Repairing and Maintenance

1. Spalled Pier Rectification
Work Using Ready to Use
Mortars
Location:- Between DSN and DSE Metro –Stations in Dwarka
Work Description:- Spalled Viaduct Piers P-1124A,1124B, 11
1104A,1103A,1103B,10063A,1059B

2. Spelled Pier
Chipped Pier
Rectified and finished Pier

3. Scope
This presentation describes the step by
step procedure for repairing spalled viaduct
concrete piers and products used in
rectification work

4. Excavation and Chipping Work
Excavation is done manually around the affected pier to expose it w
And to allow working space around the pier. Further the spelled po
is chipped manually up to sound concrete surface beneath

5. Chipping and rust cleaning

6. About the products
• SikaTop Armatec-110 EpoCem:- This is three component
product used to protect the rusted reinforcement of the
existing structure. The structure should be minimum 28 days
old.
• SikaDur-32 LP:- This is two component product used on the
well clean prepared surface of the structure and functions as
a bonding agent between the premix-ready to use mortar.
• SikaTop-122 HS:- This is single component premix-ready to
use mortar used to re-strengthen the structure at week or
spelled portions.

7. Mixing and Application of
products
 1.Sikatop Armatec-110 EpoCem
 Mixing: All three components A,B and C are mixed one
by one in proportion A:B:C::0.50:1.25:5.00 by weight in
continuous stirring condition. It is applied in two
layers(15mm thick each) at an interval of at least 1 hour.

8. Sikatop Armatec-110 EpoCem
Component A & B Component-C

9. Application of Sikatop armatec 110 EpoCem anti-rust Coating

10. 2.Sikadur-32 LP Epoxy resin Bonding
agent
Mixing and Application
Its two components A(white liquid) and B(dark grey liquid) a
mixed in ratio A:B::2:1 by weight in continuous stirring cond
It gives light grey color. It is applied after at least one hour
Sikatop Epocem -110 in single layer.
Component A & B

11. Application of Sikadur-32 LP Epoxy Resin Bonding Agent

12. 3.Sikatop-122 HS (Polymer modified ready to use
mortar)
It is single component ready-premix which is mixed with water, 7.7 kg pe
Portable water using mixing tools. It is applied in layers if treating surfac
More than 40mm by wet-on-wet process.

13. Application of Sikatop-122 HS (Mortar) 1st Layer

14. Final Layer of Sikatop-122 HS Ready to use mortar

15. Curing:
Cure with proper curing methods for 3 days by spraying
water or wrapping jute bags around piers and maintaining it
wet.
The application shall be protected from wind, rain, frost and
direct sunlight. The curing period is dependant on climate
conditions. In warm temperatures with low humidity the
application shall be protected from premature drying.
Curing the pier by Jute bags and
water

16. Application of polymer modified water-proofing
agent coat to protect the treated pier surface
by environmental conditions.

17. Application Limits:
Avoid application in direct sun and/or strong winds.
Do not add water over the maximum recommended
dosage. Always check the material’s pot life and adjust
for climate conditions. Temperature of the repair
mortar and substrate shall not differ significantly.
Where the structure is subject to dynamic loading, it is
recommended for overhead
applications to use repair systems specially tested for
this situation.

18. T H A N K S
Executed and prepared by
VIJAY KUMAR