Column jacketing with micro-concrete

The work, step by step

General guidance based on the manufacturer data sheets. Site conditions differ: confirm the system with MCT before you start. Where we do not name a product, ask us and we will confirm the right one.

1. 1

   Step 1: Engineer's design

   Jacket thickness, new bars, dowels and loading are structural design, so a structural engineer must do the calculations (Sikadur-32 LP p.3). Plan any temporary propping with the engineer.

2. 2

   Step 2: Prepare the existing column

   Remove plaster and weak concrete, roughen the surface, and delineate repair areas with a 20 mm deep saw cut (Emaco S 496 PK p.2). Clean corroded bars and protect them with MonoTop-610 (MonoTop-610 p.1, p.3).

   Sika MonoTop-610 Sika Professionals only

   Bonding primer as part of a concrete repair system Reinforcement corrosion protection as part of a concrete repair system (TDS p.1)

3. 3

   Step 3: Fix dowels and new reinforcement

   Anchor dowels and starter bars into the existing concrete with an epoxy anchoring adhesive: Sika AnchorFix-3001 is designed for rebar in cracked and uncracked, dry or damp concrete (AnchorFix-3001 p.1). Experienced professionals only (p.1). Bar sizes and embedment come from the engineer.

   Sika AnchorFix-3001 Sika Professionals only

   Anchoring adhesive for fixing of non-expanding anchors in the following: Structural work Rebar / steel reinforcement anchoring in new and refurbishment works Threaded rods Bolts and special fastening / fixing systems Metalwork, carpentry Handrails, balustra… (TDS p.1)

   Temperature stated in TDS

   -40 °C min. / +40 °C max (TDS p.2)

   Pack

   400 ml side by side cartridge

4. 4

   Step 4: Pre-wet or bond coat

   Saturate absorbent surfaces with clean water, for at least 24 hours for SikaEmaco S 496 PK (Emaco S 496 PK p.2). On large areas or very dense concrete, a bonding agent such as Sikadur-32 LP or Sikadur ADH 1414 improves adhesion (Emaco S 466 PK p.2).

   Sikadur-32 LP Sika Professionals only

   As a structural bonding agent and adhesive for: Concrete elements (including bonding fresh to hardened concrete), Hard natural stone, Ceramics, fibre-cement, Mortar, Bricks, Masonry, Render, Steel, Iron, Aluminium, Wood. (TDS p.1)

   Temperature stated in TDS

   +20 °C to +40 °C (TDS p.1)

   Sikadur ADH 1414 Sika

   Sikadur® ADH 1414 may be applied to clean, sound and durable surfaces, i.e. (TDS p.1,2)

   Temperature stated in TDS

   7°C to 10°C (TDS p.2)

   Pack

   Sikadur® ADH 1414 is available in 2 litre kits containing the base resin and

5. 5

   Step 5: Fix formwork and pour the micro-concrete

   Formwork must be secure and watertight (Sikacrete-114 PK p.2). Choose by thickness: SikaEmaco S 466 PK 25–150 mm per pour; SikaEmaco S 496 PK 50–300 mm, with aggregate added above 300 mm; Sikacrete-114 PK 50–500 mm, 10 mm maximum aggregate (each p.2; Sikacrete-114 PK p.1). For thin gaps, SikaGrout-114 PK at 10–50 mm per pour (SikaGrout-114 PK p.2).

   Sikacrete-114 PK Sika

   Sikacrete®-114 PK is used for the structural repair of deteriorated concrete. (TDS p.1)

   Temperature stated in TDS

   +5 °C min. / +35 °C max (TDS p.2)

   SikaEmaco S 466 PK Sika Request a quotation

   SikaEmaco® S 466 PK precision micro-concrete is used for repair and grouting in various applications such as: Structural repair of deteriorated concrete, Columns in precast construction, Casting sections or members where the volumes required are too large for conventional grouts, and too small an… (TDS p.1,2)

   Temperature stated in TDS

   +5 °C min. / +35 °C max (TDS p.2)

   Pack

   25 kg

   SikaEmaco S 496 PK Sika Request a quotation

   SikaEmaco® S 496 PK precision micro-concrete is used for repair and grouting in various applications such as: Structural repair of deteriorated concrete, Columns in precast construction Casting sections or members where the volumes required are too large for conventional grouts, and too small and… (TDS p.1,2)

   Temperature stated in TDS

   +10°C min. / +35°C max (TDS p.2)

   Pack

   25 Kg bag

   Other options for this stepAsk us

   The right product here depends on your site. We confirm it before naming it.

6. 6

   Step 6: Cure

   Treat exposed surfaces with a curing compound or cover with polythene sheet or wet hessian; do not start fogging until final set (Sikacrete-114 PK p.3).

7. 7

   Step 7: Protect the finished jacket

   Fill pores if needed and coat exterior columns with Sikagard-680 S Betoncolor or Sikagard-550 W Elastic (G) (p.1), after at least 5 days on cement-based materials (Sikagard-550 W Elastic (G) p.4).

   Sikagard-680 S Betoncolor Sika

   As a protective and decorative coating for: The protection and enhancement of concrete cementitious substrates on building and infrastructure elements, Reducing the deterioration of concrete and assisting with controlling the corrosion of any embedded steel reinforcement, Increasing the service l… (TDS p.1)

   Temperature stated in TDS

   +5 °C min. / +35 °C max (TDS p.3)

   Sikagard-550 W Elastic (G) Sika Request a quotation

   Sikagard®-550 W Elastic (G) is used for protection and enhancement of concrete structures (normal and lightweight concrete), especially exposed outdoor concrete surfaces with a risk of cracking. (TDS p.1)

   Temperature stated in TDS

   +8°C min. / +40°C max (TDS p.3)

Steps and product facts are taken from the manufacturer data sheets (page cited). Products are named only where the data sheet confirms the use; quantities follow a site visit or photos. General guidance: check the data sheet or ask us before you start.