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QUALITY PROCEDURE FOR


METHODOLOGY OF CONCRETE
DEFECT DETERMINATION &
CONCRETE REPAIRS

RECONSTRUCTION AND REDEVELOPMENT


1
OF PULKOVO AIRPORT PHASE 1 PROJECT
ST. PETERSBURG /RUSSIAN FEDERATION

- /

REVISION DESCRIPTION / :

Controlled Copy / : _____

0
REV. /

Assigned to / : _____________

22.12.2011

Quality Manager (QM) /



()

Project Manager (PM) /


()

Designer (SFMM)

Avtorskiy Nadzor

DATE/

PREPARED BY
/

APPROVED BY
/

APPROVED BY
/

APPROVED BY
/

Confidential
This document contains proprietary information, which is owned by IC
ICTAS-ASTALDI A.S. and is subject to copyright. IC ICTAS-ASTALDI A.S.
has contributed such information for the purpose of performance of the
Reconstruction and Redevelopment of Pulkovo Airport Phase 1 Project
only, and any use or reproduction for any other purpose is strictly
prohibited.

,
IC ICTAS-ASTALDI A.S.,
.
IC ICTAS-ASTALDI A.S.
1
,
,
.

PQC-QAC-ICA-002 Rev.0 22/12/2011

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE


DEFECT DETERMINATION & CONCRETE REPAIRS
,

Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

PQC-QAC-ICA-002
Rev. 0 / . 0
Page /

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TABLE OF CONTENTS

PAGE
.

1.

CONCRETE DEFECT SURVEY

1.

2.

2.

3.

CONCRETE DEFECTS DETERMINATION


SYMBOLS
CONCRETE DEFECTS IDENTIFICATION

3.

4.

DEFECT EVALUATION

4.

5.

REPAIR MATERIALS & METHODS IN


ACCORDANCE WITH MANUFACTURERS
RECOMMENDATION
ATTACHMENTS

5.

13

6.

16

6.

PQC-QAC-ICA-002 Rev.0 22/12/2011

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE


DEFECT DETERMINATION & CONCRETE REPAIRS
,

Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

1. CONCRETE DEFECT SURVEY

PQC-QAC-ICA-002
Rev. 0 / . 0
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1.

The reinforced concrete structural elements should



be inspected for concrete defects which are caused
,
by the root causes mentioned below;
:
A. Improper & incorrect formwork (form . (
,
supports & scaffolding, dimensions of
..)
structural element etc.)
. ,
B. Poor quality form surfaces,
.
C. Improper and inadequate material usage ,
during formwork, rebar installation ( ,
(concrete spacers, electric cables for ),
.
heating, )
( ,
D. Improper & incorrect reinforced bar
,
installation (Incorrect diameter, number & ..)
size of reinforced bars, inadequate over lap .
length etc.)
,
E. Use of Wrong Tools & Equipments during . ,
. /
concreting,
,
F. Lack of vibration of concrete,
.
G. Improper planning / sequencing for
,
concrete pouring,
. ,
H. Lack of cold weather protection,
I. Wrong concrete class pouring,
. ,
J. Improper internal concrete heating which
results in lower compressive strengths , .
rather than the project requirements.
The concrete defect survey check list should include
the below parts,
:
A.
B.
C.
D.
E.
F.

Inspection date
Structural element name
Name of the surveyor(s)
Location of structural element
Reasons that cause the defects
Description of the defects according to
defect classification
G. Sketches showing the defect locations, size
etc. on the structural element
H. Photos showing the defects

.
.
. ()
.
. ,
.

. ,
, ..
. ,

PQC-QAC-ICA-002 Rev.0 22/12/2011

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE


DEFECT DETERMINATION & CONCRETE REPAIRS
,

Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

PQC-QAC-ICA-002
Rev. 0 / . 0
Page /

3/16

The non-compliances should be reported in the


Non-compliance Reports with the copy of the
concrete defect survey check list and its , .
attachments.

The proposed corrective actions and concrete
defect survey result should be evaluated by the
designer in the light of the design effect for bearing
capacity of the structure and durability .
requirements.

PQC-QAC-ICA-002 Rev.0 22/12/2011

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE


DEFECT DETERMINATION & CONCRETE REPAIRS
,

Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

2.IDENTIFICATION OF CONCRETE DEFECTS

The concrete defects at the beams, foundations,


columns, slabs, walls, precast panels should be
identified during the defect survey in accordance
with the below defect sketch and Table 1. The
sketches which show the defect type and location
with the required data should be prepared during
the defect survey at site and signed by the
surveyor(s).

PQC-QAC-ICA-002
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2.
, ,
, , ,
,
1
. ,



().

CONCRETE DEFECTS DETERMINATION SYMBOLS


PQC-QAC-ICA-002 Rev.0 22/12/2011

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE DEFECT DETERMINATION &


CONCRETE REPAIRS/

PQC-QAC-ICA-002

,
Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

DF 1

DF 2

DF 3

Defect Symbol

Page /

3.

3. CONCRETE DEFECTS IDENTIFICATION

Defect
Type No.

Rev. 0 / . 0

Description of Defect

Record for Defect Survey


There are voids in the concrete structural element. The rebar are
exposed. The minimum concrete cover for rebar is maintained.
. .
.
The rebar are exposed on the concrete surface. The minimum
concrete cover for rebar is not maintained.
.

.
Segregation due to poor vibration appears on the concrete
surface. The defect area depth is less than protective concrete
layer.
-
. ,
.

The number of rebar which are exposed should be


shown in the sketches.

.
The number of rebar which are exposed and the
length of the exposed area should be shown in the
sketches.

.

DF 4

Segregation due to poor vibration appears on the concrete


surface. The defect area depth exceeds the protective concrete
layer. -
.
.

DF 5

Cementitious paste leakage due to improper forms, joints etc.



..

The dimension of the defect area should be shown


in the sketches.

.
The dimension of the defect area and number of
rebar which will be exposed should be shown in the
sketches.


.
The dimension of the defect area should be shown
in the sketches.

.

PQC-QAC-ICA-002 Rev.0 22/12/2011

5/16

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE DEFECT DETERMINATION &


CONCRETE REPAIRS/
,

DF 6

DF 7

Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

The marks on the concrete surface due to form release agent,


cementitious leakage, paint, rubber marks etc.

, , ,
..
Coarse aggregate delamination from cement paste due to low
strength areas.

- .

DF 8

Cracks on the concrete structural element.


.

DF 9

Opening of the construction joint due to defective construction


work.

.

DF 10

Hairline cracks with the widths less than 0.30mm opening.


0,3 .

DF 11

Violation of protective concrete cover of the reinforced bars.


.

DF 12

The corrosion of the reinforced bars.


.

DF 13

Damaged area due to the form removal, mechanical impact,


improper construction joint preparation etc.
, ,
,
..

PQC-QAC-ICA-002
Rev. 0 / . 0
Page /

The dimension of the defect area should be shown


in the sketches.

.
The dimension of the defect area should be shown
in the sketches.

.
The average width of the cracks should be shown in
the sketches.

.
The length and opening width of the construction
joint should be shown in the sketches.

.
The defect area percentage to the total area should
be shown.

.
The corroded area percentage to total area and the
thickness of corrosion should be shown.

.
The dimensions of the damaged area should be
shown. In case of presence of exposed rebar the
numbers of them should be also recorded.
.
,
.

TABLE 1
PQC-QAC-ICA-002 Rev.0 22/12/2011

6/16

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE DEFECT DETERMINATION &


CONCRETE REPAIRS/
,
Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

4. DEFECT EVALUATION

No
1

Defect Type

Exposed Rebar
(The minimum concrete cover is
maintained)

(
)

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4.

Acceptance Criteria
Repair Material & Method


The size & depth of the defect area should be evaluated by
1. Repair Materials
the Designer (Avtorskiy Nadzor) for stability, durability of Sika Monotop 910 as primer
the structural element
Sika Monotop 612 as repair material
Any repair material rather than above should be approved

by Designer & the Employer prior to usage of them
( )

2. Repair Method
.
According to the Manufacturers instructions below in the
section 5 of this document.
Note:
If the stability & durability of the structural element is found
unsatisfactory by the Designer, the structural element will
be demolished
1.
- Sika Monotop 910
- Sika Monotop 612
- , ,

.
2.
,
5.
:

, .
PQC-QAC-ICA-002 Rev.0 22/12/2011

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE DEFECT DETERMINATION &


CONCRETE REPAIRS/
,

Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

Concrete cover for the rebar is


less than project requirements

A. Segregation of the concrete


on the surfaces (The defect
depth is less than concrete
cover)
B. Cementitious paste leakage
which cause rock pockets
.
(

)
. ,

.

Segregation of the concrete on

PQC-QAC-ICA-002
Rev. 0 / . 0
Page /

8/16

The defect should be evaluated by the Designer (Avtorskiy Repair material and methods will be determined in
Nadzor) to verify that the stability, durability of the
accordance with the Designers instructions.
structural element is satisfactory
Note:
If the stability & durability of the structural element is found

unsatisfactory by the Designer, the structural element will
( )
be demolished
.

.
:



, .
1. Repair Materials
Sika Monotop 910 as primer
Sika Monotop 612 as repair material
Any repair material rather than above should be approved
by Designer & the Employer prior to usage of them
2. Repair Method
According to the Manufacturers instructions below in the
section 5 of this document.
2.
- Sika Monotop 910
- Sika Monotop 612
- , ,

.
2.
,
5.

The size & depth of the defect area should be evaluated by

1. Repair Materials
PQC-QAC-ICA-002 Rev.0 22/12/2011

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE DEFECT DETERMINATION &


CONCRETE REPAIRS/
,
Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

the surfaces (The defect depth


exceeds the concrete cover)

(

)

Concrete areas with lower


compressive strength than the
project concrete class
requirements


PQC-QAC-ICA-002
Rev. 0 / . 0
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the Designer (Avtorskiy Nadzor) for stability, durability of Sika Monotop 910 as primer
the structural element
Sika Monotop 612 as repair material
Any repair material rather than above should be approved
( )
by Designer & the Employer prior to usage of them

.
2. Repair Method
According to the Manufacturers instructions below in the
section 5 of this document.
Note:
If the stability & durability of the structural element is found
unsatisfactory by the Designer, the structural element will be
demolished
3.
- Sika Monotop 910
- Sika Monotop 612
- , ,

.
2.
,
5.
:

, .
A. Local Defects
A. Local Defect
The size & depth of the defect area should be evaluated by
the Designer (Avtorskiy Nadzor) for stability, durability of The low strength areas to be determined by NDT or applicable
the structural element
test methods. The defect area should be removed. After the
B. All the sections of structural element
removal of the defect area, the compressive strength of the
If non destructive test (NDT) and concrete core sample test concrete should be determined by NDT to ensure the existing
results do not meet the project compressive strength
strength of concrete complies with the specified concrete
PQC-QAC-ICA-002 Rev.0 22/12/2011

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE DEFECT DETERMINATION &


CONCRETE REPAIRS/
,
Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

requirements, the structural element should be


demolished
.

( )

.
.


,
.
6

Damage due to improper


construction works and
methods

The size & depth of the defect area should be evaluated by


the Designer (Avtorskiy Nadzor) for stability, durability of
the structural element

( )

.

PQC-QAC-ICA-002
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strength.
The repair method and material should be determined
according the Designers instruction.
.


.
,
,

.
,
.
1. Repair Materials
Sika Monotop 910 as primer
Sika Monotop 612 as repair material
Any repair material rather than above should be approved
by Designer & the Employer prior to usage of them

2. Repair Method
According to the Manufacturers instructions below in the
section 5 of this document.
Note:
If the stability & durability of the structural element is found
unsatisfactory by the Designer, the structural element will be
demolished
4.
- Sika Monotop 910
- Sika Monotop 612
PQC-QAC-ICA-002 Rev.0 22/12/2011

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE DEFECT DETERMINATION &


CONCRETE REPAIRS/
,

Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

Hairline cracks less than


0.30mm
0,3
Corrosion of the reinforced bars

Cracks

The number of rebar corroded should be surveyed. The


Designers inspection and according to his evaluation of
defected areas & corroded rebar for the stability &
durability of the structural element, repair methods or
demolishing the structural element will be determined.

PQC-QAC-ICA-002
Rev. 0 / . 0
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- , ,

.
2.
,
5.
:



,
No repair

Repair method should be determined according to Designers
evaluation.

Note:
If the stability & durability of the structural element is found
unsatisfactory by the Designer, the structural element will be
demolished


, .
.

:


,

.
,
If crack is observed in the tension section, the crack should The crack in the tension section will be repaired according to
the Designers evaluation and instructions.
be inspected and evaluated by the Designer (Avtorskiy
Nadzor) for stability, durability of the structural element. If the stability & durability of the structural element is found
Other crack which are not located in the tension section
unsatisfactory by the Designer, the structural element will
are accepted if the width (calculated by Designer) of it
be demolished.
within the allowed limits.
Other crack which is not located in the tension section will
be repaired according to the Designers evaluation and
PQC-QAC-ICA-002 Rev.0 22/12/2011

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE DEFECT DETERMINATION &


CONCRETE REPAIRS/
,
Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

,

( )
, .
,
, (
)
.
10

11

Marks on the fair-faced


concrete surfaces

Opening of construction joint


As per the Designers evaluation report


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instructions.

.

, .
,

.
The marks on the fair-faced concrete surfaces should be
cleaned by proper means to ensure that no damage or color
change will occur on the concrete surfaces

,
,
.
Repair method should be determined according to Designers
evaluation.

.

PQC-QAC-ICA-002 Rev.0 22/12/2011

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE


DEFECT DETERMINATION & CONCRETE REPAIRS/
,

Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

5. REPAIR MATERIALS & METHODS IN


ACCORDANCE WITH MANUFACTURERS
RECOMENDATION
A. SIKA Monotop 910
Application Conditions
Substrate Quality
Concrete:
The concrete shall be free from dust, loose material,
surface contamination and materials which reduce
bond or prevent suction or wetting by repair
materials.
The concrete substrate must be sound and have
minimum bond strength of 1.5 N / mm .
Steel reinforcement:

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5.

A.

SIKA Monotop 910

,

,
, ,


.



.

Rust, scale, mortar, concrete, dust and other loose


and deleterious material which reduces bond or
contributes to corrosion shall be removed.
Minimum Standard SA2 If anything is unclear
sample areas should be located.
Substrate Preparation
Concrete:
Delaminated, weak, damaged and deteriorated
concrete and where necessary sound concrete shall
be removed by suitable means.
The surface shall be thoroughly pre-wetted and not
be allowed to dry before application of the bonding
primer. The surface shall achieve a dark matt
appearance without glistening and surface pores
and pits shall not contain water.
Steel reinforcement:


:
, , ,
,

.

. , .
,
.
:

Surfaces shall be prepared using abrasive blast


cleaning techniques or high pressure water-blasting.

. +5; . +30
Application Conditions / Limits

Substrate Temperature min. +5C; max. +30C
. +5; . +30
Ambient Temperature min. +5C; max. +30C
Application Instructions

PQC-QAC-ICA-002 Rev.0 22/12/2011

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE


DEFECT DETERMINATION & CONCRETE REPAIRS/
,

Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

PQC-QAC-ICA-002
Rev. 0 / . 0
Page /

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Mixing Ratio;
Brush application:
5,25 litre water per 25 kg bag
Spraying application:
5 litre water per 25 kg bag
Mixing
Sika MonoTop-910 N can be mixed with a low speed
(<500 rpm) electric drill mixer. In small quantity,
Sika MonoTop-910 N can also be mixed by hand.
Pour the water in the correct proportion into a
suitable mixing container. While stirring slowly, add
the powder to the water. Mixed thoroughly to the
required consistency (brushable non-dripping
consistency).


5,25 25 .

5 25 .

Sika MonoTop -910 N
()
(<500 ./.), Sika MonoTop-910 N
.

, ,
,
.
3
.

Application Method
As a bonding primer
Apply by brush, roller or suitable spraying
equipment to the prepared (pre-wetted) substrate.
To achieve good bond, Sika MonoTop-910 N must
be applied well into the substrate, filling all
unevenness.
Subsequent repair mortar must be applied while the
bonding primer is still wet.

/

,

Sika
MonoTop-910 N
,
.
Sika MonoTop
, ..
.

As reinforcement protection
Apply first layer approx. 1.0 mm thick, using
medium hard brush or spray gun to cleaned
reinforcement. When first coat is hard to the finger
nail, for guidance~4 to 5 hours at 20C, apply second
layer approximately 1.0 mm thick.
B. SIKA Monotop 612
Surface Preparation
Sika MonoTop 612 should be applied over bonding
slurry of Sika MonoTop 910. Refer to the Sika
MonoTop 910 technical data sheet for information
on surface preparation and priming.
All feathered edges around the area to be repaired
should be squared off with an angle grinder and
chiseled down to a minimum depth of 10 mm.


~ 1.0 ,


.

. SIKA Monotop 612



Sika MonoTop 612 Sika
MonoTop 910.
Sika MonoTop 910
.


10 .

PQC-QAC-ICA-002 Rev.0 22/12/2011

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE


DEFECT DETERMINATION & CONCRETE REPAIRS/
,

Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

PQC-QAC-ICA-002
Rev. 0 / . 0
Page /

15/16

Mixing
For a hand applied mortar, pour 2.8 liters
(maximum) of clean fresh water into a suitable
mixing container and slowly add all of the powder
while mixing continuously with a Sika Propeller
Mixer attached to a slow speed (500 rpm) electric
drill.
Thoroughly mix until a smooth, lump free
consistency is achieved. A minimum mixing time of
3 minutes is recommended.
The water content can be reduced slightly to
produce a stiffer mortar if desired.
For wet spray applications the water content can be
increased to 3.25 liters/25kg bag. (Note that an
increase in water content above 2.8 liters will result
in a reduction in compressive strength.)

: 2,5 - 3,5
25
: ~ 2.5 -2.7. 25
:
,

.


.


.


24 ,
Sika
MonoTop-610.

Application
While the bonding coat of Sika MonoTop 910 is still
tacky, pack the mortar well into the cavity or
repair. Use a placing rather than a rendering
technique to fill all voids and ensure thorough
compaction is achieved.
Force the Sika MonoTop 612 against the edge of the
repair and progressively work towards the centre.
For repairs in excess of 30 mm deep apply in layers
ensuring that each previous layer is sufficiently
hardened and well keyed. If previous layers are over
48 hours old roughen the surface and dampen. Sika
MonoTop 910 should be used as bonding slurry
between layers.
Steel trowel the final layer, if required, to achieve a
smooth, tight finish.

Sika MonoTop 910 "",



. ,
,
.
Sika MonoTop
612
. 30
,

.
48
. Sika MonoTop 910

.

, ,
, .

Sika MonoTop 612 ,
, Sika
MonoTop 910.
,
Sika MonoTop 612

Important Notes
Only apply Sika MonoTop 612 to sound substrates
that have been dampened and primed with Sika
MonoTop 910.
As with all concrete and mortars, it is essential to
protect Sika MonoTop 612 from water evaporation
during the crucial early age curing period, with

PQC-QAC-ICA-002 Rev.0 22/12/2011

QUALITY PROCEDURE FOR METHODOLOGY OF CONCRETE


DEFECT DETERMINATION & CONCRETE REPAIRS/
,

Employer: Northern Capital Gateway /

Project: Reconstruction and Redevelopment of Pulkovo Airport Phase 1/

water spray, wet hessian or polythene sheets. If no


further coatings are to be applied to the finished
surface, a membrane curing compound may be
used.
High quality, long term repairs can only be achieved
if they are carried out conscientiously by
experienced applicators giving adequate detail to
surface preparation, priming of concrete and steel,
mixing of repair mortars, application and curing.

Rev. 0 / . 0
Page /

16/16

, ,
.

,
,
,
,

,
,
.

6. ATTACHMENTS
1. Technical Data Sheet of SIKA Monotop 910
2. Technical Data Sheet of SIKA Monotop 612
3. FRM-QAC-ICA-042
Rev. 0 Check List
Identification of Concrete Defects
4. FRM-QAC-ICA-043 Rev. 0 Check List for Surface
Preparation for Concrete Defects
5. FRM-QAC-ICA-044 Rev. 0 Check List for Post
Inspection of Concrete Repairs

PQC-QAC-ICA-002

6.
1. SIKA
Monotop 910

2. SIKA
Monotop 612
3.FRM-QAC-ICA-042 Rev. 0

4.FRM-QAC-ICA-043 Rev. 0

5.FRM-QAC-ICA-044 Rev. 0

PQC-QAC-ICA-002 Rev.0 22/12/2011