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Sika is a globaly active company in the speciality and construction sealing, bonding, dampening, strengthening and protection of
chemicals business. It has subsidiary manufacturing, sales and buildings and civil engineering structures.
technical support facilities in over 70 countries around the world. Sika has more than 9’200 employees worldwide and is therefore
Sika is THE global market and technology leader in waterproofing, ideally positioned to support the success of its customers.
Construction
Also available from Sika
Switzerland
Phone +41 44 436 40 40
Fax +41 44 436 46 86
www.sika.com
a
d Qu lity Sy Ma
nagemen
fie d t
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Sy
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Certif
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1
IS
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IS
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01 / E N 2
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since 1986 since 1997
05SIC_21_27_Techn_e3.Bqxd 23.09.2005 10:59 Uhr Seite 4
Corrosion Management in
Reinforced Concrete Structures
The Key Stages in the Process
1 Assessment Survey of the
Condition of the Structure
2 Diagnosis of the Cause
of Deterioration
3 Determine the Repair
and Protection Objectives
4 Select the appropriate
Repair and Protection
5 Definition of the future
Maintenance Requirements
Strategy and Procedures
Corrosion
ingress, etc).
And environmentally:
Management
tions on the works in progress, partic-
ularly the noise and the time taken
to carry out the work.
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05SIC_21_27_Techn_e3.Bqxd 23.09.2005 10:59 Uhr Seite 6
Carbon dioxide (CO2) in the atmos- Metals of different electropotential Chlorides accelerate the corrosion Impact, vibration and explosion Alkali aggregate reaction Thermal movement
phere reacting with calcium hydroxide are connected to each other in process however originally caused. Abrasion and wear Chemical exposure Freeze/thaw action
in the concrete pore liquid. the concrete and corrosion occurs. At above 0.2 – 0.4% they break Overloading Bacterial action Efflorescence/Leaching
CO2 + Ca(OH)2 > CaCO3 + H2O Corrosion can also be due to stray down the passive oxide. Earthquake Salt crystal expansion
Soluble and pH 12–13 > Almost electrical currents from transmission Chlorides can be from marine expo- Erosion
insoluble and pH 9 networks. sure or deicing salts.
Steel passivated > Steel unprotected Their use to accelerate concrete
setting at low temperatures is now
mostly banned in reinforced
concrete.
Reinforcement corrosion following reduction of the Reinforcement corrosion showing as rust staining from The damaging effects of steel corrosion accelerated Cracking caused by incorrect handling or fixing of Chemical attack (and subsequent reinforcement corro- Freeze/thaw effect on a parking structure.
passivating concrete alkalinity by carbonation. cracks after galvanized steel railings were fixed into by chloride ingress from deicing salts. precast panels. sion) on a factory roof.
the parapet.
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05SIC_21_27_Techn_e3.Bqxd 23.09.2005 10:59 Uhr Seite 8
®
Having fully considered their Ferro Gard System Positioning with ®
options, owners normally Sika® FerroGard®-903 Corrosion Inhibitor Ferro Gard
face having to «improve, In New Construction
Development of corrosion
Apply Cathodic Protection Provide Additional Concrete Concrete Repair and Protection
requirements refer to Sika Cover with Corrosion Inhibitors Visible damage
Technical Services for full Advantages Average concrete quality Average concrete quality
The only way to completely stop steel Advantages Advantages without Sika® FerroGard® with Sika® FerroGard®-903
details of the innovative
corrosion. The old traditional approach. All the advantages of conventional
Sika® CarboDur® structural Permanent solution (with full repairs concrete repair and protection.
y = rate
of corrosion
Development of corrosion
Visible damage
y = rate
of corrosion
y
/2 = rate
of corrosion
Onset of corrosion Onset of corrosion years
New start after Sika® FerroGard®-903 application
Development of corrosion
No ongoing maintenance (except with Sika systems).
protective coatings). Disadvantages Provides some protection against Visible damage
6I9
05SIC_21_27_Techn_e3.Bqxd 23.09.2005 10:59 Uhr Seite 10
SikaTop®-Armatec® 110 EpoCem® SikaTop® Repair Mortars Sika® FerroGard®-903 SikaTop® Levelling Mortars coarse/fine Hydrophobic Impregnations
Protects reinforcement in a highly Two-component prebatched polymer- Penetrates via liquid and vapour Use to fill surface defects to ensure
alkaline cementitious environment. modified repair mortars. diffusion. continuous protective coating. Sikagard® Impregnations
Can be applied on damp surfaces. Lower modulus for increased dura- Film forming inhibitor. Produce the desired surface texture. Prevents water and chloride ingress.
Increases barrier to chlorides and bility. Mixed inhibitor acting on anodic and Provides uniform substrate. Allows each way water vapour diffusion.
carbonation. cathodic sites.
Steel reinforcement primer and Blended inhibitor combining special
bonding bridge. amino-alcohol and inorganic inhibitors.
Fully complies with load transfer
requirements.
SikaCem® Gunite Mortars Sikagard®-720 EpoCem® Anti-Carbonation Coatings
Ideal for use with Aliva dry-sprayed Unique epoxy cement technology.
concrete equipment. Integral curing ability. Sikagard® Coatings
Tested for application to structures Also as a protective coating. Effectively halts carbonation.
subject to vibration under load. Ideal for levelling and reprofiling after Allows each way water vapour diffusion.
Sika® MonoTop® Tested for use with most cathodic application of Sika Ferrogard®-903. Prevents water and chloride ingress.
One-component steel reinforcement protection systems. Outstanding colour retention.
primer and bonding bridge.
One-component polymer-modified Sika® Ferro Gard Technology One-component levelling and repro- Sikagard® Coatings:
repair mortars. filing mortar. Bridges dynamically moving cracks
Suitable for hand and wet spray even at low temperatures.
machine application. Water and solvent based primers.
8 I 11
05SIC_21_27_Techn_e3.Bqxd 23.09.2005 11:00 Uhr Seite 12
Product Performance
Protecting exposed Replacing damaged Protecting against the Levelling the Profile and Sealing and Coating –
The specific criteria that Reinforcement Concrete Development of latent filling Surface Pores preventing the Ingress of
Damage aggressive Elements
Sika uses to evaluate all of
its products and systems
Bond strength to steel and concrete Bond strength Penetration ability Bond strength Sealing with Hydrophobic
for concrete repair and Corrosion protection Compressive and flexural strengths Film forming ability Permeability to carbon dioxide Impregnations
protection, are in accordance Permeability to water Permeability to water Corrosion inhibition Water permeability and absorption Penetration ability
Permeability to water vapour Elastic modulus (stiffness) Chloride displacement Permeability to water
with the requirements of
Permeability to carbon dioxide Restrained shrinkage Hydroxide displacement Permeability to water vapour
the European Standard Thermal compatibility (carbonation induced) Freeze/thaw resistance
EN 1504 where appropriate. Anti-Carbonation Coatings
Bond strength
They include the following: Cross hatch performance
Permeability to carbon dioxide
Permeability to water vapour
U.V. light resistance
Alkaline resistance
Freeze/thaw resistance
Fire resistance
Cleanability
Crack Bridging Anti-Carbonation
Coatings
As above for anti-carbonation coatings, plus:
Crack bridging ability: statically, dynamic-
ally, at low temperatures (– 20°C/– 20°F)
System Performance Application Criteria Sika has developed Product Performance Testing Sika undertakes extensive Durability Testing
There are functional and performance In addition to their performance in place, The “Bänziger Block” for Testing Repair Mortars Machine Application of Repair Mortars In the Laboratory In the Field
requirements which must be met by both it is also essential to define and test the
the individual products and components application properties of products and Sikagard® products are tested for their An international review was undertaken
of a system and by the system together systems to ensure that they can actually performance as anti-carbonation and by leading independent consultants and
as a whole. be applied practically on site, and in the water vapour diffusable coatings, both testing institutes. Major projects repaired
differing conditions that will be necessary. when freshly applied, and also after up and protected with Sika Systems between
Quality Assurance to 10000 hours accelerated weathering 1977 and 1986 were inspected
For example: Sika mortars must be suit- (equivalent to in excess of 15 years). and their durability and
It is necessary for any product or compo- able for differing thicknesses and Only this can give a complete picture of performance
nent or system to meet well defined areas/volumes of repair and applied in the product’s true performance. assessed
quality assurance and control standards as few layers as possible. Sikagard® in 1997.
in production. This is why Sika produces coatings must have adequate thixotropy Sikagard® coatings therefore continue
to ISO Standards at its factories throughout to obtain the desired wet and dry film Spray application for test under live dynamic loading. to perform long after other coatings have
the world. thicknesses in the minimum number Direct comparison worldwide ceased to provide effective protection.
Quality S
ied y of coats, and with these they must also Application horizontal, vertical and overhead Low Temperature dynamic Crack
fti
ste
Cer
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conditions
10 I 13
05SIC_21_27_Techn_e3.Bqxd 23.09.2005 11:00 Uhr Seite 14
Structure Structure
Factory roof over production facilities. Multi-storey concrete parking structure.
Problem Problem
Aggressive chemical attack on the concrete. Freeze/thaw damage on concrete
Followed by corrosion of the steel reinforce- columns and soffits from condensation
ment in a high temperature, high humidity and deicing salts exposure.
environment.
Sika Solution
Sika Solution High pressure water jetting followed
Removal of damaged concrete and by blast cleaning.
preparation of exposed reinforcement. Repair and reprofiling with SikaTop®
Protect reinforcement with SikaTop®- mortars.
Armatec®110 EpoCem®. Protection against future water and
Replace damaged concrete: deicing salt ingress with
SikaCem®-133 Gunite. Sikagard®-680 S (columns and
Protect the surface from future soffits) and Sikagard®-550 W
aggressive chemicals with (areas subject to cracking – parapets
Sikagard® high performance and external facades).
coating. Joint sealing with Sikaflex® sealants.
Steel corrosion protection with
Icosit® coatings.
12 I 15
05SIC_21_27_Techn_e3.Bqxd 23.09.2005 11:00 Uhr Seite 16
Structure Structure
Multi-storey residential housing block Historic reinforced concrete drinking water
with concrete frame and precast cladding tower.
panels.
Problem
Problem Externally carbonation depth had reached
Inadequate concrete cover to steel rein- the main steel reinforcement allowing
forcement with extensive cracking and expansive rusting to occur with subsequent
spalling after depth of carbonation concrete cracking and spalling.
reached the steel.
Sika Solution
Sika Solution Surface preparation by blast cleaning.
Concrete surface preparation by high Steel reinforcement protection
pressure water jetting. and bonding bridge with
Exposed steel reinforcement prepared SikaTop®-Armatec® 110
by blast cleaning. EpoCem®.
Steel reinforcement protection and Repair and levelling with SikaTop®
bonding bridge with SikaTop®- mortars.
Armatec® 110 EpoCem®. Anti-carbonation protection and
Repair and reprofiling with Sika repair enhanced appearance with
mortar. Sikagard®-680 S.
Crack-bridging anti-carbonation
protection on large concrete surfaces
with Sikagard®-550 W coating.
Joint sealing with Sikaflex® sealants.
Galvanized balcony handrail protection
with Icosit® coatings.
14 I 17
05SIC_21_27_Techn_e3.Bqxd 23.09.2005 11:00 Uhr Seite 18
Structure Structure
Concrete parapet wall at an airport Second floor pedestrian walkway/bridge
parking structure. at a hospital.
Problem Problem
Galvanized steel handrail fixed into the Concrete damaged by freeze/thaw action
steel reinforced concrete edge beam with and reinforcement corrosion accelerated
direct contact between galvanizing and by chlorides from deicing salts.
reinforcing steel leading to corrosion.
Sika Solutions
Sika Solution Surface preparation by high pressure
Remove and reinstall Sikagard® water jetting and exposed steel
epoxy paint coated steel handrails. reinforcement prepared by blast
with SikaGrout®-42 (epoxy grout). cleaning.
Patch repair and level damaged Steel reinforcement protection with
concrete with SikaTop® repair SikaTop®-Armatec® 110
mortars. EpoCem®.
Protect against future water ingress Repair with SikaTop® mortars.
with Sikagard®-550W. Protection against latent damages
by impregnation with
Sika® Ferrogard®-903 corrosion
inhibitor.
Crack-bridging surface protection with
Sikagard®-550 W.
Structure Project
1200 metre (3/4 mile) viaduct consisting Saint Joseph’s church in Le Havre.
of 10 bridges over road and rail tracks.
Problem
Problem Concrete surfaces had become stained,
Extensive chloride accelerated cracked and started to spall.
reinforcement corrosion particularly
below expansion joints in the deck. Sika Solution
After the necessary preparation work,
Sika Solution a complete Sika Repair and Protection
Following replacement of bridge System was applied, consisting of
deck joints. Sika® MonoTop® Primer,
Removal of all damaged concrete. SikaTop®‚ and SikaLatex®
High pressure water jetting (also modified repair mortars,
to reduce residual chloride levels). Sika® FerroGard® corrosion
Blast cleaning to prepare exposed inhibitor with Sika® Conservado
steel reinforcement. and Sikagard® protective impreg-
Repair and reprofiling with nations.
SikaCem®-133 Gunite dry spray
mortar.
16 I 19
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05SIC_21_27_Techn_e3.Bqxd 23.09.2005 13:51 Uhr Seite 20
Corrosive Contaminants
Structure
Concrete viaduct, serving as motorway
feeder.
Problem
Steel corrosion, bridge deck and parapets,
in parts destroyed by frost and de-icing
salts, need extensive repair and renovation Sika Deck Coatings Sikaflex® Joint Sealing
under permanent traffic.
For crack-bridging balcony, podium and A unique range of one-component sealants,
Sika Solution deck waterproofing plus elastic wearing specifically designed for compatibility with
Concrete for re-decking and repair surfaces. the Sika repair and protection systems.
of parapets, resistant to freeze/thaw
cycles and de-icing salts, with
Sikament®-10/-12 PLUS
and Fro-V10.
Pier cap strengthening with SCC
(self-compacting concrete) with
Sika® ViscoCrete®-1/-2.
Thin-layer mortar coating with mois-
ture barrier for edge connections with
Sikagard®-720 EpoCem®.
Bridge deck priming and sealing
with Sikadur®-186 and quartz sand
Sikadur®-501.
Edge connections and sealing of bridge Icosit® Steel Coatings Sikadur ® Resin Injection
draining system with liquid membrane and
melt primer Sikalastic®-821/-823. For the protection of steel and galvanized Structural resins for the injection and
Concrete rehabilitation work in the steel surfaces such as handrails, window bonding of cracks and voids to restore
girder boxes with frames and support structures. integrity.
Sika® MonoTop®-610/
SikaTop®-Armatec® 110
EpoCem®‚ and SikaRep®-3N
repair mortar.
Steel plate bonding for shear strength-
ening with Sikadur®-30 Epoxy adhesive
Type Rapid.
18 I 21
05SIC_21_27_Techn_e3.Bqxd 23.09.2005 10:59 Uhr Seite 2
Sika is a globaly active company in the speciality and construction sealing, bonding, dampening, strengthening and protection of
chemicals business. It has subsidiary manufacturing, sales and buildings and civil engineering structures.
technical support facilities in over 70 countries around the world. Sika has more than 9’200 employees worldwide and is therefore
Sika is THE global market and technology leader in waterproofing, ideally positioned to support the success of its customers.
Construction
Also available from Sika
Switzerland
Phone +41 44 436 40 40
Fax +41 44 436 46 86
www.sika.com
a
d Qu lity Sy Ma
nagemen
fie d t
st
rti
Sy
ie
em
Ce
Certif
stem
1
IS
®
00
IS
O
90
01 / E N 2
9
O 14 0 0 1
since 1986 since 1997