Annual Concrete Seminar 2008

Renovation and RepairRenovation and Repair of Concrete Structuresof Concrete Structures

Based on Dry Mortar TechnologyBased on Dry Mortar Technology

Ir Raymond WanIr Raymond Wan MEngMEng,, CEngCEng, MIM, MIC, MIM, MICEE, MIC, MICTT, MHKIE, RP, MHKIE, RPEE

Optimix (Hong Kong) LimitedOptimix (Hong Kong) Limited

Presentation OutlinePresentation Outline

�� What is Dry Mortar ?What is Dry Mortar ?

�� Applications in Repair & Renovation forApplications in Repair & Renovation for

�� Wall FinishesWall Finishes

�� WaterproofingWaterproofing

�� FlooringFlooring

�� InnovativeInnovative ““GreenGreen”” ApplicationsApplications

What isWhat is Dry MortarDry Mortar ??

XXPrePre--blended dry powdery materialsblended dry powdery materials ÆÆ binders + fillers + additives + pigmentsbinders + fillers + additives + pigments

XX Just add water and mixJust add water and mix ÆÆ good quality fresh mortar for immediate usegood quality fresh mortar for immediate use

+

Powder Water Mixing

Premixed Fresh Dry Mortar

Mortar

High Performance Mortars for Wide Range of Applications

OPC

HAC

GGBFS

PFA

Hydrated Lime

Gypsum

Anhydrite

Polymers

Silica Sand

Quartz Sand

Limestone

Silica Powder

Bentonite

Perlite

Polystyrene

Vermiculite

Water Retainer

Thickener

Air Entrainer

Defoamer

Accelerator

Retarder

Plasticizer

Shrinkage Compensator

Organic

Inorganic

PremixedPremixed Dry MortarDry Mortar IngredientsIngredients

Binder Filler Additive Pigment dry dry dry dry

Blended Dry Powder Packed in a Bag (Prebagged Mortar)

Polymer-Modified Cementitious Mortar

Dry Mortar TechnologyDry Mortar Technology

�� Use of specific binders & polymersUse of specific binders & polymers

�� Incorporate various types of fillersIncorporate various types of fillers

�� Adopt advanced chemical additivesAdopt advanced chemical additives

�� Formulations for designated propertiesFormulations for designated properties

�� Blending of powdery materialsBlending of powdery materials

�� Controlled production processControlled production process

Dry Mortars Æ Advanced Construction Materials with Superior Performance Properties

Batching Control PanelBatching Control Panel

Batching & Mixing

Packing

Production

Premixed Dry MortarPremixed Dry Mortar Typical Product RangeTypical Product Range

Common Problems ofCommon Problems of Wall FinishesWall Finishes

Render and Tile Failure

Patch Repair or Complete Façade Renovation

Concrete Substrate

Tile Grout

Tile

4

Tile Adhesive

Render

2

Spatterdash

Typical Wall Finishes SystemTypical Wall Finishes System

1 3

Concrete Substrate

Tile Grout

Tile

Render

Tile Adhesive

Spatterdash

Spatterdash / Render Failure

SpatterdashSpatterdash / Render Failure/ Render Failure

Spatterdash Render

Render FailureRender Failure

Render

Spatterdash

Concrete Substrate

Tile Grout

Tile

Render

Tile Adhesive

Spatterdash

Adhesive Failure

Tile FailureTile Failure

Render Tile

Tile FailureTile Failure

Tiles

Pop Out

Tile Grout FailureTile Grout Failure

Tile

Concrete Wall

Tile / Grout Failure

Spatterdash

Render

Adhesive

Grout

Tile

Water Ingress

Lime Leaching Efflorescence

Via Tile Joints

Efflorescence of Tile GroutEfflorescence of Tile Grout

Leaching Lime Via

Porous Cracked Tile Joints

Repairs for External Wall FinishesRepairs for External Wall Finishes Weak bond between wall finish layers under cyclic movements

Debond Wall Finishes Materials

Materials Aging and Cracks

Traditional Repair to Wall FinishesTraditional Repair to Wall Finishes

Materials 1 3 Deficiencies

Concrete Substrate

Tile Grout

Tile

4

Tile Adhesive

Ready Mixed Mortar Sand/Cement Render

2

Bond Coat Poor Water Retention

High Shrinkage

Stiff & Rigid

Low Early Strength

Weak Bond

Potential Problems of Traditional RepairsPotential Problems of Traditional Repairs

Bond Coat (SBR Slurry)Bond Coat (SBR Slurry) ¾¾ Premature dry outPremature dry out ÆÆ not effective adhesion or potentialnot effective adhesion or potential debonddebond layerlayer

Render (Ready Mixed or Cement / Sand Mortar)Render (Ready Mixed or Cement / Sand Mortar) ¾¾ Extremely low early strengthExtremely low early strength ÆÆ weak bond & poor sag resistanceweak bond & poor sag resistance ¾¾ High long term shrinkageHigh long term shrinkage ÆÆ cracracks & movementcks & movement

AdhesiveAdhesive ¾¾ Stiff materialStiff material ÆÆ lessless deformable to accommodate movements deformable to accommodate movements

GroutGrout ¾¾ Rigid & porous materialRigid & porous material ÆÆ cracks with risk of water seepagecracks with risk of water seepage

Repair materials of questionable properties and performance

Movements within Rigid MaterialsMovements within Rigid Materials Tile Grout

Stiff / Rigid Tile Layer

(Undesirable) Substrate

Shrinkage of Tile debond Substrate and popping out

Shrinkage

Expansion of Tile debond Tiles and popping out

Other movements: creep, moisture, thermal, wind suction, structure swing, … etc.

Tile GroutDeformable Tile Materials

(Preferable) Substrate

Shrinkage of Substrate

Deformation of Adhesive Mortar

Shrinkage

Expansion of Tiles

Deformation of Adhesive Mortar

Expansion

Movements within Deformable MaterialsMovements within Deformable Materials

¾¾ Flexible materialFlexible material ÆÆ deformable to accommodate movementsdeformable to accommodate movements (e.g. to EN12004 Class C1 or C2)(e.g. to EN12004 Class C1 or C2)

GroutGrout ¾¾ Waterproof materialWaterproof material ÆÆ reduce cracks improved water resistancereduce cracks improved water resistance

(e.g. to EN13888)(e.g. to EN13888)

Dry Mix Materials of enhanced properties and performance for repair

Preferred & Suggested Repair MaterialsPreferred & Suggested Repair Materials Bond CoatBond Coat ¾¾ Use either premixed key coat or system without bond coatUse either premixed key coat or system without bond coat

RenderRender ¾¾ Higher earlyHigher early bondbond (not compressive)(not compressive) strength (e.g. >0.5MPa at 7 days)strength (e.g. >0.5MPa at 7 days) ¾¾ Moderate compressive strength (e.g. <20MPa at 28 days)Moderate compressive strength (e.g. <20MPa at 28 days) ¾¾ Lower long term shrinkage (e.g. <0.04% at 7 days & <0.08% at 28Lower long term shrinkage (e.g. <0.04% at 7 days & <0.08% at 28 days)days)

AdhesAdhesiveive

High Performance Dry Mix SystemHigh Performance Dry Mix System

Durable and Safe System

Concrete Substrate

Waterproof Tile Grout

Tile

Premixed Mortar

Flexible Tile Adhesive

Key Coat

An enhanced system of guaranteed quality for effective and long lasting repair

Good Water Retention

Shrinkage Compensated

Flexible & Deformable

Good Bond

Water Resistant

Alternative External Wall Renovation MethodAlternative External Wall Renovation Method

Hong Kong

Landmark

External Tiled Wall Renovation

Semi-Flexible Premixed Mortar

Over Tiles

Tile Filler

Finished

Alternative External Wall Renovation MethodAlternative External Wall Renovation Method

Tile Filler

Original

Innovative Enhanced DevelopmentInnovative Enhanced Development forfor External Tile FaExternal Tile Faççade Refurbishmentade Refurbishment

Move Forward Æ Apply One Single Product for Secure Renovation Works

Good Bond Strength On Tile Surface > 1MPa

High Elasticity – Accommodate Movements

Waterproof & Seal Cracks

Safe – Prevent Sudden Tile Fall

Easy to Use – Apply by Brush or Trowel

Stable Colour and Durable

Non-Toxic & VOC-Free Environmentally Friendly

Common Problems ofCommon Problems of WaterproofingWaterproofing

Leakage and Seepage

Complete Removal & Re-install

Common Sign of Water SeepageCommon Sign of Water Seepage

Waterproofing Failure

Common Sign of Water LeakageCommon Sign of Water Leakage

Waterproofing Failure

Traditional Waterproofing Sheet Membrane

Water Ingress

Seam & Joints Poor Adhesion Sheet

MembraneFloor Screed

Leakage Seepage

Weak Seam Æ Poor lapping joints between sheetings

Poor Adhesion Æ Incompatible of adhesive and substrate

Leakage Remedial Æ Difficult to locate source and repair

Bitumen Based Æ Aging & degrade under ambient air, UV, heat (Loss of elasticity, disintegrate, cracks, etc.)

Note: Some commercial products marketed as PU products consist of significant amount of bitumen (or tar). They are also subject to natural degradation.

Failure ofFailure of WaterproofWaterproofing Membraneing Membrane

Seepage via Cracks

RoofTop

Roof Slab Under Side

Drips along Cracks

Failure ofFailure of WaterproofWaterproofing Membraneing Membrane

Poor Joint Lappings Exposed Weak Adhesion

Water Seepage via Loose Seam Cracked Membrane

Roof Tiles Removed

Suggested and ImprovedSuggested and Improved WaterproofingWaterproofing

Polymer Modified (Cementitious Based) Flexible Waterproofing

WaterDurable and More Secure System Ingress

No Seam Concrete Substrate

Waterproofing Good Bond Treatment

Good Bond Æ Full compatible with concrete substrate, no adhesive

Flexible Æ Stable and durable, no aging problem under UV & weather

Easy to Maintain Æ Easy to locate fault and carry out remedial

No Seam Æ Brush / trowel apply, easy to control thickness and quality

Restoration of Waterproofing withRestoration of Waterproofing with Premixed Dry Mortar SystemPremixed Dry Mortar System

Application by Trowel Can be Applied on Damp Substrate

Seamless Finish Ponding Test

Common Problems ofCommon Problems of FlooringFlooring

Uneven, Cracks and Dusting

Complete Removal & Re-install

Common Floor Defects & DamagesCommon Floor Defects & Damages

Weak Dusty

Uneven

Crack

Epoxy Peeling

& Wear Out

CementitiousCementitious SelfSelf LevellingLevelling FloorFloor Simple & Speedy Renovation / Re-surfacing

Car park

Self Levelling

Floor

Uneven Concrete

Floor

Foot Traffic 2 hours

Vehicle Traffic 8 hours

(5-8mm)

Speedy Re-surfacing Damaged Screed

Self Levelling Floor – Overlayment Simple and Efficient Renovation

CementitiousCementitiousCementitiousCementitious SelfSelfSelf Self LevellingLevellingLevellingLevelling FloorFloorFloorFloor

Speedy Renovation / Re-surfacingSpeedy Renovation / Re-surfacing

CementitiousCementitious SelfSelf LevellingLevelling FloorFloor Speedy Renovation / Re-surfacing

Before After

Damaged Floor

CementitiousCementitiousCementitiousCementitious SelfSelfSelf Self LevellingLevellingLevellingLevelling FloorFloorFloorFloor

Damaged Epoxy Floor Durable Re-surfacing Damaged Concrete Floor Speedy Re-surfacing

Self Levelling Floor – Overlayment Simple and Efficient Renovation

CementitiousCementitious SelfSelf LevellingLevelling FloorFloor ColourColour FinishesFinishes

DamagedTile Floor

Coloured Floor

Finished Smooth Flat Floor

Worn & Damaged Tiled Floor

CementitiousCementitiousCementitiousCementitious SelfSelfSelf Self LevellingLevellingLevellingLevelling FloorFloorFloorFloor

Damaged Tiled Floor Durable Re-surfacing Damaged Concrete Floor Speedy Re-surfacing

Self Levelling Floor – Overlayment Simple and Efficient Renovation

CementitiousCementitious SelfSelf LevellingLevelling FloorFloor Beijing National StadiumBeijing National Stadium ““Bird NestBird Nest””

Internal Self Levelling Floor : ~40,000 m2

CementitiousCementitious SelfSelf LevellingLevelling FloorFloor Beijing New CCTV HQBeijing New CCTV HQ

Internal Self Levelling Floor : 1st Phase ~20,000 m2 , 2nd Phase ~180,000 m2

(Completed) (To Be Started Soon)

Dry Mortar SystemsDry Mortar Systems

Innovative Green ApplicationsInnovative Green Applications

¾¾ Low VOC FinishesLow VOC Finishes

¾¾ Thermal InsulationThermal Insulation

¾¾ Sound DeadeningSound Deadening

¾¾ AntiAnti--RadonRadon

¾¾ Photo CatalystPhoto Catalyst

¾¾ ………… ………… …………

Green and

Healthy

Exterior Insulation and Finish System

Concrete Substrate

Adhesive for Insulation Board

Polystyrene Insulation Board (EPS / XPS)

Base Coat for Reinforcing Mesh schematic Alkali Resistant Glass Fibre Reinforcing Mesh illustration

Flexible Tile Adhesive

Low Water Absorption Tile Grout

Decorative Finishes (Coating / Tile)

Efficient energy saving on air-conditioning

Exterior Insulation & Finish SystemExterior Insulation & Finish System

Shield External Heat in Summer, Keep Interior Warm in Winter

Exterior Insulation & Finish SystemExterior Insulation & Finish System

System used extensively in Europe and America for decades

1. Substrate

2. Base Adhesive

3. EPS/XPS Board

4. Top Coat

5. Glass Fibre Mesh

6. Decorative Finish

Apply Base Adhesive

Lay Glass Fibre Mesh

Apply Top Coat

Mandatory installation in Major Cities in China since 2007

Exterior Insulation & Finish SystemExterior Insulation & Finish System Can we contribute and play our role on Energy Saving in building design ?

To Save Fuel & Minimize Pollutants Æ Environmentally Friendly

Green Buildings

EIFS

Can we adopt similar system for buildings in Hong Kong ?

Oil Crisis !

Fuel Shortage !

The End Thank You !

¾¾ Dry mix systems can play vital roles in structural or architectuDry mix systems can play vital roles in structural or architectural designsral designsfor achievfor achieving greener and healthing greener and healthier buildings / structures.ier buildings / structures.

Closing Up & CommentsClosing Up & Comments ¾¾ Based on dry mix technology, prBased on dry mix technology, premixed producemixed products of superior propets of superior propertiesrties

are made possible for a wide rangeare made possible for a wide range of applications in constructiof applications in construction.on.

¾¾ With the use of advanced powderyWith the use of advanced powdery chemical additivchemical additives, cement basees, cement basedd producproducts can be developed withts can be developed with specspecific and outstanding propertiific and outstanding properties.es.

¾¾ Dry mix systems can replace plentDry mix systems can replace plenty of traditional construction my of traditional construction materials oraterials or methods to enhance performance and extend durability.methods to enhance performance and extend durability.

¾¾ Dry mortars may not be able toDry mortars may not be able to solve all the construction problesolve all the construction problems butms but they can alwthey can alwaays provide effectivys provide effective solutions to minimize potentiae solutions to minimize potential problems.l problems.