concrete with Class 40 repair mortar
Concrete Repair – Case Studies
Patch Repair to External Walls
Spalled concrete due to water seepage and external weathering.
Repair concrete with Class 25 repair mortar and work in the gondola
Concrete Repair – Case Studies
Semi Recasting to Floor Slab
Structural strengthening works in a cantilever corridor.
Additional reinforcement bar installed
Concrete Repair – Case Studies
Semi Recasting on Floor Slab
Mix and lay high performance concrete Finish off the new concrete surfaces
Concrete Repair – Case Studies
Concrete Repair on Driveway
Spalled concrete due to wear & tear Repair the concrete with fast set heavy duty repair materials
Concrete Repair – Case Studies
Concrete Repair on Driveway
Form ribs before initial set of materials Finish the repairs & driveway re-open for use after 2 hours
Tile Bonding System - Topics
European Standard for Tile Adhesive
PCCS-TA and HKHA Specification
Selection of Tile Adhesive
Application Method
Case Studies
Tile Bonding System – European Standard for Tile Adhesive
EN 12004 – Cementitous Adhesive (C)
EN 12004 – Dispersion Adhesive (D)
EN 12004 – Reaction Resin Adhesive (R)
Tile Bonding System – European Standard for Tile AdhesiveCementitous Adhesive (C)
Characteristic C1 (Normal) C2 (Improved)
Initial Tensile Adhesion Strength ≥ 0.5 MPa ≥ 1 MPa
Tensile Adhesion Strength After Water Immersion ≥ 0.5 MPa ≥ 1 MPa
Tensile Adhesion Strength After Heat Ageing ≥ 0.5 MPa ≥ 1 MPa
Tensile Adhesion Strength After Freeze Thaw Cycles ≥ 0.5 MPa ≥ 1 MPa
Open Time : Tensile Adhesion Strength ≥ 0.5 MPa at 20 Mins. ≥ 0.5 MPa at 20 Mins.
Optional Characteristic
Slip (T) ≤ 0.5 mm ≤ 0.5 mm
Extended Open Time : Tensile Adhesion Strength (E) ≥ 0.5 MPa at 30 Mins. ≥ 0.5 MPa at 30 Mins.
Deformable Adhesive (S1) ≥ 2.5 mm & < 5 mm ≥ 2.5 mm & < 5 mm
Highly Deformable Adhesive (S2) ≥ 5 mm ≥ 5 mm
Fast Set Tile Adhesive (F)
Early Tensile Adhesion Strength ≥ 0.5 MPa at 6 hrs ≥ 0.5 MPa at 6 hrs
Open Time : Tensile Adhesion Strength ≥ 0.5 MPa at 10 Mins. ≥ 0.5 MPa at 10 Mins.
Tile Bonding System – European Standard for Tile Adhesive
Dispersion Adhesive (D)
Characteristic D1
Initial Shear Adhesion Strength ≥ 1 MPa
Shear Adhesion Strength After Heat Ageing ≥ 1 MPa
Open Time : Tensile Adhesion Strength ≥ 0.5 MPa at 20 Mins.
Optional Characteristic
Slip (T) ≤ 0.5 mm
Extended Open Time : Tensile Adhesion Strength (E) ≥ 0.5 MPa at 30 Mins.
Improved Characteristic (D2)
Shear Adhesion Strength After Water Immersion ≥ 0.5 MPa
Shear Adhesion at Elevated Temperature ≥ 1 MPa
Tile Bonding System – European Standard for Tile Adhesive
Reaction Resin Adhesive (R)
Characteristic R1
Initial Shear Adhesion Strength ≥ 2 MPa
Shear Adhesion Strength After Water Immersion ≥ 2 MPa
Open Time : Tensile Adhesion Strength ≥ 0.5 MPa at 20 Mins.
Optional Characteristic
Slip (T) ≤ 0.5 mm
Improved Characteristic (R2)
Shear Adhesion Strength After Thermal Shock ≥ 2 MPa
Tile Bonding System – European Standard for Tile Adhesive
Condition the sample in -15 degree C Tensile Adhesion Strength Test
Tile Bonding System – “PCCS – TA” Product ConformityCertification Scheme for Tile Adhesives)
Test method Initial type test Production control frequency
Audit testingCharacteristic
(Surveillance) (Recertification)Open time EN 1346 Y A D YSlip EN 1308 (y) A D (y)Normal setting adhesives
EN 1348 Y A D YInitial tensile adhesion strength (cementitious adhesives)
Fast setting adhesives- Early tensile adhesion strength (fast setting cementitious adhesives) EN 1348 (y) A D _
Tensile adhesion strength after conditioning (cementitious adhesives) EN 1348 Y B D Y
Transverse deformation EN 12002 (y) B D _
Chemical resistance EN 12808-1 (y) B D _
Wetting capability EN 1347 (y) B D _
Reaction to fire EN 13501-1 (y) C _ _
Initial test : Y means yes. (y) means yes if relevant for the product
A means 1 test for every 1000 tonnes, with a minimum of 1 time per year and a maximum of 1 time per month
B means 1 test per year for production below 2500 tonnes/year and 2 tests per year for production over 2500 tonne/year
C means no direct testing. However, the composition shall be checked at regular intervals
D means the tile adhesive property, if relevant for the product, to be selected by the Surveillance Assessment team for audit testing.
A minimum of one property shall be selected for each audit testing.
Tile Bonding System – Quality Control from HKHA
Valid Product Certificate for “PCCS-TA”
Site Mock-up & Pull-off Test Against Panel Wall at 28 Days ≥ 0.3 N/mm2
One Set of Test for Every 1500 Bags Tile Adhesive • Initial Tensile Adhesion Strength• Tensile Adhesion Strength After Water Immersion• Tensile Adhesion Strength After Heat Ageing• Tensile Adhesion Strength After Freeze-Thaw Cycle • Open Time – Tensile Adhesion Strength
Two Set of Pull-off Test for Every 10 Typical Floors• ≥ 0.3 N/mm2 for Panel Wall• ≥ 0.5 N/mm2 for Concrete Wall• ≥ 0.3 N/mm2 for Glass Mosaic Tiles
Tile Bonding System – Selection of Tile Adhesive
Type of Tile Size of Tile Location Substrate Service Condition Suggested Tile Adhesive
Ceramic Tile < 300 X 300mm Internal Concrete/Render Normal C 1
Ceramic Tile > 300 X 300mm External Wall Concrete/Render Normal Mechanical Fixing
Ceramic Tile 45 X 95mm External Wall Concrete/Render Normal C 1 T E
Homogenous Tile Internal/External Concrete/Render Normal C 2
Reconstitute Stone Internal Concrete/Render Normal C 2
Ceramic Tile > 300 X 300mm Internal Wall Cement Board Normal C 2 T S 1 or 2
Ceramic Tile < 300 X 300mm External Concrete/Render Swimming Pool C 2 T E
Ceramic Tile < 300 X 300mm Internal Concrete/Render Food Processing R 1
Tile Bonding System – Application Method
Tile Adhesive
Tile Grout
Render
Bond Coat
Tile
Spatterdash
Concrete Wall
Tile Bonding System – Application Method
Tile Adhesive
Tile GroutPrecast Façade Panelor
Drywall
Tile
Tile Bonding System – Application Method
Spatterdash – 1 : 3 : 5 : 10 = Bonding Agent : Water : Cement : Sandby volume
Tile Bonding System – Application Method
Bond Coat – 1 part of Bonding Agent mix with1 part of OPC by volume
Tile Bonding System – Application Method
Bond Coat – 1 part of Bonding Agent mix with1 part of OPC by volume
Tile Bonding System – Pricing
Products Materials Cost/m2 Labour Cost/m2 Labour & Materials Cost/m2
Spatterdash $1 $5 $6
Bond Coat $6 $10 $16
Render (15mm thick) $10 to $90 $80 $90 to $170
Tile Adhesive $12 to $40 $180 $192 to $220
Tile Grout $2 $20 $22
Total $31 to $139 $295 $326 to $434
Tile Bonding System – Case Studies
Re-tiling to De-bonded Tiles
Tiles and render de-bonded from the walls Remove bedding and render from substrates
Tile Bonding System – Case Studies
Re-tiling to De-bonded Tiles
Apply bond coat and render Fix tiles with C2 grade tile adhesive
Tile Bonding System – Case Studies
Re-tiling and Grouting to De-bonded Tiles
Tiles de-bonded due to “Open” joints Efflorescence – Lime leach out from “Open” joints
Tile Bonding System – Case Studies
Re-tiling and Grouting to De-bonded Tiles
Hack off bedding mortar Grind the substrates to match existing level
Tile Bonding System – Case Studies
Re-tiling and Grouting to De-bonded Tiles
Fix tiles with tile adhesive Grout the tile joints with colour grout mortar