Construction

Technology and Concepts

Repair and Protection
of Reinforced Concrete

Corrosion Management in Reinforced

Concrete Structures
The key stages in the
process are:-

Assessment Survey of the

Condition of the Structure

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:-

Assessment Survey
of the Condition of the
Structure

Diagnosis of the
Cause of Deterioration

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.

Following review of the original

design, construction methods
and programme, and the
assessment survey Identify the
root causes of damage:-

The process of assessment will

always include the following
aspects:-

Identify mechanical, chemical

and physical damage to the
concrete.

The current condition of the

structure including visible,
non visible and potential
defects.
Review of the past, current
and future exposure.

Identify concrete damage due

to reinforcement corrosion.

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

It is necessary to clarify the

Owners requirements and
instructions in relation to: The required durability,
requirements and performance.
Intended design life.
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.

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.

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 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.
The likely environmental/
aesthetic impact of the
improved/ reduced
appearance of alternative
solutions.

Assessment Survey
and Diagnosis of Damage
CONCRETE DAMAGE DUE TO
REINFORCEMENT CORROSION

CARBONATION

Carbon Dioxide (CO2) in

the atmosphere reacting
withCalcium Hydroxide in
the concrete pore liquid.
CO2 + Ca(OH)2CaCO3 + H2O
Soluble and pH 12-13
Almost insoluble and pH 9
Steel PassivatedSteel
Unprotected

Reinforcement corrosion following reduction

of the passivating concrete alkalinity by carbonation.

STRAY/ ELECTRICAL
CURRENT

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.

Reinforcement corrosion showing as rust

staining from cracks after galvanised steel
railings were fixed into the parapet.

CORROSIVE CONTAMINANTS
eg CHLORIDES

Chlorides accelerate the

corrosion process
however originally caused.
At above 0.2-0.4% 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.

The damaging effects of steel corrosion accelerated by chloride ingress from

deicing salts.

CONCRETE, DAMAGE
AND DEFECTS

MECHANICAL

CHEMICAL

Impact, Vibration and

Explosion

Alkali Aggregate
Reaction

Abrasion and Wear

Chemical Exposure

Overloading

Bacterial Action

PHYSICAL

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.

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 Structure: 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

Apply Cathodic Protection

Advantages:
The old traditional approach.

Advantages:
The only way to completely stop
steel corrosion.

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.

Permanent solution (with full

repairs and monitoring).
Disadvantages:
Ongoing cost to maintain.
Many structures not suitable
(access / non continuous
reinforcement / prestressing
steel etc).

Very poor appearance.

Realkalisation
or Desalination

Overcladding and Insulation

Conventional Repair
and Protection

Advantages:
Based on reversing the
principles of Cathodic protection.

Advantages:
Greatly improves appearance.

Advantages:
Meets existing national standards
(DIN/BBA/SIS/NF etc).

Limited concrete removal.

Provides the additional benefit

of insulation.

No ongoing maintenance
(except protective coatings).

Provides a long term solution.

Proven performance (over 20

years with Sika systems).

Disadvantages:
Very expensive.

Provides some protection against

latent carbonation damages.

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).

Can hide latent defects.

Extended contract period.

Cost effective.
Disadvantages:
No protection against latent
chloride damage.
Requires extensive concrete
break out.
Considerable noise, vibration
and dust.

Concrete Repair and Protection

with Corrosion Inhibitors

System Positioning with

Sika FerroGard-903
Corrosion Inhibitor
Doubling of the service life
Service life
Development of corrosion

Limit of service life

Visible damage
average concrete quality
without Sika FerroGard

y = rate
of corrosion
y

/2 = rate
of corrosion

onset of corrosion

Advantages:
All the advantages of conventional concrete repair
and protection.

average concrete quality

with Sika FerroGard -903

onset of corrosion

years

Sika FerroGard -903 In New Construction.

Greatly reduced concrete break out.

Extension of service life

Greatly reduced noise vibration and dust.

Service life

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 10-15 years).

Development of corrosion

Limit of service life

Visible damage
average concrete quality after
application of Sika FerroGard -903

average concrete quality

without Sika FerroGard

y = rate
of corrosion
y
/2 = rate
of corrosion

onset of corrosion

onset of corrosion

years

New start after Sika FerroGard -903 application

Disadvantages:
Not proven on prestressed structures (at this time).

Sika FerroGard-903 Protection before

Visible Damage.
Extension of service life
Service life
Development of corrosion

Limit of service life

Visible damage
average concrete quality
without Sika FerroGard

average concrete quality with

concrete repair and protection
including application
of Sika FerroGard -903

y = rate
of corrosion
ny = rate
of corrosion
onset of corrosion

onset 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

The Sika Principles of

Concrete Repair & Protection
Remove damaged
concrete and prepare
exposed steel

Protecting exposed
reinforcement

SikaTop-110
Armatec EpoCem

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 - 610

One component steel

reinforcement primer and
bonding bridge

Replacing damaged
concrete

SikaTop Repair Mortars

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

Sika MonoTop Mortars

Select the Appropriate

Sika System
8

One component polymer

modified repair mortars
Suitable for hand and wet
spray machine application

Protecting against the

development of latent
damage

Sika FerroGard -903

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

Levelling the profile

and filling
surface pores

SikaTop Levelling Mortars

Sealing and Coating preventing the ingress of

aggressive influences

Hydrophobic Impregnations

coarse/fine

SikaGard - 700S/-702W

Use to fill surface defects

to ensure continuous
protective coating
Produce the desired
surface texture
Provides uniform substrate

Prevents water and chloride

ingress
Allows each way water
vapour diffusion

Anti-Carbonation Coatings
SikaGard - 680S/-675W

SikaGard - 720 EpoCem

Unique epoxy cement

technology
Integral curing ability

Sika Ferro Gard

Technology

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

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:-

Bond strength to steel

and concrete

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.

Permeability to water

Compressive and
flexural strengths
Permeability to water

Permeability to water
vapour

Elastic modulus
(stiffness)

Permeability to carbon
dioxide

Restrained shrinkage

Corrosion protection

The Bnziger block for testing repair mortars

Direct comparison worldwide

Application horizontal,
vertical and overhead
Realistic site dimensions
Additional lab testing by coring
Crack free performance
under different conditions

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.
IS

10

01

m
ste

Cer
ti

Quality S
y
ied

90

0 0/E N 2 9

Thermal compatability

Sika have developed Product Performance Testing

Bond strength

Application Criteria

Sika Undertake Extensive Durability Testing

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.

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
products true performance.
SikaGard coatings therefore
continue to perform long after
other coatings have ceased to
provide effective protection.

Protecting Against the

Development of
Latent Damage

Levelling the profile and

filling surface pores

Penetration ability

Bond strength

Film forming ability

Permeability to carbon
dioxide

Corrosion inhibition

Water permeability and

absorption

Chloride displacement
Hydroxide displacement
(carbonation induced)

Sealing and Coating Preventing the Ingress of

Aggressive Elements

Sealing with
Hydrophobic
Impregnations
Penetration ability
Permeability to water
Permeability to water
vapour

Freeze thaw resistance

Machine application of
repair mortars

Low temperature dynamic crack

bridging testing of coatings

Anti-Carbonation
Coatings
Bond strength
Cross hatch
performance
Permeability to carbon
dioxide
Permeability to water
vapour

Spray application for test under live

dynamic loading.

U.V. light resistance

Alkaline resistance
Freeze thaw resistance

In the Field

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 1997.
The Lmershagen bridge A2 motorway, Germany
Original Construction: Late 1940s, Concrete Repair and Protection: 1981-82,
Inspection: 1997

The Lmershagen bridge over the A2

motorway near Bielefeld in Germany,

QUALITY
AA

N
N

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.

DD

Reason for repairs and

concept used

DURABILITY

In the course of time, damage occurred

in the form of concrete spalling over
corroding reinforcing steel. This forced

II N
N

the Motorway Department to carry out

general repairs in 1981. This was

CONCRETE
R E PA I R
AA

N
N

primarily to prevent falling concrete

causing a hazard to motorway traffic.
Photo 2 shows the typical concrete
damages - spalling over corroding
main steel reinforcement.
Substrate preparation by blast cleaning of
the concrete surfaces was carried out first.
The concrete spalling was then repaired

DD

with Icoment Steel Reinforcement Primer

plus Icoment Repair Mortar. All the

PROTECTION

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 7032.
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).

Quality and

Concrete
Bridges

in Jutland,
Denmark

Original Construc
tion: 1960s,
Inspectio
n and Assessm
Concrete
Repair and
ent: 1988,
Protectio
1991 and
n: 1983,
1994

The
Old
Custo
ms Ho
use,
Oslo,
Norw
Prot
ectio
ay
n: 1983

Cleanability

Crack Bridging
Anti-Carbonation
Coatings

Orig
inal
Con
Insp
stru
ectio
n and ction:
1921
Assessm
, Con
crete
ent:
Repair
1993
and
1997 and

The Structur
es

In the light
of durability
problems
concrete
with
bridges built
in the sixties,
Danish Road
the
Authorities
organised
inspection
an
and investigatio
n of the root
causes of
the concrete
deterioratio
n.
The Road
Authorities
also establishe
a Working
d
Group with
the objectives
providing
of
proposals
specifically
refurbishm
for the
ent of some
of the concrete
structures
with multiple
cracks, and
then also
making
Photo 1: Homogeneous appearance of structure from medium range in 1997.
suggestio
improve
ns
to
their approach
to protecting
concrete bridges
in general.

Fire resistance

The

Stru

cture
The
Old
Cust
desig
oms
ned
Origin
in reinf Hous e,
when
Oslo
Inspec al Con
orced
finish
was
ed
conc
large
tion structio
rete
st reinfo in 1921
and
and
was
in th
rced
one
Ass n: c19
e w
conc
of the
ess
72,
orld
rete
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. It
ment: Con
struc
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ng
Rep
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air
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and
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tection
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ped
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and
the found ry solut
: 198
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se
6,
ation
was
a
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132
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the
s. This
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heav
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d for
Visual and technological
stor
was
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The Problem
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ht of
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to the
Photo 1: One
condition of surface in 1997
s, situa tower
oun
s
dsw
the
of the selected
even
the
area
ded
build
On two major
orth
solid
tually
bridges on
s, serv
ing.
by
specifical
The reinforced concrete arch bridge
the M60/M61
in Lon ted in
highways
piled
The
1500 (1997).bedr ock
low
ly against
- the M60
ice
M61 - they
down
don
-ris
drive
bloc
and ingress.
future moisture
with
yard
selected
, it
e sho
retains a largely homogeneous
to
n piles
k
des
This
five
more
s and
was
bridges with
material was
character
.
igne
ppin
than
istic cracking
buil
chosen due
to its excellent
appearance from medium range
d
she
The
t circ car park g
and concrete
ar wal on the
damage.
Old
propertie
a 197
Cust
s.
s of water
resistance
rein
(photo 1).
pile
its
l and
oms
, flexibility
forc
2 and
purp
d,
Hous
(crack-brid
ed
slab
ose
rein
and its
fou
e
con
new
ging)
had
for
prin
water vapour
nda
forc
Photo
cret
The
techn
fulfill
60
cipl
tion
ed
1: Overv
ed
Photo 3: Carrying out repairs inWorking
the winter Group
of
year
resistance
grou
iques
diffusion
e with e
it obso
out
con
(breathabi
s, whe
iew of
nd floo . All
and
original constructi collected all of the
1981/82.
on the
lity).
lete
cre
con
the repair
a
logis
con
n 2
r leve
te
was
for its
stru
on data relating
tics
cret
struc
ed and
and
the bridges
raft
ctio
there
mad
l
e
ture.
3.
origi
is
to
(Lyt
protec
and the moisture
e
of insit
n abo
On three
fore
concrete protection is not completely
the
nal
ag).
See
ted structu
of the five
histo
use.
the concrete
dete
content of
u light
phot
ve
selected
The
ric
re in
It The
rmin
was measured
the edge
os
refurb
intact in some local areas.
bridges
weig
1997.
struc
ed
beams and
Pro
ished
on site.
ture
ht
Sika
that
the parapets
Area
blems
and
prepared,
In 1980
shou
were
Follo
Solu
s of
conv
repaired
ld be
The cracks
wing
erted
tion
spa
with Sika
noti
a cons
and protected
Inspe
an exten
lling
in the bridges
mortars
Photo 4 shows cracks on the structures
into
cea
evalu
ortiu
office
ctora
ble
con
identified
ation
in 1983
sma
were Elastic,
sive
m of
s.
te of
as being
with Icosit
and
of all
with a brownish edging. These
cracksdue to
and
ll sca as earl crete first
the
the
see photo
Anci
a combinatio
mark
detai
Histo
differ
Oslo
of initial
reve
3.
ent
le loca y as
bec
led
n
et, a
ent syste
plastic shrinkage
ric
Eske
Monu
aled
and
198
ame
comp
Build
ment
Prote
lise
1,
inad
together with
cracking;
cov
ms on
Photo 2: A land AS
lete
s the
ction
d inve whe
Ande close up of (arch ings ,
equ
er
The other
cracks now
Sika
n a
Syste
and damages
typical ASR
acie
nes
Espe
cons
two of the
occurring
and
Repa
rein
to alkali-silica
stig
itect
cracking
m was
s in
ortium
the bridge
selected
due were
n resul
to carryon(cont
ir
forc
s) and
atio
reaction (ASR).
ractoparapet (1983).
bridges
rein
selec
the
. This
left unprotecte
eme
n
r) was
t of
Sub
forc
previously
ted by
Tor
This was
decis
out
d to be monitored
the good
beg
nt cor
eme
refurb
seq
determine
estab
as a reference
ion was
estab
the
inni
uen
nt
ishm
d by laboratory
Cou
lishe
ros
refere
analysis as
to the efficiency
ng
ent work conv ersio lished
as a
tly
ncil
d by
ion
nces
originating
treatment.
Wa
com
of the
of
app
1980
pro
n and
s.
nds
from the
pete
and
reactive aggregates
oint
blem
), high (already
use of
nce
wor
The
Par
comp
ed
and
th Bor
s.
, see photo
techn
tne
Orig
com
lete
well
rs to Mitchell
2.
ical
inal
syste
pre
oug
The
docu
and
THE SIKA
Photo
Prob
hen
ms for
h
McF
und
1980
mak
prote
men
REPAIR AND
The Solution
the
lems
inadeq 2: The
arla
erta
Photo 2: Concrete spalling over corroding
/81
ted
ction
e reco sive
conc
of the
buildin
apa
ne
PROTECTION
.
uate
asse
concre
ke
rete
Phot
sur
steel reinforcement in 1981.
struc
facade
rtm
mm
ssme
a mor
repai
te over concre g that
failin
o 1:
Based on
vey
SYSTEM
sho
carb
ture
end
r
nt surv
this information
Sudb
The
corrod te cover
g join ents
The concrete
uldng
e
onat
reve
the and showi
atio
and
ury
owne
ingr
and analysis,
surface was
ion
ey
aled
t sea and som
the Working
repair ing reinfor firstspallin have
ns
Hous
75m
ess.
rs
effec
Photo 4: 1997 Network
of wide-meshed
g
s in 1981.
to
prepared
conc
dept
for
a 15
blast cleaning
Group
lant
m (3").
e in
repo cemenrequ
requ
On closer examination, however, surface
tively
by
hs
rete
rep
s, lead e are
Janu
yea
and vacuum
cracks with brownish
edging to the cracksselected a high
irem
ired
rt was t before
performan
reinf
airs
of
In addi
ary
r life
as
the conc stopping
ce coating,
ents
cleaning to
remove any
mai
earl
up
orce
ing
1997
from pollution/contaminants.
defects are visible which indicate that the
tabl
spa
tion
Icosit Elastic,
Acc
the deter
were
nten
y 198
residual dust.
men
rete
to wat of
.
overall protectio
ed
n to
deem
to this, to main
urat
t cove
for
- provi
anc
4.
by
iorati
ed to
e preer
n of the
tena
e. This
the
the
ding
the
r was
be insuf
nce
bridges
plac
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41
ful cons ons
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pro
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to carb vide d
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ation
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the
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the
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tem
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chos
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avai
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labil
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a phys and
ight
epa
icall
repa
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nd
Pro
tar,

Sudb
ury

Hous
e, Lo
ndon
, UK

tec

tion

As above for Anti-Carbonation

Coatings, plus: Crack bridging ability

Statically

Dynamically

At low temperatures
(-20oC/-20oF)

11

International Case Studies

Structure
MECHANICAL
DAMAGE

24 Storey Housing Block. Reinforced

Concrete Frame with Architectural
Precast Concrete Cladding Panels

Problem
Loading and impact damaged
architectural precast cladding panels
(from time of original construction).
Cracks and inadequate cover over
steel reinforcement.

Sika Solutions
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.

Structure
CHEMICAL
DAMAGE

Factory Roof over Production Facilities

Problem
Aggressive chemical attack on the
concrete.
Followed by corrosion of the steel
reinforcement in a high temperature,
high humidity environment.

Sika Solutions
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

International Case Studies

Structure
CHEMICAL
DAMAGE

Precast Reinforced Concrete

Framed Office Building

Problem
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.

Sika Solutions
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.

Structure
PHYSICAL
DAMAGE

Multi Storey Concrete Parking Structure

Problem
Freeze thaw damage on concrete
columns and soffits from condensation
and deicing salts exposure.

Sika Solutions
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

International Case Studies

Structure
PHYSICAL
DAMAGE

150 metre (500 feet) Long Major

Road Bridge

Problem
Concrete damage on the parapet and
underside of the bridge due to freeze
thaw action accelerated by deicing
salts.

Sika Solutions
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 SikaCem133 Gunite repair mortar.

Structure
CARBONATION
DAMAGE

Multi Storey Residential Housing Block

with Concrete Frame and Precast Cladding
Panels

Problem
Inadequate concrete cover to steel
reinforcement with extensive cracking
and spalling after depth of carbonation
reached the steel.

Sika Solutions
Concrete surface preparation by high
pressure water jetting.
Exposed steel reinforcement prepared
by blast cleaning.
Steel reinforcement protection and
bonding bridge with SikaTopArmatec 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

International Case Studies

Structure
CARBONATION
DAMAGE

26 Storey Lightweight Insitu Concrete,

Residential Housing Block

Problem
Inadequate concrete cover over steel
reinforcement with subsequent
cracking, staining and spalling.

Sika Solutions
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.

Structure
CARBONATION
DAMAGE

Historic Reinforced Concrete

Drinking Water Tower

Problem
Externally carbonation depth had
reached the main steel reinforcement
allowing expansive rusting to occur
with subsequent concrete cracking
and spalling.

Sika Solutions
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

International Case Studies

Structure
ELECTRICAL
DAMAGE

Concrete Parapet Wall at

an Airport Parking Structure

Problem
Galvanised steel handrail fixed into
the steel reinforced concrete edge
beam with direct contact between
galvanising and reinforcing steel
leading to corrosion.

Sika Solutions
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.

Structure
CORROSIVE
CONTAMINANTS

1200metre (3/4 mile) Viaduct consisting

of 10 bridges over road and rail tracks

Problem
Extensive chloride accelerated
reinforcement corrosion particularly
below expansion joints in the deck.

Sika Solutions
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

International Case Studies

Structure
CORROSIVE
CONTAMINANTS

Second Floor Pedestrian Walkway/Bridge

at a Hospital

Problem
Concrete damaged by freeze thaw
action and reinforcement corrosion
accelerated by chlorides from deicing
salts.

Sika Solutions
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.

Structure
CORROSIVE
CONTAMINANTS

New Light Rail Bridge Superstructure

Problem
Inadequate low concrete cover with
future deicing salt exposure on the
deck
Mechanical damage to architectural
panels by a nearby bomb explosion.

Sika Solutions
Bridge Deck Surface and Soffit
Impregnation with Sika FerroGard-903.
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

Summary Flow Chart

of the Sika Process
N

Visual
Survey

Staining,
Cracking
Spalling

Latent
damages

Break out
damaged
concrete

Detailed
survey

Root cause
analysis

Repair &
protect now?

Rusted steel
present

Prepare steel

Prepare
substrate

Apply Sika
steel primer
and bonding
bridge

Clean
concrete
and mark
repairs

Y
N
Fill with Sika
Repair mortar

Protect
against latent
damages?

Continue
regular
monitoring

Additional Complementary
Sika Systems

Sika Deck Coatings

- for crack bridging balcony,
podium and deck waterproofing
plus elastic wearing surfaces.

18

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.

Apply Sika
Icosit Steel
coatings

Apply Sika
Ferrogard 903

Protect &
enhance
appearance

Apply Sika
levelling
mortar

Crackbridging
ability
needed?

Final
inspection

Apply Sikaflex
joint sealents

Apply
Sikagard
680S/670W
coatings

Apply
Sikagard
impregnation

Maintenance
Management
Strategy

Apply
Sikagard
550W to
facades and
apply
Sikafloor to
decks

Set up
Corrosion
Monitoring
System

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

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 Sikas 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.

Environmental

Quality

90

9
01 / E N 2

Production

WP.07.04.3k

O 14 0 0 1

Protection

em
st

a
d Qu lity Sy
fie

IS

IS

stem
Sy

nagemen
Ma
t
d

Tel: (01) 8620709

Fax: (01) 8620707
email: info@sika.ie
www.sika.ie

00

Tel: 01707 394444

Fax: .01707 329129
email: sales@uk.sika.com
www.sika.co.uk

Ce
rti

Sika Ireland Limited

Unit 3
Ballymun Industrial Estate
Dublin 11
Ireland

Certif
ie

Sika Limited
Watchmead
Welwyn Garden City
Herts
AL7 1BQ