N°: 8503201

Author: M. Donadio

Corporate Construction
Method Statement for the
Application of
Concrete Repairs with The Sika MonoTop
System
Scope: ‘Step by step’ procedures for carrying out concrete
repairs with the Sika MonoTop system in line with the
recommendations of European Standard EN 1504-10

The information, and, in particular, the recommendations relating to the application and end-use of Sika
products, are given in good faith based on Sika's current knowledge and experience of the products when
properly stored, handled and applied under normal conditions. In practice, the differences in materials,
substrates and actual site conditions are such that no warranty in respect of merchantability or of fitness for a
particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from
this information, or from any written recommendations, or from any other advice offered. The proprietary rights
of third parties must be observed. All orders are accepted subject to our current terms of sale and delivery.
Users shall always refer to the most recent issue of the Product Data Sheet for the product concerned, copies
of which will be supplied on request

Sika Srbija d.o.o. Tel: +381 (22) 215 57 77

Patrijarha Pavla 1 Fax: +381 (22) 215 55 78
22310 Šimanovci, www.sika.rs
Pećinci, Srbija office@rs.sika.com

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Concrete Repairs with the Sika MonoTop System Author: M. Donadio

Index
1. Site Conditions................................................................................... 3
2. Surface Preparation .......................................................................... 3
2.1 Concrete.............................................................................................................3
2.2 Steel reinforcement ............................................................................................4

3. Material Preparation........................................................................... 4
3.1 Mix Ratio ............................................................................................................4
3.2 Mixing Procedure ...............................................................................................5

4. Consumption & Limitations .............................................................. 6

4.1 Consumption .......................................................................................................6
4.2 Layer thickness ...................................................................................................6

5. Application........................................................................................... 7
5.1 Corrosion protection.............................................................................................7
5.2 Bonding primer.....................................................................................................7
5.3 Repair material.....................................................................................................7
5.4 Smoothing / Levelling / Fairing coat ....................................................................8

6. Application Limits - Curing ................................................................ 8

7. Cleaning................................................................................................ 8
8. QC Procedures .................................................................................... 9
8.1 Before & after the preparation works ...................................................................9
8.2 Before, during and after the application works......................................................9

9. Typical system build-up ................................................................................10

10. Repair of larger concrete damage ...............................................................11

IMPORTANT NOTE:
Always refer to the latest edition of the respective product data sheets before using any
Sika MonoTop concrete repair products....

Sika Srbija d.o.o. Tel: +381 (22) 215 57 77

Patrijarha Pavla 1 Fax: +381 (22) 215 55 78
22310 Šimanovci, www.sika.rs
Pećinci, Srbija office@rs.sika.com

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 N°: 8503201
Concrete Repairs with the Sika MonoTop System Author: M. Donadio

1. Site Conditions
The working areas shall be protected from direct sun radiation,
strong winds or rain etc., to prevent adverse conditions for the
materials preparation, application and curing during and after the
repair works.

2. Surface Preparation
2.1 Concrete
Mark out all of the defective areas of concrete to be removed. These
shall be agreed with the Supervising Officer and recorded before
proceeding with the repair works.

The concrete surfaces to be repaired must be free from dust, loose or

friable materials, surface contaminants and any other materials
which could reduce the bond of the repair materials.

In order to achieve these requirements, all

delaminated, weak, damaged and deteriorated
concrete and where necessary sound concrete,
shall be removed by suitable mechanical means
or very high pressure water techniques - up to
110 N/mm2 (MPa). Tie-wire fragments, nails
and any other metal debris embedded in the
concrete must also be removed.

The edges of the areas where concrete is removed shall be cut to an

angle of more than 90o to avoid undercutting but not more than
135o to reduce the possibility of shrinkage / debonding / cracking at the
adjacent sound concrete interface. Best cutting is as described in the
drawing shown beside. These areas shall also be roughened
sufficiently to provide a mechanical key between the original
concrete and the repair mortar.

Where the repair depth corresponds to the

depth of concrete cover and the concrete
removal exposes steel reinforcement; the
breaking out shall continue to expose the full
circumference of the steel, plus a further 15-20
mm behind the bars, or as directed by the
Supervising Officer. Breaking out shall also
continue along the reinforcement until non-
corroded steel is reached or again as directed by the Supervising Officer. Care must be
taken to ensure that any reinforcement exposed is not cut or damaged.

Sika Srbija d.o.o. Tel: +381 (22) 215 57 77

Patrijarha Pavla 1 Fax: +381 (22) 215 55 78
22310 Šimanovci, www.sika.rs
Pećinci, Srbija office@rs.sika.com

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Concrete Repairs with the Sika MonoTop System Author: M. Donadio

2.2 Steel reinforcement

Rust, millscale, mortar, concrete, dust and other loose and

deleterious material which could reduce bond, or contribute to
corrosion, shall be removed. The steel surface shall be prepared to a
minimum standard equivalent to SA 2½ according to ISO 8501-1.
The steel surfaces shall be prepared using abrasive blast cleaning or
high pressure water techniques - up to 60 N/mm2 (MPa).
Where exposed reinforcement is contaminated with chlorides or
other materials which could cause corrosion, the reinforcement shall
also be cleaned by low pressure water jetting techniques - up to 18 N/mm2 (MPa)

Note: When a surface smoothing / surface leveling / fairing coat is required overall to
provide an adequate surface finish; then the whole surface area of the concrete,
inclusive of the sound concrete not subject to repair, needs to be properly prepared.
Appropriate cleaning procedures include blast cleaning, water blasting with “low”
pressure up to approximately 18 MPa or when low water volumes are necessary (i.e. to limit
the clean up operations) use high pressure water up to 60 MPa.

3. Materials Preparation

3.1 Mix Ratio

Anti Corrosion Protective Coatings:
• Sika® MonoTop®-910 Eco:
The mix ratio is to use between 19 to 21% of water by weight of powder, (approx
1 : 5) according to the consistency required and site conditions.
• SikaTop® Armatec®-110 EpoCem®:
Mix ratio in parts by weight: A : B : C = 1.14 : 2.86 : 16
Mix ratio in parts by volume: A : B : C = 1.14 : 2.86 : 10

Repair Mortar:
• Sika® MonoTop®-412 N:
The mix ratio is ~3.6 to 3.9 litres of water for 25 kg powder according to
the consistency required and site conditions.
If another Sika® MonoTop® product is used, please refer to its latest product data sheet
for the correct mix ratio.

Surface Smoothing (levelling / finishing) Coat:

• Sika® MonoTop®-620 Fine
The mix ratio is to add between approximately 5.75 to 6.25 litres of water per 25 kg
bag of powder, according to the consistency required and temperature
conditions.
If another Sika® MonoTop® product is used, please refer to its latest product sheet for the
correct mix ratio.

Sika Srbija d.o.o. Tel: +381 (22) 215 57 77

Patrijarha Pavla 1 Fax: +381 (22) 215 55 78
22310 Šimanovci, www.sika.rs
Pećinci, Srbija office@rs.sika.com

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Concrete Repairs with the Sika MonoTop System Author: M. Donadio

3.2 Mixing Procedure

Note: Always use clean, potable water to mix with the Sika® MonoTop® powder.

Anti Corrosion Protective Coatings:

1-component products such as Sika® MonoTop®-910 Eco shall be mixed mechanically
using a low speed electrical mixer (max speed 500rpm) and mixing paddle. When
required they can also be mixed in small quantities by hand.
3-component products such as SikaTop® Armatec®-110 EpoCem® cannot be part
batched and must be mixed as complete units (A+B+C) using a low speed electrical
mixer (max speed 500rpm) and mixing paddle.

Repair Mortar:
1-component products such as Sika® MonoTop®-412 N shall be mixed with a low speed
drill (<500 rpm) and mixing paddle or for machine application, using a forced action mixer
with 2 to 3 bags or more at once dependent on the type and size of the equipment. In small
quantities, Sika® MonoTop®-412 N can also be mixed by hand.
Pour the water in the correct proportion into a suitable mixing container. Whilst stirring
slowly, add the powder to the water. Mix thoroughly for at least 3 minutes and to
the
required consistency

Surface Smoothing (Levelling / Finishing) Coat:

1-component products such as Sika® MonoTop®-620 Fine shall be mixed with a low speed
(<500 rpm) drill mixer and mixing paddle, or for machine application, using a forced
action mixer with 2 to 3 bags or more at once dependent on the type and size of
the equipment.
Pour the water in the correct proportion into a suitable mixing container. Whilst stirring
slowly, add the powder to the water. Mix thoroughly for at least 3 minutes and to
the required consistency.

Note: In case of damage up to 20 mm, SikaTop®-122 SP mortar can be used. The mortar
also meets the requirements of R4 class (as well as Sika® MonoTop®-412 N mortar) and
is applied in thicknesses from 5 to 20 mm in one working step (manual procedure). All
detailed information on how to mix and apply the material can be found in the latest product
material sheet SikaTop®-122 SP.

Sika Srbija d.o.o. Tel: +381 (22) 215 57 77

Patrijarha Pavla 1 Fax: +381 (22) 215 55 78
22310 Šimanovci, www.sika.rs
Pećinci, Srbija office@rs.sika.com

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Concrete Repairs with the Sika MonoTop System Author: M. Donadio

4. Consumption & Limitations

Unless otherwise specified in the respective product sheets, the repair works shall
be carried out within a temperature range (ambient and substrate) of +5°C and +30°C.
Only apply to sound, well prepared substrates

4.1 Consumption
Sika® MonoTop®-910 Eco:
As an anti corrosion protective coating on the steel reinforcement
~2 kg per m² per coat – minimum 2 coats
As a bonding primer:
~2 to 2,5 kg per m² dependent on the substrate profile and roughness.

SikaTop® Armatec-110 EpoCem®:

As an anti corrosion protective coating on the steel reinforcement:
~2 kg per m² per coat (~1mm thickness) – minimum 2 coats
As a bonding primer:
~1,5 to 2 kg per m² dependent on the substrate profile and roughness

Sika® MonoTop®-412 N:
Dependent on the substrate roughness and thickness of the layer applied.
As a guide: ~19 kg per 1 cm thick per m2
1 x 25k bag yields approximately 13.7 litres of mortar

Sika® MonoTop®-620 Fine:

Dependent on the substrate roughness and thickness of the layer applied.
As a guide: ~17 kg per m² per 1 cm thickness.
1 x 25k bag yields approximately 14.9 litres of mortar

4.2 Layer thickness

Sika® MonoTop®-910 Eco:
As an anti corrosion protective coating: ~1mm thickness per coat

SikaTop® Armatec-110 EpoCem®:

As an anti corrosion protective coating: ~1mm thickness per coat

Sika® MonoTop®-412 N:
Minimum: ~6 mm
Maximum:~50 mm in vertical applications

Sika® MonoTop®-620 Fine:

Minimum: ~1.5 mm
Maximum:~5 mm per smoothing / levelling layer

Sika Srbija d.o.o. Tel: +381 (22) 215 57 77

Patrijarha Pavla 1 Fax: +381 (22) 215 55 78
22310 Šimanovci, www.sika.rs
Pećinci, Srbija office@rs.sika.com

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Concrete Repairs with the Sika MonoTop System Author: M. Donadio

5. Application
5.1 Corrosion protection
When concrete cover is inadequate, additional
corrosion protection to the steel reinforcement is
required. Apply the Sika® anti corrosion
protective coating (e.g. Sika® MonoTop®-910 Eco
or SikaTop® Armatec-110 EpoCem®), by brush
or by spray onto the prepared rebars. Take care to
ensure complete application behind the bars.
Always apply two coats and allow sufficient time
for the first coat to harden before applying the second.

Tips: When applying the corrosion protection by brush, the use of two brushes
simultaneously helps to ensure correct coverage behind the bars.

5.2 Bonding Primer

On the well prepared and roughened substrate (pre-wetted, min. roughness 2 mm)
a bonding primer is generally not required. When a bonding primer is not used it is
essential to thoroughly pre-wet the surface.
When a bonding primer is used, apply Sika® MonoTop®-910 Eco, worked well into
the substrate with a stiff brush, filling all of the profile. The subsequent application
of the repair mortar shall then be done ‘wet on wet’.
If a longer open time is required before application of the repair mortar or for
specific application such as overhead application under dynamic loading, use
SikaTop® Armatec®-110 EpoCem® as the bonding primer – please refer to the respective
product data sheets for the maximum waiting times allowed.

5.3 Repair Mortars

Prior to application of the repair mortar, the surface shall be
thoroughly pre-wetted and not allowed to dry out. The surface shall
have a dark matt appearance without glistening and the surface
pores and the profile shall not contain water ie. in a saturated
surface dry (SSD) condition
Sika® MonoTop®-412 N can be applied by
hand using traditional techniques, or
mechanically using ‘wet’ spray equipment.
When a bonding primer is required, ensure it is
still ‘tacky’ when the repair material is applied
using ‘wet on wet’ techniques. When applied
manually, press the repair mortar firmly with a
trowel, pushing it well into the substrate.
When the repair depth exceeds the maximum allowable thickness of
the repair material, Sika® MonoTop®-412 N shall be applied in
several layers. The previous layer must have hardened sufficiently, so as not to be
disturbed by the subsequent application. Do not finish or smoothen the first layer,
in

Sika Srbija d.o.o. Tel: +381 (22) 215 57 77

Patrijarha Pavla 1 Fax: +381 (22) 215 55 78
22310 Šimanovci, www.sika.rs
Pećinci, Srbija office@rs.sika.com

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 N°: 8503201
Concrete Repairs with the Sika MonoTop System Author: M. Donadio

order to provide a mechanical key and ensure a good mechanical bond.for the
subsequent layer.
Surface finishing works after both hand and machine application, can be done with the
relevant tools as soon as the mortar has started to stiffen sufficiently.

5.4 Smoothing (Levelling / Fairing) Coat

When required, the surface smoothing / levelling coat shall be
applied over the whole of the prepared concrete surface, including the
zones that were repaired and the adjacent unrepaired areas. Wait
until the repair material has fully hardened before applying the
smoothing coat.
Sika® MonoTop®-620 Fine can be applied by hand using floats,
notched trowels or by spray application.

As soon as the surface has stiffened sufficiently, carry out the

finishing works by rubbing down the smoothing / levelling coat with a
wooden/plastic float or a damp sponge.
Do not add additional water during surface finishing as this will
cause discoloration and cracking.
If a special finish is required (e.g. wood textured profile), use the
relevant state of the art finishing techniques before the material has
hardened.

6. Application Limits / Curing

• Avoid application in direct sun radiation and/or strong winds.
• Do not add water over the recommended dosage
• Do not add additional water during surface finishing as this will
cause discoloration and cracking
• Protect freshly applied material from freezing
• Protect the fresh mortar from early dehydration using an appropriate curing
method (e.g. curing compound, wet hessian, polyethylene sheet, etc.)
• Adapt the curing method to the type of finishing required.

7. Cleaning
Clean all tools and application equipment with water immediately after use.
Hardened material can only be removed mechanically.

Sika Srbija d.o.o. Tel: +381 (22) 215 57 77

Patrijarha Pavla 1 Fax: +381 (22) 215 55 78
22310 Šimanovci, www.sika.rs
Pećinci, Srbija office@rs.sika.com

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Concrete Repairs with the Sika MonoTop System Author: M. Donadio

8. Site QC Procedures

The following information follows the recommendations of EN1504-10 and as part of

established “Good Practice”, the repair contractor shall also provide Site QC reports
containing the following site recorded details.

8.1 Before & after the preparation works

Characteristic References Frequency Parameters

After preparation &
Cleanliness of Concrete Visual immediately before
application
After preparation &
Cleanliness of steel bars EN ISO 8501-1 immediately before Sa 2½
application

Surface roughness Visual After preparation > 2 mm

Surface tensile strength
of the prepared EN 1542 After preparation works >1.0 N/mm²
substrate

8.2 Before, during and after the materials application

Sika Srbija d.o.o. Tel: +381 (22) 215 57 77

Patrijarha Pavla 1 Fax: +381 (22) 215 55 78
22310 Šimanovci, www.sika.rs
Pećinci, Srbija office@rs.sika.com

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Concrete Repairs with the Sika MonoTop System Author: M. Donadio

9. Typical system build-up

1 Host Sound Concrete

® ®
2 Corrosion Protective Coat (e.g. Sika MonoTop -910 Eco)
® ®
3 Bonding Primer (if relevant/required: e.g. Sika MonoTop -910 Eco)
® ®
4 Repair Mortar (e.g. Sika MonoTop -412 N)
® ®
5 Smoothing Coat (e.g. Sika MonoTop -620 Fine)

Sika Srbija d.o.o. Tel: +381 (22) 215 57 77

Patrijarha Pavla 1 Fax: +381 (22) 215 55 78
22310 Šimanovci, www.sika.rs
Pećinci, Srbija office@rs.sika.com

10 10/11
 Br.: 8503201
Autor: M. Donadio
Concrete Repairs with the Sika MonoTop System

10. Repair of larger concrete damage

Damage of higher intensity can be repaired by pouring self-leveling cement mortar R4

class Sikagrout - 314 RS, with prior cleaning of the substrate, pre-wetting to saturated
surface dry and installation of formwork.

Substrate preparation should be performed as described in Chapter 2.

The surface shall be thoroughly pre-wetted and not allowed to dry out at least 2h
before application of mortar (24h is optimal time). The surface shall have a dark matt
appearance without glistening and the surface pores and the profile shall not
contain water ie. in a saturated surface dry (SSD) condition.

All exposed reinforcement should be protected with anti-corrosion protective coating

over the entire circumference, as described in section 5.1.

It is not necessary to apply a bonding primer on an adequately prepared and properly

pre-wetted substrate.
The formwork in which the mortar is poured must be sufficiently resistant, non-
absorbent, treated with a suitable product for easier separation and well connected in
order to prevent potential leakage of material from the mold. Position the formwork to
allow excess water and residual air release. Sikagrout - 314 RS material is applied in
a thickness of 10 to 120 mm in one working step and if necessary it can be applied in
several layers by applying the next layers when the previous layer has hardened
enough.
All detailed information on how to mix and apply the material can be found in the latest
product data sheet of Sikagrout-314 RS.

1. Substrate preparation 2. Formwork installation

3. Mortar pouring 4. Hardened mortar

Sika Srbija d.o.o. Tel: +381 (22) 215 57 77

Patrijarha Pavla 1 Fax: +381 (22) 215 55 78
22310 Šimanovci, www.sika.rs
Pećinci, Srbija office@rs.sika.com

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