Construction. Technology and Concepts Repair and Protection of Reinforced Concrete

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1 Construction Technology and Concepts Repair and Protection of Reinforced Concrete

2 Corrosion Management in Reinforced Concrete s The key stages in the process are:- Assessment Survey of the Condition of the The successful repair and protection of concrete structures which have been damaged or which have deteriorated requires professional assessment, then design, supervision and execution of a technically correct strategy - according to the forthcoming European Standard being developed by CEN/TC 104. This brochure is intended to give guidance on the correct procedure and on the appropriate products and systems for the selected strategy. The key stages in the process are:- Diagnosis of the Cause of Deterioration Assessment Survey of the Condition of the Diagnosis of the Cause of Deterioration Determine the Repair and Protection Objectives Select the Appropriate Repair and Protection Strategy Definition of the future Maintenance Requirements and Procedures The assessment of the condition of a damaged or deteriorated reinforced concrete structure should only be made by qualified and experienced people. The process of assessment will always include the following aspects:- The current condition of the structure including visible, non visible and potential defects. Review of the past, current and future exposure. Following review of the original design, construction methods and programme, and the assessment survey Identify the root causes of damage:- Identify mechanical, chemical and physical damage to the concrete. Identify concrete damage due to reinforcement corrosion. 2

3 Determine the Repair and Protection Objectives Select the appropriate Repair and Protection Strategy Definition of the future Maintenance Requirements and Procedures NO NOISE LIMITED HOURS With most damaged or deteriorated structures the Owner has a number of options which will effectively decide the appropriate repair and protection strategy to meet the future requirements of the structure. The options include:- Do nothing. Downgrade the structure or its capacity. Prevent or reduce further damage without repair. Improve, refurbish or strengthen all or part of the structure. Demolition. It is necessary to clarify the Owner s requirements and instructions in relation to:- The required durability, requirements and performance. Intended design life. How loads will be carried before, during and after the repair. The possibility for future repair works including access and maintenance. Costs of the alternative solutions. The consequences and likelihood of structural failure. The consequences and likelihood of partial failure (falling concrete, water ingress etc). And Environmentally:- The need for protection from sun, rain, frost, wind, salt and/or other pollutants during the works. The environmental impact or restrictions on the works in progress particularly the noise and the time taken to carry out the work. What is the mode and result of the selected materials deterioration ie. chalking, embrittlement, discolouration, delamination? What surface preparation and access systems will eventually be required and when? Who is responsible and how will it be financed? The likely environmental/ aesthetic impact of the improved/ reduced appearance of alternative solutions. 3

4 Assessment Survey and Diagnosis of Damage CONCRETE DAMAGE DUE TO REINFORCEMENT CORROSION CARBONATION STRAY/ ELECTRICAL CURRENT CORROSIVE CONTAMINANTS eg CHLORIDES Carbon Dioxide (CO 2 ) in the atmosphere reacting withcalcium Hydroxide in the concrete pore liquid. CO 2 + Ca(OH) 2 CaCO 3 + H 2 O Soluble and ph Almost insoluble and ph 9 Steel Passivated Steel Unprotected Metals of different electropotential are connected to each other in the concrete and corrosion occurs. Also corrosion can be due to stray electrical currents fromtransmission networks. Chlorides accelerate the corrosion process however originally caused. At above % they break down the passive oxide. Chlorides can be from marine exposure or deicing salts. Their use to accelerate concrete setting at low temperatures is now mostly banned in reinforced concrete. Reinforcement corrosion following reduction of the passivating concrete alkalinity by carbonation. Reinforcement corrosion showing as rust staining from cracks after galvanised steel railings were fixed into the parapet. The damaging effects of steel corrosion accelerated by chloride ingress from deicing salts. 4

5 CONCRETE, DAMAGE AND DEFECTS MECHANICAL CHEMICAL PHYSICAL Impact, Vibration and Explosion Abrasion and Wear Overloading Alkali Aggregate Reaction Chemical Exposure Bacterial Action Thermal Movement Freeze Thaw Action Efflorescence/Leaching Salt Crystal Expansion Erosion Cracking caused by incorrect handling or fixing of precast panels. Chemical attack (and subsequent reinforcement corrosion) on a factory roof. Freeze thaw effect on a parking structure. 5

6 Determine the Objectives and Select the Appropriate Strategy Having fully considered their options owners normally face having to Improve, refurbish or strengthen all or part of the :- For structural strengthening requirements refer to Sika Technical Services for full details of the innovative Sika Carbodur structural strengthening system. For concrete structures there are now alternative solutions proposed for improvement and refurbishment that are considered as corrosion management, these include:- Provide Additional Concrete Cover Advantages: The old traditional approach. Disadvantages: Very expensive if correctly applied over all of the concrete surface. Has no effect on further aggressive influence ingress. Provides no protection against latent damages. Very poor appearance. Apply Cathodic Protection Advantages: The only way to completely stop steel corrosion. Permanent solution (with full repairs and monitoring). Disadvantages: Ongoing cost to maintain. Many structures not suitable (access / non continuous reinforcement / prestressing steel etc). Realkalisation or Desalination Overcladding and Insulation Conventional Repair and Protection Advantages: Based on reversing the principles of Cathodic protection. Limited concrete removal. No ongoing maintenance (except protective coatings). Disadvantages: Very high installation cost. Not all structures are suitable (as Cathodic Protection). Where there is potential for ASR/AAR. Not environment friendly (caustic waste disposal). Advantages: Greatly improves appearance. Provides the additional benefit of insulation. Provides a long term solution. Disadvantages: Very expensive. Can hide latent defects. Extended contract period. Advantages: Meets existing national standards (DIN/BBA/SIS/NF etc). Proven performance (over 20 years with Sika systems). Provides some protection against latent carbonation damages. Cost effective. Disadvantages: No protection against latent chloride damage. Requires extensive concrete break out. Considerable noise, vibration and dust. 6

7 Concrete Repair and Protection with Corrosion Inhibitors System Positioning with Sika FerroGard -903 Corrosion Inhibitor Doubling of the service life Service life Advantages: All the advantages of conventional concrete repair and protection. Greatly reduced concrete break out. Greatly reduced noise vibration and dust. Reduced contract periods. Provides protection against residual chlorides and against incipient anode formation. Extremely cost effective. Most structures suitable No ongoing maintenance (except refresher top coatings after years). Disadvantages: Not proven on prestressed structures (at this time). Development of corrosion Development of corrosion average concrete quality without Sika FerroGard onset of corrosion Sika FerroGard -903 In New Construction. Service life average concrete quality without Sika FerroGard onset of corrosion average concrete quality after application of Sika FerroGard -903 y = rate of corrosion onset of corrosion average concrete quality with Sika FerroGard -903 y = rate of corrosion onset of corrosion Extension of service life y /2 = rate of corrosion y /2 = rate of corrosion New start after Sika FerroGard -903 application Sika FerroGard -903 Protection before Visible Damage. Limit of service life Visible damage years Limit of service life Visible damage years Service life Extension of service life Limit of service life Development of corrosion average concrete quality without Sika FerroGard onset of corrosion y = rate of corrosion average concrete quality with concrete repair and protection including application of Sika FerroGard -903 onset of corrosion Visible damage ny = rate of corrosion years New start after repair Sika FerroGard -903 as part of a Complete Repair and Protection Strategy after Visible Concrete Damage. Sika Ferro Gard Technology 7

8 The Sika Principles of Concrete Repair & Protection Remove damaged concrete and prepare exposed steel Protecting exposed reinforcement Replacing damaged concrete SikaTop -110 Armatec EpoCem SikaTop Repair Mortars Protects reinforcement in a highly alkalinecementitious environment Can be applied on damp surfaces Increases barrier to chlorides and carbonation Steel reinforcement primer and Bonding Bridge Fully complies with load transfer requirements Sika MonoTop One component steel reinforcement primer and bonding bridge Two component prebatched polymer modified repair mortars Lower modulus for increased durability SikaCem Gunite Mortars Ideal for use with Aliva dry sprayed concrete equipment Tested for application to structures subject to vibration under load Tested for use with most cathodic protection systems SikaMonoTop Mortars Select the Appropriate Sika System One component polymer modified repair mortars Suitable for hand and wet spray machine application 8

9 Protecting against the development of latent damage Levelling the profile and filling surface pores Sealing and Coating - preventing the ingress of aggressive influences Sika FerroGard -903 SikaTop Levelling Mortars coarse/fine Hydrophobic Impregnations SikaGard - 700S/-702W Penetrates via liquid and vapour diffusion Film forming inhibitor Mixed inhibitor acting on anodic and cathodic sites Blended inhibitor combining special amino alcohol and inorganic inhibitors Use to fill surface defects to ensure continuous protective coating Produce the desired surface texture Provides uniform substrate SikaGard EpoCem Prevents water and chloride ingress Allows each way water vapour diffusion Anti-Carbonation Coatings SikaGard - 680S/-675W Sika Ferro Gard Technology Unique epoxy cement technology Integral curing ability Also as a protective coating Ideal for levelling and reprofiling after application of Sika FerroGard -903 Sika MonoTop Levelling Mortars coarse/fine One component levelling and reprofiling mortar Effectively halts carbonation Allows each way water vapour diffusion Prevents water and chloride ingress Outstanding colour retention SikaGard - 550W Elastic All the special properties of SikaGard 675W/ 680S plus: Bridges dynamically moving cracks even at low temperatures Water and solvent based primers 9

10 The Worldwide Independent Proof Statements Independent Assessment and Approval Protecting Exposed Reinforcement Replacing Damaged Concrete Product Performance The specific criteria that Sika use to evaluate all of our products and systems for Concrete Repair and Protection, are in accordance with the requirements of the draft European Standard developed by CEN/TC104 where appropriate. They include the following:- System Performance There are functional and performance requirements which must be met by both the individual products and components of a system and by the system together as a whole. Quality Assurance It is necessary for any product or component or system to meet well defined quality assurance and control standards in production. This is why Sika produce to ISO Standards at our factories throughout the world. Certified Quality System ISO 9000/EN Application Criteria In addition to its performance in place, it is also essential to define and test the application properties of products and systems to ensure that they can actually be applied practically on site, and in the differing conditions that will be necessary. For example:- Sika Mortars must be suitable for differing thicknesses and areas/ volumes of repair and applied in as few layers as possible. SikaGard coatings must have adequate thixotropy to obtain the desired wet and dry film thicknesses in the minimum number of coats, and with these they must also achieve adequate opacity. Bond strength to steel and concrete Corrosion protection Permeability to water Permeability to water vapour Permeability to carbon dioxide The Bänziger block for testing repair mortars Bond strength Compressive and flexural strengths Permeability to water Elastic modulus (stiffness) Restrained shrinkage Thermal compatability Sika have developed Product Performance Testing Direct comparison worldwide Application horizontal, vertical and overhead Realistic site dimensions Additional lab testing by coring Crack free performance under different conditions Sika Undertake Extensive Durability Testing In the Laboratory SikaGard products are tested for their performance as anti-carbonation and water vapour diffusable coatings, both when freshly applied, and also after up to 10,000 hours accelerated weathering (equivalent to in excess of 15 years). Only this can give a complete picture of the product s true performance. SikaGard coatings therefore continue to perform long after other coatings have ceased to provide effective protection. 10

11 II Original Construction: Late 1940 s, Concrete Repair and Protection: , Inspection: 1997 The Lämershagen bridge over the A2 motorway near Bielefeld in Germany, was built before the Second World War in the form of a reinforced concrete spandrel-braced arch bridge. It was predominently destroyed in 1945 and rebuilt after the War. Reason for repairs and concept used In the course of time, damage occurred in the form of concrete spalling over corroding reinforcing steel. This forced the Motorway Department to carry out general repairs in This was primarily to prevent falling concrete causing a hazard to motorway traffic. Visual and technological Photo 2 shows the typical concrete condition of surface in 1997 damages - spalling over corroding The reinforced concrete arch bridge main steel reinforcement. retains a largely homogeneous appearance from medium range Substrate preparation by blast cleaning of (photo 1). the concrete surfaces was carried out first. The concrete spalling was then repaired with Icoment Steel Reinforcement Primer plus Icoment Repair Mortar. All the surfaces were then levelled with Icoment 520 Mortar. Finally, the reinforced concrete structure was given a protective coating of Icosit Concrete Cosmetic in grey shade RAL The repair and protection works took place during the winter from October 1981 to January 1982 (photo 3), i.e. at a time of year which should not normally be chosen in this region (for repair work of this kind) due to the largely unfavourable climatic conditions (high humidity and/or very low temperature). 6 Photo 1: Homogeneous appearance of structure from medium range in Photo 2: Concrete spalling over corroding steel reinforcement in Photo 4: 1997 Network of wide-meshed On closer examination, however, surface cracks with brownish edging to the cracks defects are visible which indicate that the from pollution/contaminants. Quality and Durability in Concrete Repair and Protection Photo 3: Carrying out repairs in the winter of 1981/82. concrete protection is not completely intact in some local areas. Photo 4 shows cracks on the structures with a brownish edging. These cracks 4 Icosit Elastic (1994). 41 Protecting Against the Development of Latent Damage Levelling the profile and filling surface pores Sealing and Coating - Preventing the Ingress of Aggressive Elements Penetration ability Film forming ability Corrosion inhibition Chloride displacement Hydroxide displacement (carbonation induced) Bond strength Permeability to carbon dioxide Water permeability and absorption Sealing with Hydrophobic Impregnations Penetration ability Permeability to water Permeability to water vapour Freeze thaw resistance Machine application of repair mortars Spray application for test under live dynamic loading. In the Field QUALITY A N D DURABILITY N CONCRETE REPAIR A N D PROTECTION An International review was undertaken by leading independent Consultants and Testing Institutes. Major projects repaired and protected with Sika Systems between 1977 and 1986 were Inspected and their Durability and Performance Assessed in The Lämershagen bridge A2 motorway, Germany The s In the light of durability problems with concrete bridges built in the sixties, the Danish Road Authorities organised an inspection and investigation of the root causes of the concrete deterioration. The Road Authorities also established a Working Group with the objectives of providing proposals specifically for the refurbishment of some of the concrete structures with multiple cracks, and then also making suggestions to improve their approach to protecting concrete bridges in general. specifically against future moisture On two major highways - the M60 and ingress. This material was chosen due M61 - they selected five bridges with to its excellent properties of water characteristic cracking and concrete resistance, flexibility (crack-bridging) damage. and its water vapour diffusion resistance (breathability). The s The Working Group collected all of the original construction data relating to the bridges and the moisture content of the concrete was measured on site. The cracks in the bridges were identified as being due to a combination of initial plastic shrinkage cracking; together with cracks now occurring due to alkali-silica reaction (ASR). This was previously determined by laboratory analysis as originating from the use of reactive aggregates, see photo 2. The Solution Low temperature dynamic crack bridging testing of coatings Based on this information and analysis, the Working Group selected a high performance coating, Icosit Elastic, for overall protection of the bridges Concrete Bridges in Jutland, Denmark Original Construction: 1960 s, Concrete Repair and Protection: 1983, Inspection and Assessment: 1988, 1991 and 1994 On three of the five selected bridges the edge beams and the parapets were prepared, repaired with Sika mortars and protected in 1983 with Icosit Elastic, see photo 3. The other two of the selected bridges were left unprotected to be monitored as a reference to the efficiency of the treatment. THE SIKA REPAIR AND PROTECTION SYSTEM The concrete surface was prepared by blast cleaning and vacuum cleaning to remove any residual dust. Photo 1: One of the selected bridges on the M60/M61 (1997). Quality and Durability in Concrete Repair and Protection Photo 2: A close up of typical ASR cracking and damages on the bridge parapet (1983). Photo 3: The Bridge parapet after repair and protection with crack-bridging The Old Customs House, Oslo, Norway Original Construction: 1921, Concrete Repair and Protection: 1983, Inspection and Assessment: 1993 and 1997 The The Old Customs House, Oslo was designed in reinforced concrete and when finished in 1921 was one of the largest reinforced concrete structures in the world. It had a long and complicated construction period, the original project was stopped and delayed three times before a satisfactory solution was found for the foundations. This was due to the very heavy weight of the building. Which was eventually piled down to the solid bedrock with more than 1500 driven piles. The Old Customs House had fulfilled its purpose for 60 years, when new techniques and logistics made it obsolete for its original use. It was therefore determined that the historic structure should be refurbished and converted into offices. In 1980 a consortium of the Oslo Inspectorate of Ancient Monuments and Historic Buildings, Espen Eskeland AS (architects) and Tor Andenes (contractor) was established to carry out the conversion and refurbishment works. The Original s The 1980/81 assessment survey of the structure revealed concrete carbonation depths of up to 75mm (3"). In addition to this, the reinforcement cover was also deemed to be insufficient in several places. From 1921 to 1980 no external repairs nor preventative out on the structure. See photos 2 and 3. The Sika Solution Following an extensive and detailed evaluation of all different systems on the market, a complete Sika Repair and Protection System was selected by the consortium. This decision was as a result of the good references (already established by 1980), high technical competence and well documented complete systems for concrete repair and protection. The owner s requirements were effectively stopping the deterioration of the concrete - providing a durable and maintenance free structure for the future. The following procedure and products were used as the system for the concrete repair and protection. Where necessary removing all maintenance had ever been carried damaged concrete. Quality and Durability in Concrete Repair and Protection Photo 1: Overview of the repaired and protected structure in Photo 2: The building facade showing inadequate concrete cover and spalling concrete over corroding reinforcement before repairs in Photo 3: Close up of the typical concrete damages in Sudbury House is a 25 storey tower block of 132 housing units, situated in the centre of Wandsworth in London, it is surrounded by low-rise shopping areas, service yards and car parks. The block was built circa 1972 and designed on the reinforced concrete shear wall and slab principle with a piled, reinforced concrete raft foundation. All construction above ground floor level is of insitu lightweight concrete (Lytag). The s Sudbury House, London, UK Quality and Durability in Concrete Repair and Protection Original Construction: c1972, Concrete Repair and Protection: 1986, Inspection and Assessment: 1997 Areas of spalling concrete first became noticeable as early as 1981, when a small scale localised investigation revealed inadequacies in reinforcement cover and the beginning of reinforcement corrosion problems. Subsequently Wandsworth Borough the apartments and some areas of Council appointed Mitchell McFarlane failing joint sealants, leading to water and Partners to undertake a more ingress. comprehensive survey and to make recommendations for repairs Accurate pre-contract assessment of that should have a 15 year life span to the full extent of concrete degradation the first required maintenance. This was not feasable nor cost effective, report was tabled by the engineers in due to the greatly varied nature of the early carbonation even over small areas from between 5mm and 45mm ( 1 / 4" to Their main area of concern was the 1 3 / 4"). However there was a definite poor overall condition of the exposed tendency for the carbonation to be lightweight concrete, which owing to greater on the lower seven floors of the high levels of carbonation and building. This was eventually attributed inadequate concrete cover to in the main, to the fact that the block embedded steel reinforcement was was observed to dry out quickly after After careful consideration the complete cracked and spalling in many areas. rain on the lower levels, and to remain Icoment system from Sika, was chosen Extensive micro-cracking was also wet for long periods on the higher. This as the system offering the best evident in the surface of the cement residual moisture provided a reference credentials, track record and matrix together with other deficiencies temporary barrier to carbonation in test data. The availability of a physically such as areas of condensation within these areas. compatible lightweight repair mortar, Photo 1: Sudbury House in January Photo 2: Application of Sika Lightweight Repair Mortar during the 1986 contract. Repair Solutions Anti-Carbonation Coatings Bond strength Cross hatch performance Permeability to carbon dioxide Permeability to water vapour U.V. light resistance Alkaline resistance Freeze thaw resistance Fire resistance Cleanability Crack Bridging Anti-Carbonation Coatings As above for Anti-Carbonation Coatings, plus:- Crack bridging ability Statically Dynamically At low temperatures (-20 o C/-20 o F) 11

12 International Case Studies MECHANICAL DAMAGE 24 Storey Housing Block. Reinforced Concrete Frame with Architectural Precast Concrete Cladding Panels Loading and impact damaged architectural precast cladding panels (from time of original construction). Cracks and inadequate cover over steel reinforcement. Removal of loose concrete and preparation of exposed reinforcement. Protect reinforcement with: SikaTop -Armatec 110 EpoCem. Replace damaged concrete with: Sika repair mortar. Provide a uniform, attractive surface finish and protection with: SikaGard -550W. CHEMICAL DAMAGE Factory Roof over Production Facilities Aggressive chemical attack on the concrete. Followed by corrosion of the steel reinforcement in a high temperature, high humidity environment. Removal of damaged concrete and preparation of exposed reinforcement. Protect reinforcement with: SikaTop -Armatec 110 EpoCem. Replace damaged concrete: SikaCem -133 Gunite. Protect the surface from future aggressive chemicals with: SikaGard high performance coating. 12

13 International Case Studies CHEMICAL DAMAGE Precast Reinforced Concrete Framed Office Building Alkali Aggregate Reaction (AAR/ASR) in the concrete leading to typical cracking and expansive gel formation. Requirement Durable holding repairs to bridge moving cracks and to significantly reduce the rate of deterioration thereby extending the service life of the structure. Mechanical preparation. Patch repair and fill surface defects and cracks with SikaDur -31 epoxy mortar. Provide crack bridging protection against future water ingress with SikaGard -550W. PHYSICAL DAMAGE Multi Storey Concrete Parking Freeze thaw damage on concrete columns and soffits from condensation and deicing salts exposure. High pressure water jetting followed by blast cleaning. Repair and reprofiling with: SikaTop mortars. Protection against future water and deicing salt ingress with SikaGard -680S (columns and soffits) and SikaGard -550W (areas subject to cracking - parapets and external facades). Joint sealing with Sikaflex sealants. Steel corrosion protection with Sika Icosit coatings. 13

14 International Case Studies PHYSICAL DAMAGE 150 metre (500 feet) Long Major Road Bridge Concrete damage on the parapet and underside of the bridge due to freeze thaw action accelerated by deicing salts. Surface preparation and defective concrete removal by high pressure water jetting. Parapet: Sika MonoTop -610 as corrosion protection for exposed reinforcement and as a bonding bridge followed by Sika MonoTop repair mortar at 3-6cm thickness. Substructure: SikaTop -Armatec 110 EpoCem as corrosion protection, allowed to cure, and then repair by dry spray application of SikaCem Gunite repair mortar. CARBONATION DAMAGE Multi Storey Residential Housing Block with Concrete Frame and Precast Cladding Panels Inadequate concrete cover to steel reinforcement with extensive cracking and spalling after depth of carbonation reached the steel. Concrete surface preparation by high pressure water jetting. Exposed steel reinforcement prepared by blast cleaning. Steel reinforcement protection and bonding bridge with SikaTop - Armatec 110 EpoCem. Repair and reprofiling with Sika repair mortar. Crack bridging anti carbonation protection on large concrete surfaces with SikaGard -550W coating. Joint sealing with Sikaflex sealants. Galvanized balcony handrail protection with Sika Icosit coatings. 14

15 International Case Studies CARBONATION DAMAGE 26 Storey Lightweight Insitu Concrete, Residential Housing Block Inadequate concrete cover over steel reinforcement with subsequent cracking, staining and spalling. Preparation by blast cleaning. Exposed steel reinforcement protection with SikaTop -Armatec 110 EpoCem. Repair with SikaTop lightweight mortar. Levelling and pore filling with SikaTop levelling mortars. Crack bridging anti carbonation protection and architectural design feature with SikaGard -550W and Sikagard -680S. Joint sealing with Sikaflex sealants. CARBONATION DAMAGE Historic Reinforced Concrete Drinking Water Tower Externally carbonation depth had reached the main steel reinforcement allowing expansive rusting to occur with subsequent concrete cracking and spalling. Surface preparation by blast cleaning. Steel reinforcement protection and bonding bridge with SikaTop -Armatec 110 EpoCem. Repair and levelling with SikaTop mortars. Anti carbonation protection and enhanced appearance with SikaGard -680S. 15

16 International Case Studies ELECTRICAL DAMAGE Concrete Parapet Wall at an Airport Parking Galvanised steel handrail fixed into the steel reinforced concrete edge beam with direct contact between galvanising and reinforcing steel leading to corrosion. Remove and reinstall Sikagard epoxy paint coated steel handrails with SikaGrout -42 (epoxy grout). Patch repair and level damaged concrete with SikaTop repair mortars. Protect against future water ingress with Sikagard -550W. CORROSIVE CONTAMINANTS 1200metre (3/4 mile) Viaduct consisting of 10 bridges over road and rail tracks Extensive chloride accelerated reinforcement corrosion particularly below expansion joints in the deck. Following replacement of bridge deck joints. Removal of all damaged concrete. High pressure water jetting (also to reduce residual chloride levels). Blast cleaning to prepare exposed steel reinforcement. Repair and reprofiling with SikaCem -133 Gunite dry spray mortar. 16

17 International Case Studies CORROSIVE CONTAMINANTS Second Floor Pedestrian Walkway/Bridge at a Hospital Concrete damaged by freeze thaw action and reinforcement corrosion accelerated by chlorides from deicing salts. Surface preparation by high pressure water jetting and exposed steel reinforcement prepared by blast cleaning. Steel reinforcement protection with SikaTop -Armatec 110 EpoCem. Repair with SikaTop mortars. Protection against latent damages by impregnation with Sika FerroGard -903 corrosion inhibitor. Crack bridging surface protection with SikaGard -550W. CORROSIVE CONTAMINANTS New Light Rail Bridge Superstructure Inadequate low concrete cover with future deicing salt exposure on the deck Mechanical damage to architectural panels by a nearby bomb explosion. Bridge Deck Surface and Soffit Impregnation with Sika FerroGard Protective coating to prevent future water and chloride ingress with SikaGard -550W. Architectural Precast Parapet Panels. Replacement with new thin section panels using Sikament superplasticiser and Sika FerroGard -901 corrosion inhibiting admixture. 17

18 Summary Flow Chart of the Sika Process N Visual Survey Staining, Cracking Spalling Y Detailed survey Break out damaged concrete Rusted steel present Y Prepare steel Prepare substrate N Latent damages N Y Root cause analysis Repair & protect now? N Y Clean concrete and mark repairs Apply Sika steel primer and bonding bridge Fill with Sika Repair mortar Protect against latent damages? Y Continue regular monitoring N Additional Complementary Sika Systems Sika Deck Coatings - for crack bridging balcony, podium and deck waterproofing plus elastic wearing surfaces. Sikaflex Joint Sealing - a unique range of one component sealants, specifically designed for compatibility with the Sika repair and protection systems. Sika Icosit Steel Coatings - for the protection of steel and galvanised steel surfaces such as handrails, window frames and support structures. 18

19 Apply Sika Ferrogard 903 Apply Sikagard impregnation N Protect & enhance appearance Y Apply Sika levelling mortar Apply Sikagard 680S/670W coatings N Crackbridging ability needed? Y Apply Sikagard 550W to facades and apply Sikafloor to decks Apply Sika Icosit Steel coatings Apply Sikaflex joint sealents Maintenance Management Strategy Y Set up Corrosion Monitoring System N Final inspection HAND OVER Sika Structural Waterproofing - well proven systems that provide internal waterproofing for both new and refurbishment projects in basements, lift pits, cellars, car parks etc. Sikadur Resin Injection - structural resins for the injection and bonding of cracks and voids to restore integrity. Sika Carbodur Structural Strengthening - externally bonded composite reinforcement system for structural strengthening and to increase load bearing capacity of floors, walls, beams etc. 19

20 Technology and Concepts for the Repair and Protection of Reinforced Concrete Also Available from Sika Sika Technology Series Sika Product Series Sika Concrete Series Sika Ferrogard Technology The information, and, in particular, the recommendations relating to the appli-cation and end-use of Sika products, 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 practice, the differences in materials, substrates and actual site conditions are such that no warranty in respect of merchantability or of fitness for a particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from this information, or from any written recommendations, or from any other advice offered. The proprietary rights of third parties must be observed. All orders are accepted subject to our current terms of sale and delivery. Users should always refer to the most recent issue of the Product Data Sheet for the product concerned, copies of which will be supplied on request. Sika Limited Watchmead Welwyn Garden City Herts AL7 1BQ Tel: Fax: sales@uk.sika.com Sika Ireland Limited Unit 3 Ballymun Industrial Estate Dublin 11 Ireland Tel: (01) Fax: (01) info@sika.ie Environmental Quality Certified Management System ISO Protection ISO Certified Quality System 9001/ EN Production WP k

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