Sika CarbDur Near Surface Munted Reinfrcement
TABLE OF CONTENTS 1 Intrductin 3 2 System Descriptin 3 2.1 References 3 2.2 Limitatins 3 3 Prducts 4 3.1 Material Strage 4 4 Equipment 5 4.1 Tls 5 4.2 Cleaning 5 5 Health and Safety 6 5.1 Risk Assesment 6 5.2 Persnal Prtectin 6 5.3 First Aid 6 5.4 Waste Dispsal 7 6 Substrate Preparatin 7 7 Applicatin 8 7.1 Adhesive 8 7.2 Installatin 9 7.3 Flexible NSM strengthening 10 8 Inspectin and Testing 10 9 Appendix 11 9.1 Resin Cnsumptin 11 9.2 Use in timber and masnry 12 9.3 On-site checklists 12 10 Legal Nte 13 11 Key Wrds 13 Sika CarbDur Near Surface Munted Reinfrcement Sika Ltd Mark Shaw 2/13
1 INTRODUCTION This Technical Infrmatin Manual is written as a guideline fr the use f the Sika CarbDur Near Surface Munted (NSM) system. This dcument must be used and referred t, in cmbinatin with all ther relevant Prduct Data Sheets (PDS), Material Safety Data Sheets (MSDS) and the specific Prject Specificatins. Structural strengthening must nly be carried ut by trained and experienced specialists, if additinal clarificatin r advice is needed, please cntact Sika Technical Services Team. 2 SYSTEM DESCRIPTION The Sika CarbDur NSM system is a high perfrmance structural strengthening system cnsisting f Sika CarbDur plates r rds and Sikadur -30, Sikadur -330 r Sikadur 33 adhesives. It is used fr the pst cnstructin reinfrcement f buildings and civil engineering structures and their structural elements. Alternatively t the CarbDur plates and rds, the SikaWrap FX can be used as a flexible NSM strengthening material. 2.1 REFERENCES The Technical Infrmatin Manual has been written in accrdance with the recmmendatins cntained in ACI 440.2R-08. 2.2 LIMITATIONS The prducts must nly be used fr their intended applicatins. Lcal differences in sme prducts may result in perfrmance variatins. The mst recent and relevant cuntry Prduct Data Sheets (PDS) and Material Safety Data Sheets (MSDS) shall apply and must be referred t. Fr any ther specific cnstructin / build infrmatin refer t the Architect s, Engineer s r Specialist Cntractr s details, drawings, specificatins and risk assessments. All f the wrks must be carried ut as directed by a suitably qualified Structural Engineer as the Supervising Officer. Sika CarbDur Near Surface Munted Reinfrcement Sika Ltd Mark Shaw 3/13
3 PRODUCTS Sika Brand Sika CarbDur plates Sika CarbDur BC rds SikaWrap FX Sikadur -330 Sikadur -300 Sikadur -30 Sikadur - 33 Descriptin Sika CarbDur plates are pultruded carbn fibre reinfrced plymer (CFRP) laminates designed fr strengthening cncrete, timber and masnry structures. The plates cme in different widths and can be btained pre-cut r as a cil t be cut n site. Sika CarbDur BC rds are pultruded carbn fibre reinfrced plymer (CFRP) laminates. They are designed fr strengthening cncrete, masnry and timber structures. The bars cme with different diameters and can be btained pre-cut r as a cil t be cut n site. SikaWrap FX is a unidirectinal carbn r glass fibre string, encased in plastic. Sikadur -330 is a tw part, thixtrpic, epxy resin based, impregnating resin / adhesive. Sikadur -300 is a tw part, epxy resin based, impregnating resin. It is clear and liquid when mixed. Sikadur -30 is a thixtrpic, structural tw part adhesive, based n a cmbinatin f epxy resins and special fillers. Sikadur - 33 is a slvent-free, thixtrpic, tw part, epxy resin-based, cartridge gun applied structural adhesive. Fr mre detailed infrmatin n the prducts, refer t the crrespnding PDS. 3.1 MATERIAL STORAGE Materials must be stred prperly in undamaged riginal sealed packaging, in dry and cled cnditins. Refer t specific infrmatin cntained in the Prduct Data Sheets regarding minimum and maximum strage temperatures. Prtect the prducts frm direct sunlight. Sika CarbDur plates and BC rds may nly be transprted in their riginal packaging r therwise adequately prtected against any mechanical damage. Sika CarbDur Near Surface Munted Reinfrcement Sika Ltd Mark Shaw 4/13
4 EQUIPMENT 4.1 TOOLS Diamnd saw High pressure cleaner Vacuum cleaner Brush Trwel Adhesive gun & cartridges Mixing Cntainer Mixer Spindle Mixing Paddle (fr larger quantities) Paintbrush 4.2 CLEANING Clean all tls and applicatin equipment with Sika Thinner C, immediately after use. Hardened material can nly be remved mechanically. Sika CarbDur Near Surface Munted Reinfrcement Sika Ltd Mark Shaw 5/13
5 HEALTH AND SAFETY 5.1 RISK ASSESMENT The risks t health and safety frm everything including any defects in the structure, wrking prcedures and all f the chemicals used during the materials installatin must be prperly assessed and safely accmmdated. Any wrking areas n platfrms and temprary structures must als prvide a stable and safe area t wrk. All wrk and wrking prcedures must be carried ut fully in accrdance with the relevant lcal health and safety legislatin. 5.2 PERSONAL PROTECTION Wrk Safely! Safety shes, glves and ther apprpriate skin prtectin shuld be wrn at all times. The use f dispsable r new / clean prtective clthing during the materials preparatin and applicatin is strngly recmmended. Always wear nitrile based prtective glves when handling epxy adhesives as they can cause skin irritatin. Apply barrier cream t hands and any unprtected skin befre starting wrk. Apprpriate eye prtectin shuld be wrn at all times whilst handling, mixing and installing the prducts. Carrying an eye wash with yu at all times is recmmended. Always wash hands with suitable sap and clean water after handling the prducts and befre fd cnsumptin, smking, visiting the tilet and after finishing wrk. The wrk area needs t be well ventilated and peratives shuld take frequent breaks in fresh air t avid any ther health issues. Silica dust prduced by the grinding r blast cleaning f cncrete can be hazardus. Prtect yurself and thers by using a vacuum grinder r vacuum blast cleaning equipment with dust extractin and abrasive recycling attachments respectively. Always wear a dust mask/respiratr when grinding cncrete. D nt inhale the cncrete dust. Fr mre detailed health and safety infrmatin, refer t the relevant Material Safety Data Sheet (MSDS) 5.3 FIRST AID If the epxy resin based adhesive prducts cme int cntact with eyes r mucus membranes, remve any glasses r cntact lenses and rinse with clean warm water fr 10 t 15 minutes then seek medical attentin. Any chemical spillages n skin must be cleaned immediately and rinsed thrughly with clean warm water. Fr mre detailed health and safety infrmatin, please refer t the relevant Material Safety Data Sheet (MSDS). Sika CarbDur Near Surface Munted Reinfrcement Sika Ltd Mark Shaw 6/13
5.4 WASTE DISPOSAL lcal regulatins. D nt empty any surplus material int drainage r water systems; dispse f all waste materials and packaging respnsibly thrugh licensed waste dispsal facilities r cntractrs, fully in accrdance with lcal legislatin and the authrities requirements. Als avid any chemical materials run-ff int sil r int waterways, drains r sewers. Any uncured adhesive waste r spillages must be dispsed f as hazardus waste. Waste and / r residual Sika Thinner C must be dispsed f accrding t lcal regulatins. Cured adhesive waste can be dispsed f safely as nrmal building materials waste accrding t the relevant Fr mre detailed health and safety infrmatin, please refer t the relevant Material Safety Data Sheet (MSDS) 6 SUBSTRATE PREPARATION Nte: This Sectin nly treats the preparatin f cncrete substrates fr the installatin f the Sika CarbDur NSM system. Fr ther substrate types, please refer t the appendix f this dcument (Sectin 9.2). Unlike in ther applicatins, installatin f the NSM system int cracked (see picture belw) r slightly damaged cncrete is pssible and independent f the surface tensile strength f the cncrete. T prepare the cncrete surface, the cncrete has t be checked fr the depth f reinfrcements and care must be taken nt t cut thrugh existing reinfrcing steel, steel tendns, embedded ducts, r ther materials within the substrate. Grves are cut with a depth and width accrding t the table belw. The surface must be clean and sund. It may be dry r damp, but free f standing water and frst. Remve dust, laitance, grease, curing cmpunds, impregnatins, waxes, r ther freign particles, tgether with any damaged cncrete r ther bnd inhibiting materials frm the surface. In additin, immediately prir t installatin, clean the cut grve with high pressure water and remve the excess water with il-free cmpressed air. Sika CarbDur Grve size Sika minm Recmmendatin Grve size Accrding t ACI 440.2R-08 Bar type Width Depth Width Depth BC6 9 mm 9 mm 9 mm 9 mm BC8 11 mm 11 mm 12 mm 12 mm BC10 13 mm 13 mm 15 mm 15 mm BC12 15 mm 15 mm 18 mm 18 mm Plate type S1.030 6-8 mm 15 mm 9 mm 15 mm S1.525 6-8 mm 20 mm 7.5 mm 22.5 mm S2.025 6-8 mm 25 mm 7.5 mm 30 mm SikaWrap FX fibre cnnectr 15 mm 15 mm 15 mm 15 mm The table abve lists the recmmended grve sizes fr standard applicatin cnditins in reinfrced cncrete. Specific site r structural cnditins r standards may require different grve sizes. Sika CarbDur Near Surface Munted Reinfrcement Sika Ltd Mark Shaw 7/13
7 APPLICATION Befre starting the wrks n site, we always recmmend that yu prepare a checklist (an example is given in Sectin 9.3 t ensure that all f the necessary tls and materials are available n site ready fr the installatin wrks. Review the ambient cnditins and cnfirm that the mst apprpriate type f Sikadur adhesive is available fr the cnditins n site, the specified prgram and the desired perfrmance and expsure in service. 7.1 ADHESIVE Dependent n the applicatin requirements (substrate quality, applicatin type, grve width), different adhesives can be used fr the installatin f the Sika CarbDur NSM system, see belw. The mst cmmn adhesive is Sikadur-330, which is suitable fr mst applicatins as utlined in the table belw. Layut Grve Width Prduct Hrizntal 12 mm 12 mm all Sikadur -330 Sikadur -30, Sikadur -33* Sikadur -300 Vertical 12 mm Sikadur -330 12 mm Sikadur -30, Sikadur -33* Overhead 12 mm Sikadur -330 12 mm Sikadur -30, Sikadur -33* * PLEASE NOTE: Sikadur 33 has a shrt pen time and may nt be suited fr large applicatins / lng grves The adhesives can be supplied and mixed in their pre-batched units, r supplied and mixed frm bulk packaging, accrding t the vlumes required and the practical situatin n site: Sika Sikadur -33 is always supplied in pre-packaged cartridges and des nt need t be mixed r filled int a different cartridge fr applicatin. Fr mre details n the respective and cmparative perfrmance f the different adhesives, their pt life and ther characteristics, refer t the relevant Prduct Data Sheets. Pre-batched packs: Add cmpnent B t cmpnent A and stir with a mixing spindle fitted t an electric lw speed mixer (max. 500 rpm) t avid entrapping air. Mix thrughly fr abut 3 minutes t a hmgeneus mix with a unifrm grey clr and appearance. Then, pur the whle mix int a clean cntainer and stir again fr apprx. ne mre minute, again at lw speed t keep air entrapment at a minimum. Bulk packing, nt pre-batched: Stir the material cmpnents well in their individual cntainers. Measure and add the cmpnents tgether, in the crrect prprtins, in a suitable mixing cntainer, then stir using an electric lw speed mixer and cntinue as stated abve fr the pre-batched packs. Fr larger quantities use a mixing paddle (jiffy mixer) instead f a mixing spindle. The adhesive pt life begins when the resin and hardener are mixed. It is shrter at high temperatures and lnger at lw temperatures. Additinally the greater the quantity / vlume f material mixed tgether at ne time, the shrter the pt life. T btain lnger wrkability at high temperatures, the mixed adhesive may subsequently be divided int prtins; alternatively anther methd is t chill the cmpnents A and B befre mixing them. Sika CarbDur Near Surface Munted Reinfrcement Sika Ltd Mark Shaw 8/13
After mixing, the adhesive is filled int cartridges fr applicatin with the adhesive guns (see picture left). If metal barrel guns r cartridges are used, such as prfessinal sausage sealant guns, then they must be cleaned immediately after use with Sika Thinner C as any hardened adhesive can nly be remved mechanically. As an alternative, dispsable single-use plastic cartridges can be used. The table in the appendix (sectin 9.1) summarizes the apprximate cnsumptin f adhesive per metre fr the different cmbinatins f prducts. Actual adhesive cnsumptin achieved is nt nly dependent n the specific grve dimensins, but als n the filling levels, any ver-filling, lss and wastage. 7.2 INSTALLATION After cutting and cleaning f the grves, the dew pint must be measured prir t the system installatin t make sure n cndensed water impairs the applicatin. The ambient temperature must be at least 3 abve the dew pint. The installatin shuld then be perfrmed as fllws: Rds and plates may be supplied pre-cut r cut t an apprpriate length n site with a diamnd blade n a chp saw, r with a grinding disc. The cutting zne shuld be wrapped with adhesive tape t minimize any splintering. Immediately prir t installatin, all rd r plate surfaces shuld be wiped with Sika Thinner C t remve any pssible cntaminants. The rds and plates may nly be installed if the surface is cmpletely dry befre applying the adhesive. A A suitable adhesive is selected and prepared accrding t the relevant PDS The adhesive is filled int an empty cartridge / barrel gun and the grves are filled frm the bttm up, with the tip f the nzzle squeezed flat (see image A, right), in rder t reach the bttm f the grve. Special care shall be taken that the grves are filled cmpletely and that n air is entrapped. Within the pen time f the epxy (dependent n the temperature), the CarbDur rds r plates are pressed int the adhesive in the grves (see image B, right). If necessary, additinal adhesive can be applied t fill the grves, r any excess adhesive is remved. D nt re-use the excess adhesive. B Strike the surface with a trwel t frce ut any air and prvide a clean installatin. Fr ptimum adhesin f any pssible additinal layers, the adhesive may be bradcast and cvered lightly with quartz sand,(see image C, right). Nte that any sand must be graded, clean and kiln dried. C Sika CarbDur Near Surface Munted Reinfrcement Sika Ltd Mark Shaw 9/13
7.3 FLEXIBLE NSM STRENGTHENING Fr the applicatin f the SikaWrap FX fibre cnnectr as a near surface munted reinfrcement, the substrate is prepared and cleaned as described abve. The SikaWrap FX is then cut t length with special scissrs and impregnated with Sikadur -300 r Sikadur -52 resin n a plastic sheet. The excess resin is squeezed ut f the fibres and the cnnectr is fixed with a cable tie every 40 50 cm. The fibres will stick tgether with the help f the resin. Only wrk in fibre directin during impregnatin in rder t keep the fibres aligned and untangled. The grves are then filled up t 2/3 with a suitable adhesive (see table in sectin 7.1) and the fibre cnnectr is placed in the grve. It must be pushed int the adhesive gently and special care has t be taken that the fibres remain undisturbed and aligned in parallel. If a lng cnnectr needs t be installed, the impregnated string can be wund n a cardbard cne fr transprtatin and handling. After placing the SikaWrap FX int the grve, it is cvered with additinal adhesive as necessary t fill the grve and may be sanded with quartz sand if specified. 8 INSPECTION AND TESTING Visual assessment and recrding f the installatin is necessary during every stage. Check the filled grves fr any air vids r premature drying f the adhesive befre insertin f the rds, plus always ensure that the plates r rds are cmpletely embedded in the adhesive. If necessary, the cmpressive strength and air cntent f the adhesive can als be tested accrding t EN 196. Sika CarbDur Near Surface Munted Reinfrcement Sika Ltd Mark Shaw 10/13
9 APPENDIX 9.1 RESIN CONSUMPTION Sika CarbDur Grve size Rd type Width Prduct Cnsumptin Sikadur -30 ~ 0.09 kg/m BC6 9 mm Sikadur -300 Sikadur -330 ~ 0.06 kg/m ~ 0.07 kg/m Sikadur -33 ~ 0.06 l/m Sikadur -30 ~ 0.16 kg/m BC8 11 mm Sikadur -330 ~ 0.13 kg/m Sikadur -33 ~ 0.10 l/m BC10 13 mm Sikadur -30 ~ 0.23 kg/m BC12 15 mm Sikadur -30 ~ 0.30 kg/m Plate type Width Prduct Cnsumptin 6-8 mm Sikadur -30 ~0.13 kg/m S1.030 Sikadur -300 Sikadur -330 Sikadur -33 ~0.04 kg/m ~0.05 kg/m ~0.04 l/m S1.525 6-8 mm S2.025 6-8 mm Sikadur -300 Sikadur -330 Sikadur -300 Sikadur -330 ~0.06 kg/m ~0.07 kg/m ~0.08 kg/m ~0.09 kg/m SikaWrap FX Impregnatin FX Type Prduct Cnsumptin FX-50C Sikadur -30 Sikadur -52 ~0.30 kg/m Sika CarbDur Near Surface Munted Reinfrcement Sika Ltd Mark Shaw 11/13
9.2 USE IN TIMBER AND MASONRY In additin t reinfrced cncrete, the NSM system can als be used n timber and masnry structures. Timber: Cut grves int the timber and remve all dust with il-free cmpressed air and / r vacuum immediately befre applicatin f the adhesive. The surface must be sund and reasnably flat, s the whle Sika CarbDur rd r plate can be cmpletely embedded. Prceed as described fr cncrete in Sectin 7.2. Masnry: Make sure that the masnry structure is sund and fit fr the installatin f the Sika CarbDur NSM system. It is pssible t install the system int a slightly cracked surface, but crumbling bricks and deterirated material will impair the quality and effectiveness f the reinfrcement system. The respnsible Structural Engineer must make the necessary inspectin and calculatins. T install, cut grves int the masnry and remve all dust with il-free cmpressed air and / r vacuum immediately befre applicatin f the adhesive. Prceed as described fr cncrete in Sectin 7.2. 9.3 ON-SITE CHECKLISTS Diamnd saw fr cncrete High pressure cleaner Vacuum cleaner Cmpressed air Mixing cntainer Mixer Mixing paddle Adhesive gun (with empty cartridges) Trwels Dew pint measuring device Sika CarbDur plates r rds SikaWrap FX Cutting equipment Adhesive Quartz sand Nitrile glves Hard hat Safety gggles Dust mask Ear prtectin Des the air and surface temperature exceed 5 C? The actual average temperature is: [ C] Is the ambient temperature at least 3 abve the dew pint? Is the misture cntent f the cncrete belw 4%? Is there standing water n the surfaces? YES NO Have there been any deviatins frm r changes f the initial Engineer s specificatin? If Yes, describe and detail further: Sika CarbDur Near Surface Munted Reinfrcement Sika Ltd Mark Shaw 12/13
10 LEGAL NOTE The infrmatin, and, in particular, the recmmendatins relating t the applicatin and end-use f Sika prducts, are given in gd faith based n Sika's current knwledge and experience f the prducts when prperly stred, handled and applied under nrmal cnditins in accrdance with Sika s recmmendatins. in practice, the differences in materials, substrates and actual site cnditins are such that n warranty in respect f merchantability r f fitness fr a particular purpse, nr any liability arising ut f any legal relatinship whatsever, can be inferred either frm this infrmatin, r frm any written recmmendatins, r frm any ther advice ffered. The user f the prduct must test the prducts suitability fr the intended applicatin and purpse. Sika reserves the right t change the prperties f its prducts. The prprietary rights f third parties must be bserved. All rders are accepted subject t ur current terms f sale and delivery. Users must always refer t the mst recent issue f the lcal Prduct Data Sheet fr the prduct cncerned, cpies f which will be supplied n request. 11 KEY WORDS Structural strengthening, negative mments, NSM, near surface munted, CarbDur S plates, CarbDur BC Rds, SikaWrap FX, Sikadur resin, Sikadur-30, Sikadur-330, Sikadur-300, Sikadur-52, Sikadur-33 SIKA LIMITED Head Office Watchmead Welwyn Garden City Hertfrdshire AL7 1BQ United Kingdm Phne: +44 1 707 394444 Fax: +44 1 707 329129 www.sika.c.uk Nr 850 73 05 Sika CarbDur Near Surface Munted Reinfrcement Sika Ltd Mark Shaw 13/13