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Presentation of

Selection, Application and Pricing of Concrete Repair and Tile Bonding System

to

Hong Kong Institute of Surveyors

on

28th April 2015

Speaker : Mr. Lewis Lam

Company : Ronacrete (Far East) Ltd.

www.ronacrete.com.hk

Concrete Repair - Topics

Crack Repair

Overhead Concrete Repair

Floor Concrete Repair

Case Studies

Concrete Repair – Crack Repair

Method Description

1 Simply seal the crack with waterproofing coatings

2 Fill the crack by brushing dry cement and moistening

3 Seal the crack with cement grout

4 Cut V-groove and fill up with concrete repair mortar

5 Fill the crack with polymer resin by gravity or injection

6 Inject epoxy resin

7 Inject epoxy resin and seal the crack with waterproof coatings

Concrete Repair – Crack RepairElement Crack Width Through/Non-through Crack Repair Method

Underground ≤ 0.3mm Through and Non-through 1

Underground > 0.3mm Through and Non-through 7

Slabs ≤ 0.3mm Non-through 2

Slabs ≤ 0.3mm Through 5

Slabs (Soffit Only) ≤ 0.3mm Non-through 3

Slabs > 0.3mm Non-through 3

Slabs > 0.3mm Through 5 or 6

Beams ≤ 0.3mm Non-through 3

Beams ≤ 0.3mm Through 5

Beams > 0.3mm Non-through 4

Beams > 0.3mm Through 5 or 6

Wall/Columns ≤ 0.3mm Non-through 3

Wall/Columns ≤ 0.3mm Through 5

Wall/Columns > 0.3mm Non-through 4

Wall/Columns > 0.3mm Through 5 or 6

Concrete Repair – Crack Injection Method

• Clearly identify the full length of crack• Surface seal the crack with epoxy paste• Drill holes along the crack at interval equivalent to the

thickness of concrete• Insert injection packers into the holes• Starting at the lowest position (for vertical wall) and keep

injecting resin until some resin being emitted from the next injection packer

• Move to the next injection packer and repeat the same step until the full length of crack is injected

Concrete Repair – Crack Injection Method

Concrete Repair – Crack Injection Materials

For Water Seepage Repair – Polyurethane Resin

• Single Component – Flexible Foam• Two Component – Rigid Foam, Fast Water Cut-off

For Structural Repair – Epoxy Resin

• Two Component – Rigid Plastic• Two Component – Flexible Plastic

Concrete Repair – Crack Injection Pricing

Chemical Polyurethane Polyurethane Epoxy Epoxy

No. of Component Two One Two Two

Form after dry Rigid Foam Flexible Foam Rigid Plastic Flexible Plastic

Leaking Cracks Suitable Suitable Not Suitable Not Suitable

Materials Cost/m(1mm X 150mm) $ 20 $ 25 $ 20 $ 25

Labour and Materials Cost/m $ 500 $ 500 $ 500 $ 500

Concrete Repair – Specification for Repair Mortars

Test Technical Performance Class 25 Class 40TM 1 Compressive Strength at 28 days 20-40 MPa 30-60 MPa

TM 2 Minimum Tensile Strength at 7 days 1.5 MPa 2.0 MPa

TM 3 Elastic Modulus at 28 days 9-15 GPa 15-25 GPa

TM 4 Minimum Bond Strength at 7 days 1.5 MPa 2.0 MPa

TM 5 Cracking in Coutinho Ring at 28 days Nil Nil

TM 6 Minimum Figg Air Permeability 150 seconds 200 seconds

Site Minimum Pull-off Strength at 7 days 0.375 MPa 0.5 MPa

HD 002 Polymer Content by Mass of Cement > 5% > 5%

HD 002 Aggregate Cement Ratio (A/C Ratio) 2/1 to 4.5/1 2/1 to 4.5/1


Compressive Strength Test Tensile Strength Test


Coutinho Ring Test Figg Air Permeability Test

Concrete Repair – “PCCS – RM” (Product ConformityCertification Scheme for Repair Mortars)


Hong Kong Accreditation Service (HKAS)

Hong Kong Concrete Institute (HKCI)

Hong Kong Certification Body Accreditation Scheme (HKCAS)

Hong Kong Laboratory Accreditation Scheme (HOKLAS)

Concrete Repair – Quality Control from HKHA Valid Product Certificate for “PCCS-RM”

Local Test ( 1 set per 100m3 or 6 months )• Compressive Strength• Bond Strength• Coutinho Ring• Polymer Content

Full Test ( 1 set per 500m3 or 18 months ) • Compressive Strength• Bond Strength• Tensile Strength• Elastic Modulus• Coutinho Ring• Air Permeability• Polymer Content

Concrete Repair – Quality Control from HKHA

Pull-off Test – Test for Every 25 m2 Patch Repairs

Inspection Core Test – Test for Every 25 m2 Patch Repairs

Test by Void Detector – Test for All Patch Repairs

Visual Inspection – Test for All Patch Repairs

Concrete Repair – Quality Control from HKHA

Inspection Core TestSite Pull-off Test

Concrete Repair – Patch Repair Method

• Saw-cut the perimeter of the repair area to a minimum depth 6 mm to avoid feather edges

• Remove all defective concrete until sound substrates are exposed• Concrete around exposed reinforcement steel should be hacked back

by minimum 13 mm• Remove any rust appeared on the reinforcement steel• Immediately apply corrosion protection primer to the reinforcement

steel and allow to dry• Dampen concrete substrates with water and apply surface bond coat to

the concrete surface and reinforcement steel• Apply the repair mortar while the surface bond coat is still tacky• Build-up the thickness by multi-layers if required. Intermediate layers

should be keyed and primed before the next layer is applied• Cure the surface properly with curing compound

Concrete Repair – Overhead Patch Repair Method

Concrete Repair – Floor Patch Repair Method

Concrete Repair – Patch Repair Pricing

Class 25 Pre-bagged Class 40 Pre-bagged

Max. thickness per layer/mm 50 40

Elastic Modulus/GPa 9-15 15-25

Materials Cost/m3 $10,000 $11,500

Materials Cost/m2 (25mm thick) $250 $288

Labour and Materials Cost/m2 (25mm thick) $1,200 $1,400

Concrete Repair – Case Studies

Polyurethane Injection to Ceiling of Carpark

Water seepage on ceiling.Inject flexible PU resin

Use hand injection pump to pump resin into the crack through the non-return packers

Cured PU foam cut-off water


Epoxy Injection to Wall

Remove tiles to expose the crack. Drill holes to insert injection packers

Mix the two components of epoxy resin

Inject mixed epoxy resin to crack through non-return injection packers


Patch Repair to Ceilings

Spalled concrete on the ceiling of a open corridor.

Patch repair the concrete with Class 40 repair mortar


Patch Repair to External Walls

Spalled concrete due to water seepage and external weathering.

Repair concrete with Class 25 repair mortar and work in the gondola


Semi Recasting to Floor Slab

Structural strengthening works in a cantilever corridor.

Additional reinforcement bar installed


Semi Recasting on Floor Slab

Mix and lay high performance concrete Finish off the new concrete surfaces


Concrete Repair on Driveway

Spalled concrete due to wear & tear Repair the concrete with fast set heavy duty repair materials


Concrete Repair on Driveway

Form ribs before initial set of materials Finish the repairs & driveway re-open for use after 2 hours

Tile Bonding System - Topics

European Standard for Tile Adhesive

PCCS-TA and HKHA Specification

Selection of Tile Adhesive

Application Method

Case Studies

Tile Bonding System – European Standard for Tile Adhesive

EN 12004 – Cementitous Adhesive (C)

EN 12004 – Dispersion Adhesive (D)

EN 12004 – Reaction Resin Adhesive (R)

Tile Bonding System – European Standard for Tile AdhesiveCementitous Adhesive (C)

Characteristic C1 (Normal) C2 (Improved)

Initial Tensile Adhesion Strength ≥ 0.5 MPa ≥ 1 MPa

Tensile Adhesion Strength After Water Immersion ≥ 0.5 MPa ≥ 1 MPa

Tensile Adhesion Strength After Heat Ageing ≥ 0.5 MPa ≥ 1 MPa

Tensile Adhesion Strength After Freeze Thaw Cycles ≥ 0.5 MPa ≥ 1 MPa

Open Time : Tensile Adhesion Strength ≥ 0.5 MPa at 20 Mins. ≥ 0.5 MPa at 20 Mins.

Optional Characteristic

Slip (T) ≤ 0.5 mm ≤ 0.5 mm

Extended Open Time : Tensile Adhesion Strength (E) ≥ 0.5 MPa at 30 Mins. ≥ 0.5 MPa at 30 Mins.

Deformable Adhesive (S1) ≥ 2.5 mm & < 5 mm ≥ 2.5 mm & < 5 mm

Highly Deformable Adhesive (S2) ≥ 5 mm ≥ 5 mm

Fast Set Tile Adhesive (F)

Early Tensile Adhesion Strength ≥ 0.5 MPa at 6 hrs ≥ 0.5 MPa at 6 hrs

Open Time : Tensile Adhesion Strength ≥ 0.5 MPa at 10 Mins. ≥ 0.5 MPa at 10 Mins.


Dispersion Adhesive (D)

Characteristic D1

Initial Shear Adhesion Strength ≥ 1 MPa

Shear Adhesion Strength After Heat Ageing ≥ 1 MPa

Open Time : Tensile Adhesion Strength ≥ 0.5 MPa at 20 Mins.


Slip (T) ≤ 0.5 mm

Extended Open Time : Tensile Adhesion Strength (E) ≥ 0.5 MPa at 30 Mins.

Improved Characteristic (D2)

Shear Adhesion Strength After Water Immersion ≥ 0.5 MPa

Shear Adhesion at Elevated Temperature ≥ 1 MPa


Reaction Resin Adhesive (R)

Characteristic R1

Initial Shear Adhesion Strength ≥ 2 MPa

Shear Adhesion Strength After Water Immersion ≥ 2 MPa

Open Time : Tensile Adhesion Strength ≥ 0.5 MPa at 20 Mins.


Slip (T) ≤ 0.5 mm

Improved Characteristic (R2)

Shear Adhesion Strength After Thermal Shock ≥ 2 MPa


Condition the sample in -15 degree C Tensile Adhesion Strength Test


Deformation Test Slip Test

Tile Bonding System – “PCCS – TA” Product ConformityCertification Scheme for Tile Adhesives)

Tile Bonding System – “PCCS – TA” Product ConformityCertification Scheme for Tile Adhesives)

Test method Initial type test Production control frequency

Audit testingCharacteristic

(Surveillance) (Recertification)Open time EN 1346 Y A D YSlip EN 1308 (y) A D (y)Normal setting adhesives

EN 1348 Y A D YInitial tensile adhesion strength (cementitious adhesives)

Fast setting adhesives- Early tensile adhesion strength (fast setting cementitious adhesives) EN 1348 (y) A D _

Tensile adhesion strength after conditioning (cementitious adhesives) EN 1348 Y B D Y

Transverse deformation EN 12002 (y) B D _

Chemical resistance EN 12808-1 (y) B D _

Wetting capability EN 1347 (y) B D _

Reaction to fire EN 13501-1 (y) C _ _

Initial test : Y means yes. (y) means yes if relevant for the product

A means 1 test for every 1000 tonnes, with a minimum of 1 time per year and a maximum of 1 time per month

B means 1 test per year for production below 2500 tonnes/year and 2 tests per year for production over 2500 tonne/year

C means no direct testing. However, the composition shall be checked at regular intervals

D means the tile adhesive property, if relevant for the product, to be selected by the Surveillance Assessment team for audit testing.

A minimum of one property shall be selected for each audit testing.

Tile Bonding System – Quality Control from HKHA

Tile Bonding System – Quality Control from HKHA

Valid Product Certificate for “PCCS-TA”

Site Mock-up & Pull-off Test Against Panel Wall at 28 Days ≥ 0.3 N/mm2

One Set of Test for Every 1500 Bags Tile Adhesive • Initial Tensile Adhesion Strength• Tensile Adhesion Strength After Water Immersion• Tensile Adhesion Strength After Heat Ageing• Tensile Adhesion Strength After Freeze-Thaw Cycle • Open Time – Tensile Adhesion Strength

Two Set of Pull-off Test for Every 10 Typical Floors• ≥ 0.3 N/mm2 for Panel Wall• ≥ 0.5 N/mm2 for Concrete Wall• ≥ 0.3 N/mm2 for Glass Mosaic Tiles

Tile Bonding System – Selection of Tile Adhesive

Type of Tile Size of Tile Location Substrate Service Condition Suggested Tile Adhesive

Ceramic Tile < 300 X 300mm Internal Concrete/Render Normal C 1

Ceramic Tile > 300 X 300mm External Wall Concrete/Render Normal Mechanical Fixing

Ceramic Tile 45 X 95mm External Wall Concrete/Render Normal C 1 T E

Homogenous Tile Internal/External Concrete/Render Normal C 2

Reconstitute Stone Internal Concrete/Render Normal C 2

Ceramic Tile > 300 X 300mm Internal Wall Cement Board Normal C 2 T S 1 or 2

Ceramic Tile < 300 X 300mm External Concrete/Render Swimming Pool C 2 T E

Ceramic Tile < 300 X 300mm Internal Concrete/Render Food Processing R 1

Tile Bonding System – Application Method

Tile Adhesive

Tile Grout

Render

Bond Coat

Tile

Spatterdash

Concrete Wall


Tile Adhesive

Tile GroutPrecast Façade Panelor

Drywall

Tile


Spatterdash – 1 : 3 : 5 : 10 = Bonding Agent : Water : Cement : Sandby volume


Spatterdash


Bond Coat – 1 part of Bonding Agent mix with1 part of OPC by volume


Render – Ready Mix Render or Prebagged Dry Mix Mortar


Render


Tile Adhesive – Prebagged Powder Mix With Water or Liquid


Tile Adhesive – Single Bed Application


Tile Adhesive – Double Bed Application


Grouting – After-Grout or Pre-Grout Method

Tile Bonding System – Pricing

Products Materials Cost/m2 Labour Cost/m2 Labour & Materials Cost/m2

Spatterdash $1 $5 $6

Bond Coat $6 $10 $16

Render (15mm thick) $10 to $90 $80 $90 to $170

Tile Adhesive $12 to $40 $180 $192 to $220

Tile Grout $2 $20 $22

Total $31 to $139 $295 $326 to $434

Tile Bonding System – Case Studies

Re-tiling to De-bonded Tiles

Tiles and render de-bonded from the walls Remove bedding and render from substrates


Re-tiling to De-bonded Tiles

Apply bond coat and render Fix tiles with C2 grade tile adhesive


Re-tiling and Grouting to De-bonded Tiles

Tiles de-bonded due to “Open” joints Efflorescence – Lime leach out from “Open” joints



Hack off bedding mortar Grind the substrates to match existing level



Fix tiles with tile adhesive Grout the tile joints with colour grout mortar

For further enquires, please contact :

Mr. Lewis Lam – General ManagerContact No. : 2865 5872

Mr. Edmond Chan – Senior Technical Sales ManagerContact No. : 2865 5872 / 9433 7552

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