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05 CE Marking
Summary Flow Chart and Phases of the Correct Concrete Repair &
42 Protection Procedure
Examples of Typical Concrete Damage & its Repair & Protection with Sika
52 Systems
THE EUROPEAN STANDARDS
EN 1504 SERIES
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4 The Repair & Protection of Reinforced Concrete with Sika
THE EUROPEAN STANDARDS EN 1504 CONSIST OF 10 PARTS.
WITH THESE DOCUMENTS PRODUCTS FOR THE PROTECTION AND
REPAIR OF CONCRETE STRUCTURES ARE DEFINED. QUALITY CONTROL
OF THE REPAIR MATERIALS PRODUCTION AND THE EXECUTION OF THE
WORKS ON SITE ARE ALSO ALL PART OF THESE STANDARDS.
EN 1504 2 Provides specifications for surface protection products / systems for concrete
EN 1504 8 Describes the quality control and evaluation of conformity for the manufacturing companies
EN 1504 9 Defines the general principles for the use of products and systems, for the repair and protection of concrete
EN 1504 10 Provides information on site applications of products and quality control of the works
These standards will help owners, engineers and contractors successfully complete concrete repair and protection works to all types of
concrete structures.
CE MARKING
The European Standards EN 1504 have n CE Symbol
been fully implemented since January n Identification number of the notified body
1st, 2009. Existing National Standards 01234
which have not been harmonized Sika Services AG
with the new EN 1504 were therefore Tffenwies 16, CH-8048 Zrich n Name or identifying mark of the producer
withdrawn at the end of 2008 and CE Factory No 1111 n Year in which the marking was affixed
09 n Certificate number as on the attestation
Marking has become mandatory.
01234-CPD-00234 certificate
All products used for concrete repair
and protection now have to be CE EN 1504-3
marked in accordance with the Concrete Repair product for structural repair
CC mortar (based on hydraulic cement) n Number of the relevant part of the European
appropriate part of EN 1504. This
CE conformity marking contains the Compressive strength: class R4 Standard
following information using the Chloride ion content: 0,05% n Description of the product
example of a concrete repair mortar Adhesive Bond: 2,0 MPa
Carbonation resistance: Passes
suitable for structural use:
Elastic modulus: 20 GPa n Additional Information on the regulated
Thermal compatibility part 1: 2,0 MPa
characteristics
Capillary absorption: 0,5 kg m-2 h-0,5
Dangerous substances: comply with 5.4
Reaction to fire: Euroclass A1
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The Repair & Protection of Reinforced Concrete with Sika 5
THE PROJECT PHASES OF THE
CONCRETE REPAIR & PROTECTION
PROCESS
In accordance with European Standard EN 15049
1 2
PROCESS OF ASSESSMENT
3
MANAGEMENT STRATEGY
INFORMATION ABOUT THE
STRUCTURE
A study is carried out at the beginning In-depth condition survey shall be Based on the assessment of the
of a project to collect information made of the visible and not readily survey, the owner has a number of
about the structure. This may include: visible defects of a structure to address options to be selected while deciding
n General condition and history the root causes of the damage. This the relevant actions to meet the future
n Documentation e.g. calculations, will be used to assess the ability of the requirements
drawings and specifications etc. structure to perform its function. of the structure.
n Repair and maintenance schedule
The survey and its assessment shall For example the repair options can be
This information will provide valuable only be carried out by a suitably defined from the following:
data to understand the existing qualified and experienced person. n Do nothing or downgrade the
condition of the structure capacity
In the event of not carrying out any n Prevent or reduce further damage
repairs to the concrete structure without repair
a qualified Engineer may give an n Repair all or part of the structure
estimation of the remaining service n Reconstruction of all or part of the
life. structure
n Demolition
The aim of a concrete survey is to
identify defects. Important factors when considering
n Types of defects to the concrete these options:
Mechanical n Intended design life following repair
Chemical and protection
Physical n Required durability or performance
n Defects in concrete due to n Safety issues during repair works
reinforcement corrosion n Possibility of further repair works
in the future including access and
maintenance
n Consequences and likelihood of
structural failure
n Consequences and likelihood of
partial failure
And environmentally:
n Protection from sun, rain, frost,
wind, salt and/or other pollutants
during the works
n Environmental impact of; or
restrictions on the works in progress
n Noise and dust pollution
n Time needed to carry out the work
, etc.
Future maintenance:
Any future inspection and
maintenance work that will need to
be undertaken during the defined
service life of the structure, shall also
be defined as part of the management
strategy.
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6 The Repair & Protection of Reinforced Concrete with Sika
4 5 6
ACCEPTANCE OF REPAIR WORK
DESIGN OF REPAIR WORK REPAIR WORK
The relevant protection and repair Based on the relevant principles Complete records of all the materials
principles will be defined from selected from EN 1504, the appropriate used in the works shall be provided for
EN 1504-9 and the repair options method of work is then based on: future reference at the end of each
contained in the management n Site access project.
strategy. n Site conditions (e.g. selection of These shall include the answer to these
appropriate repair method patch following issues:
The design philosophy for repair shall repair, pouring or spray application) n What is the anticipated new life
take into consideration the following: n Health and safety issues, etc. expectancy?
nT ype, causes and extend of defects n What is the mode and result of
nF uture service conditions The surface preparation, application the selected materials eventual
nF uture maintenance program and Quality Control procedure for the deterioration, i.e. chalking,
repair works shall be carried out in embrittlement, discolouration or
Following the selection of the relevant accordance with the recommendations delamination?
principles from EN 1504-9, the Design contained in Part 10 of EN 1504. n What is the inspection period?
Engineer shall also consider the n What remedial work might be
intended use of the structure. required in case of deterioration?
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The Repair & Protection of Reinforced Concrete with Sika 7
THE ROOT CAUSE(S) OF CONCRETE
DAMAGE AND DETERIORATION
Assessment from the Condition Survey and the Results of Laboratory Diagnosis
CHEMICAL ATTACK
Aggressive chemical
Exposure Principles 1,2,6
Bacterial or other
biological action Principles 1,2,6
Efflorescence /
leaching Principles 1,2
PHYSICAL ATTACK
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8 The Repair & Protection of Reinforced Concrete with Sika
CONCRETE DAMAGE DUE TO STEEL
REINFORCEMENT CORROSION
CHEMICAL ATTACK
Cause Relevant principles for
repair and protection
Carbon dioxide (CO ) in the
atmosphere reacting with calcium Principles 1,2,3,7,8,11
hydroxide in the concrete pore
liquid.
CO + Ca (OH) CaCO + H O
Soluble and strongly alkaline pH
1213 almost insoluble and much
less alkaline pH 9
Steel protected (passivation)
steel unprotected
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The Repair & Protection of Reinforced Concrete with Sika 9
AN OVERVIEW OF THE PRINCIPLES OF
CONCRETE REPAIR AND PROTECTION
ACCORDING TO EN 1504-9
The repair and protection of concrete structures require relatively complex assessment and design.
By introducing and defining the key principles of repair and protection, EN 1504-9 helps owners and
construction professionals to fully understand the problems and solutions throughout the different
stages of the repair and protection process.
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10 The Repair & Protection of Reinforced Concrete with Sika
THE PRINCIPLES RELATING TO THE PRINCIPLES RELATING TO STEEL
CONCRETE DEFECTS REINFORCEMENT CORROSION
Principle 2 (MC)
Moisture control
Principle 8 (IR)
Increasing resistivity
Principle 3 (CR)
Concrete restoration
Principle 9 (CC)
Cathodic control
Principle 4 (SS)
Structural
strengthening
Principle 10 (CP)
Cathodic protection
Principle 5 (PR)
Increasing physical
resistance
Principle 11 (CA)
Control of anodic areas
Principle 6 (RC)
Resistance to chemicals
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The Repair & Protection of Reinforced Concrete with Sika 11
THE PRINCIPLES OF CONCRETE
REPAIR AND PROTECTION
Expertise and Experience from Sika
WHY PRINCIPLES?
For many years the different types of damage and the root causes of this damage
have been well known and equally the correct repair and protection methods have
also been established. All of this knowledge and expertise is now summarized
and clearly set out as 11 Principles in EN 1504, Part 9. These allow the Engineer to
correctly repair and protect all of the potential damage that can occur in reinforced
concrete structures. Principles 1 to 6 relate to defects in the concrete itself, Principles
7 to 11 relate to damage due to reinforcement corrosion.
The European Union fully introduced all of the European Standards 1504 on 1st
January 2009. These Standards define the assessment and diagnostic work required,
the necessary products and systems including their performance, the alternative
procedures and application methods, together with the quality control of the
materials and the works on site.
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12 The Repair & Protection of Reinforced Concrete with Sika
THE SIKA SOLUTIONS IN ACCORDANCE WITH EN 1504
Sika is a global market and technology leader in the development and production
of specialist products and systems for construction. The "Repair and Protection"
of concrete structures is one of Sikas core competencies, with the Sika range
including concrete admixtures, resin flooring and coating systems, all types of
waterproofing solutions, sealing, bonding and strengthening solutions, as well as
the complete range of products developed specifically for the repair and protection
of concrete structures. These Sika products have all relevant international
approvals and are available worldwide through the local Sika companies and our
specialist contracting and distribution partners.
During the past 100 years, Sika has gained extensive experience and expertise in
all aspects of concrete repair and protection, with documented project references
dating back to the 1920s. Sika provides ALL of the necessary products for the
technically correct repair and protection of concrete, ALL of which are fully in
accordance with the Principles and Methods now defined in European Standards
EN 1504. These include systems to repair damage and defects in the concrete
and also to repair damage caused by steel reinforcement corrosion. Special Sika
products and systems are also available for use on many different specific types
of structures and for carrying out concrete repair works in all different application,
climatic and exposure conditions.
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The Repair & Protection of Reinforced Concrete with Sika 13
AN OVERVIEW OF THE PRINCIPLES
AND METHODS OF REPAIR AND
PROTECTION FROM EN 1504-9
Tables 1 and 2 include all of the repair Principles and Methods in accordance with Part 9 of EN 1504.
Following assessment from the condition survey and diagnosis of the root causes of damage, together with the owners repair
objectives and requirements, the appropriate EN1504 repair Principles and Methods can be selected.
PRINCIPLE 1 Protection against 1.1 Hydrophobic Impregnations Sikagard range of hydrophobic impregnations
(PI) ingress. 1.2 Impregnations Sikafloor range of impregnations
Reducing or preventing 1.3 Coatings Sikagard range of elastic and rigid coatings Sikafloor
the ingress of adverse range for flooring applications
agents, e.g. water, other 1.4 Surface bandaging of cracks Sikadur Combiflex System, and Sika SealTape
liquids, vapour, gas, 1.5 Filling of cracks Sika Injection systems, Sikadur range
chemicals and biological 1.6 Transferring cracks into joints Sikaflex range, Sikadur-Combiflex System
agents. 1.7 Erecting external panels SikaTack-Panel System
1.8 Applying membranes Sikaplan sheet membranes, Sikalastic liquid membranes
PRINCIPLE 2 Moisture control. 2.1 Hydrophobic impregnations Sikagard range of hydrophobic impregnations
(MC) Adjusting and 2.2 Impregnations Sikafloor range of impregnations
maintaining the 2.3 Coatings Sikagard range of elastic and rigid coatings Sikafloor
moisture content in range for flooring applications
the concrete within a 2.4 Erecting external panels SikaTack-Panel System
specified range of values. 2.5 Electrochemical treatment A process
PRINCIPLE 3 Concrete restoration. 3.1 Hand applied mortar Sika MonoTop, SikaTop, SikaQuick Sikadur and SikaRep
(CR) Restoring the original range
concrete to the originally 3.2 Recasting with concrete or Sika MonoTop range, SikaGrout range
specified profile and mortar
function. 3.3 Spraying concrete or mortar SikaCem, Sikacrete-Gunite ranges, SikaRep and Sika
Restoring the concrete MonoTop systems
structure by replacing 3.4 Replacing elements Sika bonding primers and Sika concrete technology
part of it.
PRINCIPLE 6 Resistance to chemicals. 6.1 Coatings Sikagard and Sikafloor reactive coatings range
(RC) Increasing resistance
6.2 Impregnations
of the concrete surface As for Methods 3.1, 3.2 and 3.3
6.3 Adding mortar or concrete
to deteriorations from
chemical attack.
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14 The Repair & Protection of Reinforced Concrete with Sika
TABLE 2: PRINCIPLES AND METHODS RELATED TO STEEL REINFORCEMENT CORROSION
PRINCIPLE 7 Preserving or restoring passivity. 7.1 Increasing cover with additional mortar Sika MonoTop, SikaTop, SikaCem, Sikacrete,
(RP) Creating chemical conditions or concrete SikaRep and Sika EpoCem range
in which the surface of the
reinforcement is maintained in or 7.2 Replacing contaminated or carbonated As for Methods 3.2, 3.3, 3.4
is returned to a passive condition. concrete
PRINCIPLE 8 (IR) Increasing resistivity. 8.1 Hydrophobic impregnations Sikagard range of hydrophobic impregnations
Increasing the electrical resistivity
of the concrete. 8.2 Impregnations Sikafloor range of impregnations
PRINCIPLE 9 (CC) Cathodic control. 9.1 Limiting oxygen content (at the Sika FerroGard admixtures and surface applied
Creating conditions in which cathode) by saturation or surface coating corrosion inhibitors
potentially cathodic areas of Sikagard and Sikafloor reactive
reinforcement are unable to coatings range
drive an anodic reaction. Sikadur-32 reactive coatings
PRINCIPLE 10 Cathodic protection. 10.1 Applying an electrical potential Sika overlay mortars
(CP)
Principle 11 (CA) Control of anodic areas. 11.1 Active coating of the reinforcement SikaTop Armatec-110 EpoCem,
Creating conditions in which Sika MonoTop-910
potentially anodic areas of 11.2 Barrier coating of the reinforcement Sikadur-32
reinforcement are unable to take
11.3 Applying corrosion inhibitors in or to Sika FerroGard admixtures and
part in the corrosion reaction.
the concrete surface applied corrosion inhibitors
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EN 1504-9 PRINCIPLE 1:
PROTECTION AGAINST INGRESS (PI)
Protecting the Concrete Surface against Liquid and Gaseous Ingress
Sikafloor-CureHard-24
An impregnation is defined as the treatment of concrete Penetration depth:
nS odium silicate base
to reduce the surface porosity and to strengthen the 5 mm
nE xcellent abrasion and surface hardening
surface. The pores and capillaries are then partly or totally nG reater densification capacity
filled. Capillary absorption:
This type of treatment usually also results in a w <0.1 kg/(m h)
Sikafloor-CureHard-LI
discontinuous thin film of 10 to 100 microns thickness on n L ithium silicate base
the surface. n Increased penetration and aesthetics
This serves to block the pore system to aggressive agents. nR educed application costs
Refer to local availability
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EN 1504-9 PRINCIPLE 1:
PROTECTION AGAINST INGRESS (PI)
Protecting the Concrete Surface against Liquid and Gaseous Ingress (continued)
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18 The Repair & Protection of Reinforced Concrete with Sika
DESCRIPTION MAIN CRITERIA SIKA PRODUCTS (EXAMPLES)
Cracks to be treated to prevent the passage of aggressive Classification of Waterproof Sealing of Joints/Cracks/Voids:
agents should be filled and sealed. injection Class D:
materials: Sika Injection-201/-203
Non-moving cracks These are cracks that have been D: ductile
formed by initial shrinkage for example, they need only to S: swelling Class S:
be fully exposed and repaired / filled with a suitable repair Sika Injection-29/-304/-305
material.
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EN 1504-9 PRINCIPLE 2:
MOISTURE CONTROL (MC)
Adjusting and Maintaining the Moisture Content in the Concrete
TO BE PROTECTED AGAINST
WATER PENETRATION.
For many years, Sika has been one of the Corresponding part of the Standards: EN
pioneers in concrete protection through the 1504-2
use of deeply penetrating silane and siloxane
hydrophobic impregnations, plus durable
acrylic and other resin based protective
coatings.
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20 The Repair & Protection of Reinforced Concrete with Sika
DESCRIPTION MAIN CRITERIA SIKA PRODUCTS (EXAMPLES)
A hydrophobic impregnation is defined as the treatment Penetration: Sikagard-700 range
of concrete to produce a water-repellent surface. The Class I: <10 mm n Based on silane or siloxane hydrophobic
pores and capillary network are not filled, but only lined Class II: 10 mm impregnations
with the hydrophobic material. This function by reducing n Penetrate deeply and provide a liquid
the surface tension of liquid water, thus preventing its Capillary absorption: water repellent surface
passage through the pores, but still allowing each way w <0.1 kg/(m h)
Sikagard-706 Thixo (Class II)
water vapour diffusion, which is in accordance with
Sikagard-705 L (Class II)
standard good practice in building physics. Drying rate coefficient
Sikagard-704 S (Class I)
Sikagard-740 W (Class I)
Sikagard-700 S (Class I)
Sikafloor-CureHard-24
An impregnation is defined as the treatment of concrete Penetration depth:
n Sodium silicate base
to reduce the surface porosity and to strengthen the 5 mm
n Excellent abrasion and surface hardening
surface. The pores and capillaries are then partly or totally
n Greater densification capacity
filled. Capillary absorption:
This type of treatment usually also results in a discon- w <0.1 kg/(m h) Sikafloor-CureHard-LI
tinuous thin film of 10 to 100 microns thickness on n Lithium silicate base
the surface. This serves to block the pore system to n Increased penetration and aesthetics
aggressive agents. n Reduced application costs
Refer to local availability
Surface coatings are defined as materials designed to Capillary absorption: Rigid systems:
provide an improved concrete surface, for increased w <0.1 kg/(m h) Sikagard-680 S
resistance or performance against specific external n Acrylic resin, solvent based
influences. n Waterproof
Fine surface cracks with a total movement of up to Water vapour Elastic systems:
0.3 mm can be safely repaired, then sealed and their permeability: Sikagard-550 Elastoflex W
movement accommodated by crack bridging coatings Class I: Sd <5 m n Acrylic resin, water based
which are also for waterproof and carbonation resistant. n Waterproofing and crack-bridging
Adhesion strength:
Sikagard-545 Flexfill W
This is to accommodate thermal and dynamic movement Elastic: 0.8 N/mm or
n One component acrylic resin
in structures subject to wide temperature fluctuation, 1.5 N/mm
n Elastic
vibration, or that have been constructed with inadequate (trafficking)
or insufficient jointing details. Sikagard-675 Color W
Rigid: 1.0 N/mm or n Acrylic resin, water based
2.0 N/mm n Waterproof
(trafficking) Sikagard-674 Lazur W
n Acrylic resin
n Clear glaze
As long as the concrete surface is not exposed, no water No specific criteria SikaTack-Panel System
can penetrate and the reinforcement can not corrode. nF or the discrete or secret fixing of
curtain wall faade systems
nO ne-component polyurethane
By applying an electric potential in the structure, moisture No specific criteria This is a process
can be moved towards the negatively charged cathode
area.
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The Repair & Protection of Reinforced Concrete with Sika 21
EN 1504-9 PRINCIPLE 3:
CONCRETE RESTORATION (CR)
Replacing and Restoring Damaged Concrete
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22 The Repair & Protection of Reinforced Concrete with Sika
METHODS DESCRIPTION MAIN SIKA PRODUCTS
CRITERIA (EXAMPLES)
Method 3.1 Hand- Traditionally the localised repair of concrete Structural repair: Class R4:
applied mortar defects and damage has been undertaken Class R4 Sika MonoTop-412 range
using hand-placed repair mortars. Sika Class R3 nH igh performance repair mortar
Corresponding part provides an extensive range of pre-batched, nE xtremely low shrinkage behavior
of the Standards: EN hand-applied repair mortars for general repair Non structural
1504-3 purposes and also for very specific repair repair: Class R3:
requirements. These include lightweight Class R2 Sika MonoTop-352 range
mortars for overhead application and Class R1 n Extremely low shrinkage behavior
chemically resistant materials to protect n Lightweight repair mortar
against aggressive gases and chemicals.
Typical recasting repairs, which are also Structural repair: Class R2:
Method 3.2 R ecasting frequently described as pourable or grouting Class R4 Sika MonoTop-211 range
with concrete or mortar repairs, are employed when whole sections Class R3 n Fast setting repair mortar
or larger areas of concrete replacement are n Corrosion inhibitor inside
Corresponding part required. These include the replacement of (FerroGard-
of the Standards: EN all, or substantial sections of, concrete bridge Technology)
1504-3 parapets and balcony walls etc.
Class R2:
This method is also very useful for complex Sikadur-43 HE range
structural supporting sections, such as cross n Epoxy based filling mortar
head beams, piers and column sections, which nN on shrink
often present problems with restricted access
and congested reinforcement. Class R4:
Sika MonoTop-438 R
The most important criteria for the successful n One component
application of this type of product is its n Pourable
flowability and the ability to move around n Rapid hardening
obstructions and heavy reinforcement.
Additionally they often have to be poured in SikaGrout-318
relatively thick sections without problems of nH igh final strengths
thermal shrinkage cracking. This is to ensure nE xpands during the plastic phase
that they can fill the desired volume and areas of
completely, despite the restricted access or curing
application points. Finally they must also nE xcellent flow characteristics
harden to provide a suitably finished surface,
which is tightly closed and free of cracks. Sikafloor-82/-83 EpoCem
nE poxy modified cement mortar
nH igh performance characteristics
* This table is continued on pages 22 and 23. n Temporary moisture barrier
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The Repair & Protection of Reinforced Concrete with Sika 23
EN 1504-9 PRINCIPLE 3:
CONCRETE RESTORATION (CR)
Replacing and Restoring Damaged Concrete (continued)
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24 The Repair & Protection of Reinforced Concrete with Sika
METHODS DESCRIPTION MAIN SIKA PRODUCTS
CRITERIA (EXAMPLES)
Method 3.3 Spraying Spray applied materials have also been Structural repair: Class R4:
concrete or mortar used traditionally for concrete repair works. Class R4 SikaCem Gunit-133
They are particularly useful for large volume Class R3 nH igh performance repair mortar
Corresponding part of the concrete replacement, for providing additional n Very dense, high carbonation resistance
Standards: EN 1504-3 concrete cover, or in areas with difficult access n Dry spray mortar
for concrete pouring or the hand placement of
repairs. Sika MonoTop-412 range
n High performance repair mortar
Today in addition to traditional dry spray n Extremely low shrinkage behaviour
machines, there are also wet spray machines. n Applied by hand or wet spray applied
These have a lower volume output, but also
much lower rebound, plus they produce less Class R3:
dust than the dry spray machines. Therefore Sikacrete-103 Gunit
they can also be used economically for smaller n One-component
or more sensitive repair areas, where there is n Contains silica fume
restricted access, or in confined environments. n Dry spray mortar
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EN 1504-9 PRINCIPLE 4:
STRUCTURAL STRENGTHENING (SS)
Increasing or Restoring the Structural Load Capacity
The selection of the appropriate size and configuration No specific criteria For embedded bars:
of such reinforcement, plus the locations where it is to Sikadur-30
be fixed, must always be determined by the structural nS tructural adhesive
engineer. nH igh mechanical strength
nE xcellent bond characteristics
The points for anchorages into the concrete should be Pull-out: SikaAnchorFix-1
designed, produced and installed in accordance with Displacement 0.6 mm nF ast setting methacrylate based anchoring
EN 1504 Part 6 and the relevant European Technical at load of 75 kN adhesive
Approval Guideline (ETAG-001). The surface cleanliness nC an be used at low temperatures (-10 C)
of the grooves or anchor holes cut in the concrete Creep under tensile
should be prepared to be in accordance with EN 1504 load: SikaAnchorFix-2
Part 10 Sections 7.2.2 and 7.2.3. Displacement 0.6 mm nE TA approved for structural applications
after continuous nF ast and secure bonding of additional steel
loading reinforcement into concrete structures
of 50 kN after 3 month
SikaAnchorFix-3+
Chlorid ion content: nH igh performance epoxy adhesive
0.05% nS hrink-free hardening
Sikadur-42
nE poxy grout system
n Non-shrink
These methods and Sika systems are well documented Mortar/Concrete: Repair mortars:
in Principle 3 Concrete restoration. To ensure the Class R4 or R3 Sika MonoTop-412 /-352 range
necessary performance, these products also have to
fulfill the requirements of EN 1504-3, class 3 or 4. Sikafloor-82/-83 EpoCem
Sikadur-41 CF
nE poxy based patching mortar
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EN 1504-9 PRINCIPLE 4:
STRUCTURAL STRENGTHENING (SS)
Increasing or Restoring the Structural Load Capacity (continued)
restressing (post
Method 4.7 P
tensioning)
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28 The Repair & Protection of Reinforced Concrete with Sika
DESCRIPTION MAIN CRITERIA SIKA PRODUCTS (EXAMPLES)
The cracks should be cleaned and prepared in accordance Classification of Sikadur-52 Injection
with the guidelines of EN 1504 Part 10 Section 7.2.2. injection material: n Two-component epoxy resin
Then the most suitable Sika system for resealing and F: transmitting force / n Low viscosity
bonding can be selected to fully reinstate the structural load transfer
integrity. Sikadur-53
n Two-component epoxy resin
n Insensitive to humidity
Sika Injection-451
nH igh strength structural epoxy resin
n Very low viscosity
Sika InjectoCem-190
n Two part micro-cement injection
n Corrosion protection of embedded
reinforcement
When inert cracks, voids or interstices are wide enough, Classification of Sikadur-52 Injection
they can filled by gravity (pouring) or by using an epoxy injection material: n Two-component epoxy resin
patching mortar. n Low viscosity
F: transmitting force /
load transfer Sikadur-53
n Two-component epoxy resin
n Insensitive to humidity
Sika Injection-451
nH igh strength structural epoxy resin
n Very low viscosity
Sika InjectoCem-190
n Two part micro-cement injection
n Corrosion protection of embedded
reinforcement
Sikadur-31
n Two part epoxy adhesive
n High strengths
n Thixotropic: non sag-flow in vertical or
overhead applications
Pre-stressing: with this method the system involves No specific criteria Carbon fibre prestressing systems:
applying forces to a structure to deform it in such a way Sika CarboStress system
that it will withstand its working loads more effectively,
or with less total deflection. (Note: post-tensioning is Traditional bonded prestressing systems:
a method of pre-stressing a poured in place concrete SikaGrout-300 PT
structure after the concrete has hardened).
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EN 1504-9 PRINCIPLE 5:
PHYSICAL RESISTANCE (PR)
Increasing the Concretes Resistance to Physical and/or Mechanical Attack
Method 5.3 A
dding mortar or concrete
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30 The Repair & Protection of Reinforced Concrete with Sika
DESCRIPTION MAIN CRITERIA SIKA PRODUCTS (EXAMPLES)
Only reactive coatings are able to provide sufficient Abrasion (Taber-Test): Class II:
additional protection for the concrete to improve its mass-lost <3000 mg Sikafloor-261/-263 SL
resistance against physical or mechanical attack. n Good chemical and mechanical
Capillary absorption: resistance
w <0.1 kg/(m h) n E xcellent abrasion resistance
n Solvent free
Impact resistance:
Class I to Class III Class I:
Sikafloor-2530 W
Adhesion strength: n Two part, water dispersed epoxy resin
Elastic: 0.8 N/mm or n Good mechanical and chemical
1.5 N/mm resistance
(trafficking)
Sikafloor-390
Rigid: 1.0 N/mm or n High chemical resistance
2.0 N/mm n Moderate crack-bridging capability
(trafficking)
The Methods to be used and suitable systems for this Mortar/Concrete: Class R4:
are defined in Principle 3 Concrete restoration and the Class R4 Sika MonoTop-412 range
products have to fulfill the requirements of EN 1504- Class R3 nV ery low shrinkage
3, Class R4 or R3. In some specific instances products nO ne component repair mortar
may also need to fulfill additional requirements such
as resistance to hydraulic abrasion. The engineer must Sikafloor-82/-83 EpoCem
therefore determine these additional requirements on n Epoxy modified cement mortar
each specific structure. n High frost and deicing salt resistance
Sika Abraroc
n High mechanical strength
n Excellent abrasion resistance
SikaGrout range
n High performance levelling mortar
n Excellent flow characteristics
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EN 1504-9 PRINCIPLE 6:
CHEMICAL RESISTANCE (RC)
Increasing the Concretes Resistance to Chemical Attack
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32 The Repair & Protection of Reinforced Concrete with Sika
DESCRIPTION MAIN CRITERIA SIKA PRODUCTS (EXAMPLES)
Only high performance reactive coatings are able to Resistance to strong Class II:
provide sufficient protection to concrete and improve its chemical attack: Sikagard-63 N
resistance to chemical attack. Class I to Class III n Two part epoxy resin with good
chemical and mechanical resistance
Adhesion strength: n T ightly cross-linked surface
Elastic: 0.8 N/mm or
1.5 N/mm Sikafloor-390
(trafficking) n High chemical resistance
n Moderate crack-bridging behaviour
Rigid: 1.0 N/mm or
2.0 N/mm Class I:
(trafficking) Sikafloor-261/-263 SL
n Good chemical and mechanical
resistance
n E xcellent abrasion resistance
n Solvent free
The Methods and systems required are defined in No specific criteria Sikagard-720 EpoCem,
Principle 3, Sikafloor-81/-82/-83 EpoCem
Concrete restoration. To be able to resist a certain level n Epoxy modified cement mortars
of n Good chemical resistance
chemical attack, cement based products need to be n Very dense and watertight
formulated with special cements and/or combined with
epoxy resins.
The engineer has to define these specific requirements
on each structure.
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EN 1504-9 PRINCIPLE 7: PRESERVING
OR RESTORING PASSIVITY (RP)
Treating or Replacing Concrete Surrounding the Reinforcement
lectrochemical chloride
Method 7.5 E
extraction
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34 The Repair & Protection of Reinforced Concrete with Sika
DESCRIPTION MAIN CRITERIA SIKA PRODUCTS (EXAMPLES)
If the reinforcement does not have adequate concrete cover, then by Carbonation resistance: Class R4:
adding cementitious mortar or concrete the chemical attack (e.g. from Class R4 or R3 Sika MonoTop-412 range
carbonation or chlorides) on the reinforcement will be reduced. Sikacrete-103 Gunit
Compressive strength: SikaTop-121/-122
Class R4 or R3 Sikafloor-82 EpoCem
Through removing damaged concrete and rebuilding the concrete cover Carbonation resistance: Class R4:
over the reinforcement, the steel is again protected by the alkalinity of Class R4 or R3 Sika MonoTop-412 range
its surroundings. Sikacrete-103 Gunit
Compressive strength:
Class R4 or R3 Class R3:
Sika MonoTop-352 range
Adhesive bond:
Class R4 or R3 Sika concrete technology for
quality concrete replacement:
Sika ViscoCrete
Sikament
There is limited long term experience with this method. It requires No specific criteria For post-treatment:
the application of a very alkaline coating over the carbonated concrete Sikagard-720 EpoCem
surface and the realkalisation is achieved by the slow diffusion of the
alkali through the carbonated zone. This process takes a very long time For post-treatment:
and it is very difficult to control the right distribution of the material. Sikagard-680 S
After treatment, it is also always recommended to prevent further
carbonation by applying a suitable protective coating.
The electrochemical chloride extraction process is very similar in nature No specific criteria For post-treatment:
to cathodic protection. The process involves the application of an penetrating hydrophobic
electrical current between the embedded reinforcement and an anode impregnation with Sikagard-705
mesh placed at the outer surface of the concrete structure. As a result, L or
the chlorides are driven out toward the surface. Sikagard-706 Thixo
Once the treatment is completed, the concrete structure has to be plus protective coating
protected with a suitable treatment to prevent the further ingress of Sikagard-680 S
chlorides (post treatment).
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EN 1504-9 PRINCIPLE 8:
INCREASING RESISTIVITY (IR)
Increasing the Electrical Resistivity of the Concrete to reduce the Risk of Corrosion
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36 The Repair & Protection of Reinforced Concrete with Sika
METHODS DESCRIPTION MAIN SIKA PRODUCTS
CRITERIA (EXAMPLES)
Method 8.1 H
ydrophobic A hydrophobic impregnation is defined Penetration: Sikagard-700 range
Impregnation as the treatment of concrete to produce Class I: <10 mm n Based on silane hydrophobic
a water-repellent surface. The pores and Class II: 10 mm n Penetrate deeply and provide a
Corresponding part of the capillary network are not filled, but only liquid--water repellent surface
Standards: EN 1504-2 lined with the hydrophobic material. These Drying rate coefficient:
function by reducing the surface tension of Class I: >30% Sikagard-706 Thixo (Class II)
liquid water, thus preventing its passage Class II: >10% Sikagard-705 L (Class II)
through the pores, but still allowing each Sikagard-704 S (Class I)
way water vapour diffusion, which is in Water absorption and Sikagard-740 W (Class I)
accordance with standard good practice in resistance to alkali:
building physics. absorption rate: <7.5%
alkali solution: <10%
Method 8.3 C
oating Surface coatings are defined as materials Capillary absorption: Rigid systems:
designed to provide an improved concrete w <0.1 kg/(m h) Sikagard-680 S
Corresponding part of the surface, for increased resistance or n Acrylic resin
Standards: EN 1504-2 performance against specific external Water vapour n Waterproof
influences. Fine surface cracks with a permeability:
total movement of up to 0.3 mm can Class I: Sd <5 m Sikagard Wallcoat T
be safely repaired, then sealed and their Class II: 5 m Sd 50 m n Two part epoxy resin
movement accommodated by elastic, Class III: Sd >50 m n Water barrier
crack bridging coatings, which are also
Adhesion strength:
waterproof and carbonation resistant. This Elastic systems:
Elastic: 0.8 N/mm or
is to accommodate thermal and dynamic Sikagard-550 Elastoflex W
1.5 N/mm
movement in structures subject to wide n Acrylic resin
(trafficking)
temperature fluctuation, vibration, or that n Waterproofing and Elastic (crack-
have been constructed with inadequate or Rigid: 1.0 N/mm or bridging)
insufficient jointing details. 2.0 N/mm
(trafficking)
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The Repair & Protection of Reinforced Concrete with Sika 37
EN 1504-9 PRINCIPLE 9:
CATHODIC CONTROL (CC)
Preventing Corrosion of the Steel Reinforcement
Method 9.1 L imiting oxygen Creating conditions in which any Sika Corrosion inhibitors:
content (at the potentially cathodic areas recommendation Sika FerroGard-901
cathode) by of the reinforcement are unable to of: (admixture)
surface saturation drive an anodic reaction. >100 ppm (parts
and surface per Sika FerroGard-903+
coating. Although not mention on the standard million) (surface applied)
as method 9.1, inhibitors (added to concentration of
Corresponding part of the the concrete as admixtures or surface corrosion inhibitor n Amino alcohol based inhibitors
Standards: None applied on the hardened concrete as at the n Long term protection and durability
an impregnation) form a continious rebar level in n Economic extension of the service
film on the surface of the steel the presence of life of reinforced concrete structures
reinforcement which acts as a barrier chlorides.
to oxygen.
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38 The Repair & Protection of Reinforced Concrete with Sika
EN 1504-9 PRINCIPLE 10:
CATHODIC PROTECTION (CP)
Preventing Corrosion of the Steel Reinforcement
PRINCIPLE 10 REFERS TO
CATHODIC PROTECTION
SYSTEMS. THESE ARE
ELECTROCHEMICAL SYSTEMS
WHICH DECREASE THE
CORROSION POTENTIAL TO
A LEVEL WHERE THE RATE
OF THE REINFORCING STEEL
DISSOLUTION IS SIGNIFICANTLY
REDUCED.
This can be achieved by creating a direct
electric current flow from the surrounding
concrete to the reinforcing steel, in order to
eliminate the anodic parts of the corrosion
reaction. This current is provided by an
external source (Induced Current Cathodic
Protection), or by creating a galvanic
current through connecting the steel to a
less noble/more reactive metal (galvanic
anodes e.g. zinc).
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The Repair & Protection of Reinforced Concrete with Sika 39
EN 1504-9 PRINCIPLE 11:
CONTROL OF ANODIC AREAS (CA)
Preventing Corrosion of the Steel Reinforcement
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40 The Repair & Protection of Reinforced Concrete with Sika
DESCRIPTION MAIN CRITERIA SIKA PRODUCTS (EXAMPLES)
These coatings contain active pigments that can Compliance with Cement based:
function as an inhibitor or/and provide a passive EN 1504-7
environment due to their alkalinity. Although care Sika MonoTop-910 N
must be taken to apply them properly, they are less
sensitive to application defects than barrier coatings. n 1-component corrosion protection
n Good resistance to water and chloride
penetration
nH
igh density, suitable for demanding
environments
nE
xcellent adhesion to steel and
concrete
These barrier coatings work by completely isolating Compliance with Epoxy based:
the reinforcement from oxygen or water. Therefore EN 1504-7 Sikadur-32
they require higher levels of surface preparation and n Low sensitivity to moisture
application control. This is because they can only be n Very dense, no chloride penetration
effective if the steel is completely free from corrosion
and fully coated without any defects this can be very
difficult to achieve in site conditions. Any effective
reduction in the bonding of the repair material to the
treated reinforcement should also be considered.
Applying corrosion inhibitors to the concrete surface, Sika recommendation of: Corrosion inhibitors:
they diffuse to the reinforcement and form a >100 ppm (parts per Sika FerroGard-901
protective layer on the surface of the bars. These million) concentration of (admixture)
corrosion inhibitors can also be added as admixtures corrosion inhibitor at the
to the repair mortar or concrete that is used for the rebar level in the Sika FerroGard-903+
concrete reinstatement works. presence of chlorides. (surface applied)
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The Repair & Protection of Reinforced Concrete with Sika 41
SUMMARY FLOW CHART & PHASES
OF THE CORRECT CONCRETE REPAIR
AND PROTECTION PROCEDURE
In Accordance with European Standards EN 1504
THE PHASES OF CONCRETE REPAIR AND PROTECTION PROJECTS IN ACCORDANCE WITH EN 1504 PART 9
See more details on page 4 See more details on page 6/7 See more details on page 42 45
FLOW CHART OF CONCRETE REPAIR AND PROTECTION PROCEDURE WITH THE SIKA SYSTEMS
S
Y
U Visible Carry out Concrete
R cracking and
Y Condition
root cause
Structural
repair
survey assessment
V staining analysis necessary?
E
Y N N
Y
Any
latent Y Define the Any actions
damage? further life cycle required?
Check of necessary
N
N concrete or
steel protection
Continue
regular
monitoring
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42 The Repair & Protection of Reinforced Concrete with Sika
Design of Repair Work Repair Work Acceptance of Repair Work
EN 1504 Parts 27 and EN 1504-9, EN 1504-9, Clause 9 and 10 and EN 1504-9, Clause 8 and
Clauses 6, 7 and 9 EN 1504-10 EN 1504-10
See more details on page 12 39 See more details on page 46 47 See more details on page 5
H
Specify bonding Create
Structural Y primer (as Apply structural repair mortar N A
maintenance Final
concrete required) n Sika MonoTop (class R4)
management inspection N
repair n Sika MonoTop (class R3)
and repair mortar strategy? D
(Class R3 or R4)
O
N Specify Apply structural repair mortar Y V
repair mortar n Sika MonoTop (class R2) E
(Class R2 or R1) n Sika MonoTop (class R1)
R
Set up corrosion
monitoring
system
Apply
Crack-
Enhance Y bridging
n Sikagard elastic coatings
appearance? n Sikalastic membranes
abilities
n Sikafloor elastic coatings
needed?
n Sikaflex joint sealants
N N Apply
n Sikagard coatings
n Sikafloor coatings
n SikaCor steel coatings
Apply
n Sika FerroGard inhibitors and/or
n Sikagard hydrophobic
impregnations
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The Repair & Protection of Reinforced Concrete with Sika 43
SELECTION OF THE METHODS TO BE
USED FOR CONCRETE REPAIR
IN THE MATRIX TABLES BELOW THE MOST COMMON DEFECTS AND DAMAGE OF CONCRETE STRUCTURES
AND THEIR POSSIBLE REPAIR METHODS ARE LISTED. THIS LIST IS INTENDED TO BE INDICATIVE RATHER
THAN EXHAUSTIVE. THE REPAIR PROPOSALS MUST BE CUSTOMISED ACCORDING TO THE SPECIFIC
CONDITIONS ON EACH PROJECT. DEVIATIONS FROM THIS MATRIX OF OUTLINE RECOMMENDATIONS ARE
THEREFORE POSSIBLE AND THESE MUST BE DETERMINED INDIVIDUALLY FOR EACH SITUATION. THE
NUMBERS INDICATED IN THE TABLES ARE REFERENCE TO THE RELEVANT PRINCIPLES AND METHODS
DEFINED IN EN 1504-9.
DAMAGE TO CONCRETE
CONCRETE MINOR DAMAGE MEDIUM DAMAGE HEAVY DAMAGE
DEFECTS/DAMAGE
Concrete cracks 1.5 Filling of cracks 1.5 Filling of cracks 4.5 Injecting cracks, voids
or interstices
1.6 T
ransferring cracks 4.6 F illing cracks, voids
into joints or interstices
Scaling from Freeze/ 3.1 Hand applied mortar 5.1 Coating (cement based) 5.3 Adding mortar or concrete
Thaw action
5.1 Coating (cement 5.3 A
dding mortar or concrete
based)
Damage from chemical 6.1 Coating (cement 6.1 Coating (cement based) 6.3 A
dding mortar or concrete
attack based) 6.3 A
dding mortar or concrete 3.2 R
ecasting with concrete or
mortar
3.3 S
praying concrete or mortar
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44 The Repair & Protection of Reinforced Concrete with Sika
DAMAGE DUE TO REINFORCEMENT CORROSION
CONCRETE MINOR DAMAGE MEDIUM DAMAGE HEAVY DAMAGE
DEFECTS/DAMAGE
Concrete spalling due to 3.1 Hand applied mortar 3.1 Hand applied mortar 3.2 Recasting with concrete or mortar
carbonation and
3.2 Recasting with concrete 4.1 Adding or replacing embedded or
or mortar external reinforcing bars
3.3 Spraying concrete or mortar
3.3 S
praying concrete
and
or mortar
4.2 Adding reinforcement anchored in pre-
formed or drilled holes
7.2 Replacing contaminated or carbonated
concrete
Stray electrical currents 3.1 Hand applied mortar 3.2 Recasting with concrete 3.2 R
ecasting with concrete or mortar
or mortar and
3.2 Recasting with 4.2 A
dding reinforcement anchored in pre-
concrete or mortar 3.3 Spraying concrete or formed or drilled holes
mortar
3.3 Spraying concrete or mortar
and
4.1 Adding or replacing embedded or
external reinforcing bars
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The Repair & Protection of Reinforced Concrete with Sika 45
SELECTION OF THE METHODS TO
BE USED FOR CONCRETE AND
REINFORCEMENT PROTECTION
THE OVERALL PROTECTION REQUIRED FOR CONCRETE STRUCTURES as well as that required for their
embedded steel reinforcement, is dependent on the type of structure, its environmental exposure and
location, its use and the selected maintenance strategy. Therefore protection proposals should be adapted to
individual structures, their specific conditions and their specific requirements.
Deviations from these outline recommendations are therefore possible and should always be determined on
each individual project.
The prefix numbers in the following tables are the references of the relevant Principles and Methods of EN
1504-9.
PROTECTION TO CONCRETE
Cracks 1.1 H
ydrophobic 1.1 Hydrophobic 1.1 H
ydrophobic impregnation
impregnation impregnation and
1.3 Coating (elastic)
1.3 C
oating 1.3 Coating (elastic)
1.8 A
pplying sheet or liquid membranes
Mechanical impact 5.2 Impregnation 5.1 Coating 5.3 Adding mortar or concrete
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46 The Repair & Protection of Reinforced Concrete with Sika
PROTECTION TO REINFORCEMENT
Carbonation 11.3 Applying corrosion 1.3 Coating 11.3 Applying corrosion inhibitors in or to
inhibitors in or to the the concrete
concrete 7.3 E
lectrochemical and
realkalisation of 1.3 Coating
carbonated concrete
7.3 Electrochemical realkalization of
7.4 Realkalization of carbonated carbonated concrete
concrete by diffusion and
1.3 Coating
Chlorides 1.1 Hydrophobic 11.3 Applying corrosion inhibitors 7.5 Electrochemical chloride extraction
impregnation in or to the concrete and
and 1.3 Coating
1.2 Impregnation 1.1 Hydrophobic impregnation
7.5 Electrochemical chloride extraction
11.3 Applying corrosion and
inhibitors in or to the 11.2 Barrier coating of the reinforcement
concrete
and 10.1 Applying an electrical potential
1.3 Coating
Stray electrical If disconnection of the If disconnection of the If disconnection of the electrical
currents electrical current is not electrical current is not current is not possible:
possible: possible:
10.1 Applying an electrical potential
2.2 Impregnation 2.5 Electrochemical treatment
and
2.3 Coating
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The Repair & Protection of Reinforced Concrete with Sika 47
THE INDEPENDENT ASSESSMENT
AND APPROVALS OF SIKA
PRODUCTS AND SYSTEMS
Plus Testing and Proof Statements in Accordance with the Requirements of EN 1504
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48 The Repair & Protection of Reinforced Concrete with Sika
THE PERFORMANCE CRITERIA
Product and System Performance
There are functional and performance requirements which must
be met by both the individual products as components of a system
and the system functioning together as a whole.
For example:
Sika repair mortars must be suitable for use in differing
thicknesses, areas and volumes of repair, which need to be applied
in as few layers as possible. They must then rapidly become
weather resistant.
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ADDITIONAL PERFORMANCE
TESTING AND THE EXTENSIVE
INDEPENDENT DURABILITY
ASSESSMENTS OF SIKA PRODUCTS
AND SYSTEMS
CONCRETE REPAIR
Filled Baenziger
Block with crack
sensitive Mortar.
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50 The Repair & Protection of Reinforced Concrete with Sika
CONCRETE PROTECTION
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The Repair & Protection of Reinforced Concrete with Sika 51
EXAMPLES OF TYPICAL CONCRETE
DAMAGE AND ITS REPAIR AND
PROTECTION WITH SIKA SYSTEMS
oncrete
C Applying concrete or repair mortar by Concrete Applying concrete or repair mortar by
Spalling Hand or Spray Spalling Hand or Spray
Sika MonoTop -412 NFG Sika MonoTop -412 N
or Admixtures for concrete with
SikaCem -Gunit 133 Sika ViscoCrete
Admixtures for concrete with
Sika ViscoCrete xposed
E Protect the rebars from corrosion
Steel SikaTop Armatec -110 EpoCem, Sikadur -32
Exposed Protect the rebars from corrosion for highly corrosive environments
Steel SikaTop Armatec -110 EpoCem for highly
corrosive environments Cracks For non-moving cracks
Sikagard-720 EpoCem
Embedded Protection of the reinforcement by
Steel applying corrosion inhibitors For fine surface cracks
Sika FerroGard-903+ Sikafloor-390 Thixo
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The Repair & Protection of Reinforced Concrete with Sika 55
BUILDING TRUST FROM BASEMENT TO ROOF
SEALING & BONDING
STRUCTURAL GLAZING
FLOORING & COATINGS
ROOFING
TILING SYSTEMS
GREEN ROOFING
WATERPROOFING
REPAIR & PROTECTION
SEISMIC STRENGTHENING
CONCRETE
Sika 1282
You may know us for just one skill area. But Sika has over 100 years of global experience in providing
solutions for many crucial areas of construction, from basement to roof. And over 50 years of hands-on
experience on significant projects around New Zealand.
www.sika.co.nz
INFORMATION:
WHO WE ARE
Sika AG, Switzerland, is a globally active specialty chemicals company.
Sika supplies the building and construction industry as well as
manufacturing industries (automotive, bus, truck, rail, solar and wind
power plants, faades). Sika is a leader in processing materials used
in sealing, bonding, damping, reinforcing and protecting loadbearing
structures. Sikas product lines feature high quality concrete admixtures,
specialty mortars, sealants and adhesives, damping and reinforcing
materials, structural strengthening systems, industrial flooring as well
as roofing and waterproofing systems.