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Concrete repair hand book will describe the method and sequence to repair the concrete structure after taking-off the shutter
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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® MonoTop®- pore sealer
and smoothing mortar
Sika® MonoTop® -repair and profi ling
mortar
Sika® MonoTop®/SikaTop® Armatec®-
reinforcementcorrosion protection
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
4
Health and Safety
Work Safely!
SITE HANDBOOK - Patch Repair and Spray Applications
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
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
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
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
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
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.
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
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
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
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
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
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
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
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
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
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.
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
m®
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
m®
Pore
Sea
ler
Hand
wet
spr
ayR4
Epo
xy c
emen
t
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
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)
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