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CFRP Wrapping Sika Wrap Wet application

1. System Description : The Sika Wrap composite system is a high

performance strengthening system containing FRP fabrics and
impregnation resins. They are applied on the strengthening site and
formed into a fibre composite.

2. The range of Applications

1. Increasing the load bearing capacity of structural elements

2. Shear strengthening

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3. Flexural strengthening
4. Masonry strengthening

5. Column strengthening (for Confinement and / or Ductility)

6. Changes of building use

7. Structural upgrading to comply with current standards
8. Improved functionality
9. General seismic upgrading and / or retrofitting
10. Prevention of damage by seismic action
11. Improved seismic performance for masonry walls
12. Blast mitigation (accidents or terrorism)
13. Impact protection
14. Structural design construction defects
15. To replace and substitute missing rebars

3 PRODUCTS

3.1 SYSTEM COMPONENTS

Fabric:

Dependent on the application, fabrics with different fibre types (i.e.

Carbon, glass etc.), fabrics with different weights (from 230 g/m2 to
930 g/m2) and fabrics with different widths (100 mm, 300 mm, 600
mm) are used. The table below gives an overview of these different
fabric types, weights and widths available.

Product Description Area Available

Weight Width
(g/m2) (mm)
Sika Wrap 231 C Unidirectional woven 230 300
carbon fibre fabric for 600
installation by dry or
wet application
process.
Sika Wrap 301 C Unidirectional woven 300 300
carbon fibre fabric for 600
installation by dry or
wet application
process
Sika Wrap 600 C Unidirectional stitched 600 300
heavy carbon fibre
fabric for installation
by dry or wet
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application process
Sika Wrap 900 C Unidirectional fleece 900 300
stabilized stitched
heavy carbon fibre
fabric for installation
by wet application
process
Sika Wrap 930 G Unidirectional woven 930 600
glass fibre fabric for
installation by wet
application process
Impregnation Resin
:
Sikadur300 Sikadur 300 is a two
(Impregnation part, epoxy based, low
Resin) viscus, unfilled primer
or impregnation resin.
Designed to be used
for Sikawrap fabric
installation by wet
application method.
Sikadur 330 Epoxy based primer ,
Impregnation resin
and adhesive.
Sikadur 30 Epoxy based
structural adhesive
paste
Sikadur 41 Epoxy based repair
mortar
Sikadur 52N Epoxy based injection
resin

3.2 MATERIALS STORAGE

Materials must be stored properly in undamaged, original sealed

packaging, in dry cooled conditions at temperatures between +5°C and
+25°C (Resins), or between +5°C and +35°C (Fabrics). Protect all of
the products from direct sunlight.

4 EQUIPMENT

4.1 TOOLS:

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Concrete grinder , Vacuum cleaner, Brush, Application trowels, Brush,
Plastic roller, Paint roller, Mixing container and Mixing spindle Mixing
paddle (for larger quantities)

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4.2 CLEANING

Clean all tools and application equipment with Sika Thinner C

immediately after use. Any uncured epoxy should be wiped up with a
rag wetted with solvent. Hardened material can only be removed
mechanically.

5 PERSONAL PROTECTION

Safety shoes, gloves and other appropriate skin protection should be

worn at all times. The use of disposable or new / clean protective
clothing during the materials preparation and application is strongly
recommended. Always wear nitrile based protective gloves when
handling epoxy adhesives / impregnating resins, as they can otherwise
cause skin irritation. Additionally apply barrier cream to hands and any
unprotected areas of skin before starting work. Appropriate eye
protection should be worn at all times whilst handling, mixing and
installing the products.

6 PREPARATION

6.1 PRE-PROJECT

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It is recommended that the SikaWrap fabrics to be applied are cut into
their prescribed lengths with sharp scissors in advance of the mixing of
the Sikadur resin. Caution should be taken when handling the fabrics to
insure that the fibres are not bent or broken. Do not fold the fabrics.
Protect any adjacent surfaces, vehicles etc., surrounding the work area
from any dust or damage due to the preparation and execution of the
strengthening works.

6.2 SUBSTRATE

The SikaWrap strengthening system can be used on concrete, masonry

and wooden structures. Where none of these are specifically mentioned
below, then the statements refer to concrete. Before preparing the
substrate for the application, it must be thoroughly inspected and any
unsound material (such as any areas of damaged concrete, pieces of
formwork or tie-wires etc.) must be removed. Where concrete repairs
are necessary on a structure prior the application of a SikaWrap
strengthening system,

It is important that the repair materials are designed and installed to

be fully compatible with the Sikadur adhesive and suitable for use in a
structural situation (i.e. they must have low shrinkage, compatible
modulus of elasticity, good interface bond, adequate strength and an
appropriate finished surface).

Repairs to concrete surface irregularities such as blowholes or voids

must be made with a suitable repair mortar such as Sikadur-41.
Sikadur-30 adhesive must also be used as a bonding bridge layer for
both of these surface repair options, to ensure a good bond with the
substrate and no voids in the repairs. Any non-moving structural cracks
can be filled by injection with Sikadur-52 or other suitable Sikadur
injection resin with the Structural Engineer’s agreement. Concrete must
normally be older than 28 days (dependent on the environmental
situation, the mix design and effective strength requirements). The
concrete, stone and masonry substrates must be prepared
mechanically using abrasive blast cleaning, or grinding equipment.

During this preparation work, an integrated vacuum system should be

used, in order to reduce the risk of contamination, plus a dust mask
should be worn to prevent the inhalation of concrete dust.

The mechanical preparation is carried out to remove cement laitance,

any loose and friable materials and achieve a profiled, open textured
surface. Any surface defects such as honeycombing, blowholes and
voids must be fully exposed.

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All prepared surfaces must be brushed, air blasted and vacuumed to

achieve a dust free condition. No loose particles should be left on any
of the substrate surfaces. External corners and arises must generally
be rounded to a minimum radius of 20 mm. This can be achieved either
by grinding, or by building up with Sikadur mortars. Internal corners
must be made smooth by trowel application of Sikadur epoxy mortar
into the prepared corners.

The surfaces to be strengthened must be levelled. The plane and level

of the substrate is to be checked with a suitable straight edge.
Tolerance for 2 m length 10 mm, Tolerance for 0.3 m length 4 mm,
formwork marks 0.5 mm

The final surface must be smooth, dry and free of damaged concrete
and any other contaminants as dust, foreign particles, cement laitance,
oil, grease, surface coatings, curing compounds, waxes and
impregnations etc., which could adversely affect or inhibit the bond of
the strengthening system to the concrete. The substrate moisture
content must be less than 4% pbw.

6.3 RESIN

For the wet application of the SikaWrap system, Sikadur-300 is normally

used for the resin priming coat and as the impregnating resin, whilst
Sikadur-330 can be used as the resin primer on rougher concrete
surfaces.

Sikadur-330 should also be used as primer if heavy fabrics or multiple

layers are applies, as it increases the green tack of the system. The
resins should be mixed and used as described below. Avoid aeration
during all mixing actions.

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The pot life begins when the resin and hardener are mixed. It is shorter
at high temperatures and longer at low temperatures. The greater the
quantity that is mixed, the shorter the pot life becomes. To obtain
longer workability at high temperatures, the mixed adhesive may be
divided into portions. Another method is to chill components A and B
before mixing them.

The sequence of operations shall be planned to ensure that the

adhesive can be applied, joined and the work with it completed within
three hours of mixing the adhesive or within 80% of the pot life,
whichever comes first.

Resin Primer Coat: Ground substrates are generally 'smoother',

abrasive blast cleaned ones are generally 'rougher'. This difference is
the deciding factor for the selection of the most appropriate Sikadur
primer resin. For ‘smoother’ surfaces, the more liquid resin products
such as Sikadur-300 should be used. When dealing with rough surfaces,
the more filled resins such as Sikadur-330 are best suited to
accommodate the surface profile and irregularities.

Sikadur-330:
Sikadur-330 serves as both primer and impregnation resin for the
fabrics. It is supplied in pre-batched units.

Pre-batched Units: Continuously mix all of Part A of total 5.0 kg in its

container at a low speed (max 500 rpm) then gradually add all of Part B
until a fully homogeneous mix, with a uniform grey colour and
appearance has been achieved. Then pour the whole mix into a clean
container and mix for a second time (3 minutes, max 500 rpm).

Sikadur-300:
Sikadur-300 has an extended, longer pot life and a slow curing speed.
Continuously mix all of Part A of total 30kg unit in container then
gradually add all of Part B continuing to mix at a low speed (max 500
rpm) for 3 minutes.

Consumption:
The actual consumption, especially of the priming layer, is primarily
dependent on the roughness of the substrate and the type and amount
of SikaWrap fabric to be impregnated. The table below shows the
estimated consumption for the different fabric weights (excluding loss
and wastage).

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Resin Consumption
( kg/m2)

Sikawrap Area Resin Type First layer Following

Product Weight incl. priming layers
(kg/m2)
Sikawrap 231C 230 Sikadur 300 1.0-1.3 0.6
Sikawrap 301C 300 Sikadur 300 1.0-1.5 0.7
Sikawrap 600C 600 Sikadur 300 1.3-1.8 >=0.75
Sikawrap 900C 900 Sikadur 300 1.3-1.8 >=0.80
Sikawrap 930G 930 Sikadur 300 1.3-1.8 >=0.75

7 APPLICATION

7.1 GENERAL

Prior to starting the application, measure and record the substrate

moisture content (to be less than 4%), the relative humidity and
determine the dew point. The temperature must be min. 3°C above the
dew point. Cut the SikaWrap fabric to the desired dimensions for the
installation.

Always work in the same direction as the fibres. Avoid excessive force
and moving the roller back and forth when laminating to prevent any
folding or creasing of the SikaWrap fabric.

Overlapping pieces of fabric must be installed in the same direction as

the fibres and the overlap must be at least 100 mm, or according to the
project specifications.

When placing several uni-directional SikaWrap fabrics side by side, no

overlapping in the weft direction (perpendicular to the fibres) is
generally required, unless specified otherwise in the strengthening
design. For multi-directional fabrics, overlapping in the weft direction
must be by at least 100 mm (dependent on the SikaWrap fabric type)
or again according to the project specifications.
After application, protect the finished installation of SikaWrap FRP
Reinforcement from rain, sand, dust and any other contaminants using
protective plastic sheets or other barriers. Do not allow the protective
sheets to come into contact with the finished SikaWrap installation.

7.2 WET APPLICATION PROCESS

The name of the ‘wet’ application method comes from the state of the
fabric at the time it is applied in its final position. For this process,
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Sikadur-300 is used as impregnating resin and Sikadur-330 (rougher
substrates) or Sikadur-300 (smooth substrates) can be used as primer.

The wet application method is suitable for the non-woven fabrics as

well as for any woven fabric, especially with an area weight of higher
than 300 g/m2, depending on the fibre type.

Primer Application

Primer application is the same procedure for manual impregnation or

mechanical saturator impregnation. Apply the primer (Sikadur-330 for
‘rougher’ substrates, Sikadur-300 for ‘smoother’ substrates) to the
prepared substrate with a trowel, brush or roller. The Sikadur-300 resin
is very liquid and if necessary, it is possible

to apply a second coat after the first coat has penetrated into the
concrete substrate.

Manual Resin Application

Distribute 2/3 of the expected Sikadur-300 quantity on a clean PE sheet

and then place the pre-cut fabric onto the resin covered sheet.
Saturate SikaWrap fabric by rolling with a mohair or plastic roller in the
fibre direction until the resin penetrates through the fabric. Distribute
the remaining 1/3 of the Sikadur-300 onto the fabric and evenly spread
with roller to fully saturate fabric. Remove the excess resin. The resin
consumption can be checked by taking the weight of the fabric before
and re- weighing after wetting with Sikadur-300.

Fabric Positioning / Lamination

Place the pre-wetted, saturated SikaWrap fabric onto the primed wet
surface in the required direction (within the open time of the primer)
and smooth by hand to remove folds, creases and large air
entrapments.

The easiest way to transport the impregnated fabric is to roll it onto a

cardboard tube as illustrated on the right. This way the fabric is less
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likely to get distorted or wrinkled. If possible, leave the fabric on the
roll for 5-10 minutes, so the resin can soak into the fibre bundles. For a
better grip of the fabric to the tube, it is possible to cover it with quartz
sand before use. Heavy fabrics (>600 g/m2)

After smoothing and placement, the fabric is laminated onto the

substrate using the plastic Sika impregnating roller or a squeegee,
working parallel to the fibre direction and until the resin is distributed
evenly over the fabric and all entrapped air is released. Avoid excessive
force when laminating to prevent folding or creasing of the SikaWrap
fabric.

Additional Fabric Layers

If additional layers are required, repeat the impregnation and

lamination process described above. The application must take place
wet on wet and within 60 minutes (at +23 °C) of the previous layer. If it
is not possible to apply the subsequent layers of fabric within 60
minutes of the previous one, then a waiting time of at least 12 hours
must be observed before application of the next layer, and again a
priming layer is necessary. Take note of the open times mentioned in
the PDS of Sikadur-300. In all situations where application is onto a
cured layer of the epoxy resin, the surface must be dry and free of dust
prior to the application. The overlapping sections of the additional
layers should be distributed around the circumference of the column.

Preparation for Cementitious Overlays

The surface must be wiped until it is clean and dry before application of
any coatings to ensure an adequate bond. If a cementitious overlay is
to be applied over the SikaWrap fabric, then an additional layer of
Sikadur-300 resin must be applied over final laminating layer
(approximately 0.3 kg/m2) and broadcast whilst still wet with Sika kiln
dried quartz sand, which will improve the adhesion of the overlay (see
picture right). If a colored coating is to be applied, the ‘wet’ Sikadur-
300 surface can also be smoothed with a brush.

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7.3 ADDITIONAL OVERCOATING
The applied and cured SikaWrap fabric can be coated with a colored
protective coating for aesthetic and/or protective purposes. Selection of
the appropriate product will be dependent on the exposure
requirements. The table below illustrates some common demands and
suitable coating products.

Situation Special Need Product

Direct sunlight UV Protection Sikagard 550W,
Sikagard Elastocolor
675W
Application in water Constantly wet Sikagard 63N
substrate, Immersion
of product in water

8 QUALITY ASSURANCE
ON-SITE CHECKLIST:

Substrate preparation: YES NO

Have 3 pull-off tests been carried out? Average value measured on 3
locations: [MPa] (avg. should be 1.0 MPa)

Are there cracks above 0.2 mm wide in the concrete?

Has any damage to the structure been repaired?

Have the cracks been injected?

Is the concrete surface even?

Climate:

Does the air and surface temperature exceed 5°C?

The actual average temperature is: [°C]

Is the ambient temperature at least 3° above the dew point?

Is the average moisture content of the concrete below 4%?

Is there free standing water on the surfaces?

Are the surfaces to be bonded cleaned?

Is there any dust or other contaminants present?

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After installation:

Are there any voids?

Is there any adhesive with areas of discoloration?

Have there been any deviations or changes from the initial
specification and schedule?

Method Statement for Sika Wrap FX Fibre Connector

1 SYSTEM DESCRIPTION
SikaWrap FX is used in combination with the SikaWrap Structural
Strengthening System. The individual products combine to form a high
performance Strengthening System consisting of CFRP fabrics, carbon
fibre strings and impregnating epoxy resins. The System is applied and
built-up on site where it is formed into a fibre composite. The SikaWrap FX
is installed to secure SikaWrap Fabric and improve the end anchorage of
non-overlapping fabric strips.

The SikaWrap FX can be installed in three different configurations:

Single Connector: Into a prepared hole in the substrate perpendicular to

the SikaWrap Fabric, with the outer half of the connector fibres placed into
star-shaped slits

Double Connectors: Into a prepared hole or channel through the

substrate perpendicular to the SikaWrap Fabric, with the fibres placed into
star-shaped slits on both sides of the channel.

Parallel Connector: Into a prepared hole in the substrate parallel or

slightly angled to the SikaWrap Fabric, with the outer half of the connector
fibres placed into V-shaped slits.

2 PRODUCTS
2.1 SYSTEM COMPONENTS
SikaWrap FX
SikaWrap FX is used in combination with the other components of the
SikaWrap Structural Strengthening System.

Sika Brand Description

SikaWrap FX- SikaWrap FX-50 C consists of a ‘rope’ of unidirectional
50 C carbon fibres, held together by a plastic sleeve. It is cut

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to length and impregnated on site.

The Epoxy Resin Products

As described below, different epoxy resin products are used for the
impregnation and adhesive bonding of the SikaWrap Fibre Connectors to
the substrate.

Sika Brand Description

Sikadur-330 Sikadur-330 is a two-part, thixotropic, epoxy resin based,
impregnating resin / adhesive.
Sikadur-300 is a two-part, epoxy resin based impregnating
Sikadur-300
resin. It is a clear light-yellow liquid when mixed.
Sikadur-55 Sikadur-55 Injection Normal is a two-part, solvent-free, low
Injection viscosity injection-liquid, based on high strength epoxy resin.
Normal
Sika Sika AnchorFix-3030 is a solvent-free, thixotropic, two-part,
AnchorFix- epoxy resin-based, high performance anchoring adhesive.
3030

2.2 SikaWrap Fabric Strengthening System

SikaWrap FX Fibre Connectors are generally installed in combination with
SikaWrap Fabrics. The Table below shows a short summary of the available
types and their normal application process. For more detailed information
on the application of the SikaWrap Fabrics themselves, please refer to the
relevant Method Statements.

Sika® Brand Descripti Application Process

SikaWrap-231 C Unidirectional woven carbon fibre fabric Dry or Wet
SikaWrap-301 C Unidirectional woven carbon fibre fabric Dry or Wet
SikaWrap-600 C Unidirectional stitched carbon fibre Wet
fabric
SikaWrap-900 C Unidirectional stitched carbon fibre Wet
fabric
SikaWrap-930 G Unidirectional woven glass fibre fabric Wet

3 EQUIPMENT

3.1 TOOLS

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3.2 PERSONAL PROTECTION

Work Safely!
• Safety boots, gloves and other appropriate skin protection should be
worn at all times. The use of disposable or new / clean protective
clothing during the materials’ preparation and application is strongly
recommended.
• Always wear Nitrile based protective gloves when handling epoxy
adhesives / impregnating resins as they can cause skin irritation. Apply
barrier cream to hands and any unprotected skin before starting work.
• Appropriate eye protection should be worn at all times whilst handling,
mixing and installing the products. Carrying an eye wash with you at
all times is recommended.
• Always wash hands with suitable soap and clean water after handling
the products and before food consumption, smoking, visiting the toilet
and after finishing work.
• The work area needs to be well ventilated, and operatives should take
frequent breaks in fresh air to avoid any other health issues.
• Silica dust produced by the drilling, grinding or blast cleaning of
concrete can be hazardous. Protect yourself and others by using a
vacuum grinder or vacuum blast cleaning equipment with dust
extraction and abrasive recycling attachments respectively. Always
wear a dust mask / respirator when grinding concrete. Do not inhale
the concrete drilling dust.

4 PREPARATION

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4.1 PRE-PROJECT
Review the project specifications in detail. Inspect the site conditions and
the concrete surfaces to receive the treatment .
It is recommended that SikaWrap FX Fibre Connectors are cut to their
specified lengths with sharp scissors before beginning to mix the Sikadur
epoxy resin products.

When planning the anchoring works always consider the likely ambient
temperatures, as these also affect the epoxy resins pot-life and with that
the possibility of using wet-on-wet application techniques, i.e., for
SikaWrap Fabric to the SikaWrap FX Fibre Connectors.

4.2 SUBSTRATE
SikaWrap FX Fibre Connectors can be installed in concrete, stone and
masonry substrates. Where none of these are specifically mentioned, the
following statements refer to installation in concrete substrates.
Before preparing the substrate for the application, it must be thoroughly
inspected and any unsound material (such as any areas of damaged
concrete, pieces of formwork or tie-wires etc.) must be removed.
Where concrete repairs are necessary on a structure prior to the
application of a SikaWrap FX Fibre Connector and Fabric Strengthening
System, it is important that the repair materials are designed and
installed to be fully compatible with the Sikadur adhesive and suitable for
use in a structural situation (i.e., they must have low shrinkage,
compatible modulus of elasticity, good interface bond, adequate strength
and an appropriate finished surface).
Repairs to concrete surface irregularities such as blowholes or voids must
be made with a suitable repair mortar such as Sikadur-31,. Sikadur-32
adhesive must also be used as a bonding bridge layer for both of these
surface repair options, to ensure a good bond with the substrate and no
voids in the repairs. Any non-moving structural cracks must be filled by
injection with Sikadur-55 Injection Normal .

The actual tensile strength of the concrete substrate

must be verified on all projects by pull-off testing
carried out to BS EN 1542. If the concrete has to be
repaired, then further tests must be performed after
the repairs are completed and adequately cured.
Concrete must normally be older than 28 days
(dependent on the
environmental situation, the
mix design and effective strength requirements).
The concrete, stone and masonry substrates must
be prepared mechanically using abrasive
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blast cleaning or grinding equipment. During this preparation work, an
integrated vacuum system (see picture on the right) should be used, in
order to reduce the risk of contamination, plus a dust mask should be
worn to prevent the inhalation of concrete dust.
The mechanical preparation is carried out to remove cement laitance, any
loose and friable materials and achieve a profiled, open textured surface.
Any surface defects such as honeycombing, blowholes and voids must be
fully exposed.

All prepared surfaces must be brushed, air blasted and

vacuumed to achieve a dust free
condition. No loose particles should
be left on any of the substrate
surfaces.
External corners and arises where
fabrics will be applied must generally
be rounded to a minimum radius of 20 mm, or as required by the
Engineer’s specification. This can be achieved either by grinding, or by
building up with Sikadur mortars. Internal corners must be made smooth
by trowel application of a Sikadur epoxy mortar into the prepared corners.
The final surface must be smooth, dry and free of damaged concrete and
any other contaminants as dust, foreign particles, cement laitance, oil,
grease, surface coatings, curing compounds, waxes and impregnations
etc., which could adversely affect or inhibit the bond of the Strengthening
System to the concrete.
The substrate moisture content must be less than 4% pbw (percentage by
weight).
For the installation of the SikaWrap Fibre
Connector, a hole needs to be drilled with a
diameter of 20 mm and a depth of 100 mm, or
according to the engineer’s specifications.
Depending of the type of installation, the hole can
also be drilled through the substrate. The edges of
the hole must be rounded to a radius of 20 mm to
avoid any fibre damage to the FX during
installation. If it is installed through the substrate
as opposed to inserted from one side the hole has
to be drilled from both sides, with special care
being taken that the hole is straight .
The drilled hole has to be thoroughly cleaned so that it is free from dust
and any loose particles. Clean the hole with the blow-out tool and the
round brush, alternating the two tools at least three times.

On the substrate surface, eight star-shaped slits are cut into the substrate
as illustrated in the picture above. The slits must have a minimum width
and depth of 8-10 mm and 5-10 mm respectively. After cutting, the slits

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must be cleaned from dust and other residue by pressurized air or vacuum
cleaner.

4.3 RESINS
As outlined in the Table below, different Sika resins are used for the
different steps in the installation of SikaWrap FX Fibre Connectors.

Resin Type Application Step

Sikadur-300 Impregnation of the SikaWrap FX Fibre
Sikadur-55 Injection Connector
Normal Priming of slits, installation of upper part
of the connector
Sikadur-330 Filling of the drilled hole
Sika AnchorFix-3030 Filling of the drilled hole (alternative adhesive
material)

Pre-Batched Packs:
Add component B to component A and stir with a mixing spindle fitted to
an electric low speed drill (maximum 500 rpm) to avoid entrapping air.
Mix thoroughly for about 3 minutes to a homogeneous mix with a uniform
grey color and appearance. Then, pour the whole mix into a clean
container and stir again for approx. one more minute, again at low speed
to keep air entrapment at a minimum.

The adhesive pot-life begins when the resin and hardener are first mixed.
It is shorter at high temperatures and longer at low temperatures.
Additionally, the greater the quantity or volume of material mixed
together at one time is, the shorter is the pot-life. To obtain longer
workability at high temperatures, the mixed adhesive may subsequently
be divided into portions; alternatively, another method is to chill the
components A and B before mixing them.

If Sikadur-330 is used to fill the holes, the mixed resin is either filled into a
cartridge or rolled into a plastic sheet to facilitate the resin application .

Resin Consumption
Sikadur-300 Sikadur-330 Sika AnchorFix-
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3030
Impregnation (length 50 g – 60 g * - -
20 cm)
Filling of hole (10 cm - 80 g – 100 g 80 g – 100 g *
deep) *
Fabric layer Depends on fabric weight, see relevant PDS
*Values include waste. If a large series of connectors is installed, total
consumption decreases due to less waste.

5 INSTALLATION
The SikaWrap FX is inserted into the prepared hole and slits and installed
under the SikaWrap Fabric according to the steps listed below.

5.1 INSTALLATION UNDERNEATH FABRIC LAYER

After the substrate has been prepared, and both the substrate surface
with the slits and the hole for the connector are free from dust and loose
particles, the connector is prepared and installed according to the steps
outlined below.

i) Cut the sikawrap FX to size and prepare all tools [Link] the
impregnation resin according to the relevant PDS

ii) Impregnate one half of the connector with resin until completely
saturated and squeeze out any air and excess resin.

iii) Tie all fibres on the impregnated end of the connector together with
a cable tie and cut off the free end of the tie.

iv) If the connector is still held together by the plastic sleeve , remove
it.

v) Insert a knitting needle through the length of the connector with the
tip wedged in the cable tie.

vi) Apply adhesive to the prepared slits with a brush.

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vii) Fill the hole drilled in the substrate with adhesive from the bottom
up , either using an adhesive gun or a rolled plastic sheet funnel.

viii) If the hole goes through the substrate , fill the hole from bottom
side , if necessary, avoid any air pockets.

ix) Insert the connector into the hole with the use of knitting needle.

x) Split the dry upper half of the connector in 8 parts of equal size and
place the fibre bundles into the slits, impregnate the fibres with a
brush while pushing them into the slits.

xi) Remove the knitting needle carefully without pulling the connector
back out.

xii) Fill the slits with Sikadur 330 to level the surface.

xiii) Apply additional resin for the installation of the Sikawrap fabric.

xiv) Install the Sikawrap fabric on top of the connector as per the
approved method statement.

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-
.

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5.2 INSTALLATION THROUGH THE SUBSTRATE

SikaWrap FX Fibre Connectors can be installed
either into a hole drilled and terminated in the
substrate, or into a hole which passes through
the substrate (for example through a beam).
The two possibilities are illustrated in the
drawing on the right. The upper connectors
(red) are inserted into holes, but they could
also be installed as one continuous piece like
the lower connector (red) shown above the
flange. Dependent on the project
requirements, one or the other options may
be more suitable.
When installing SikaWrap Fibre Connectors
into a channel, the following additional points
have to be taken into consideration:

• The channel has to be drilled from both sides to prevent concrete

spalling one side. Take care that the hole is straight; otherwise, it
will not be possible to insert the connector.
• To avoid excessive waste of the resin adhesive, the hole can be only
partially filled, leaving the “back end”, where the connector exits,
empty, as resin will be pushed into this area when the connector is
inserted from the other side, and the hole will still be filled
completely. Air enclosures must be avoided.
• After inserting the connector, adjust it to ensure both sides have the
same length of connector sticking out, then cut off the cable tie and
apply the fibres into the slits as described above
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6 INSPECTION AND TESTING

6.1 BEFORE APPLICATION

The substrate tensile strength (concrete, masonry or natural stone) must
always be checked and verified in all situations. This is done by means of
a series of pull-off tests as outlined in BS EN 1542. The mean adhesive
tensile strength of the prepared concrete substrate must be minimum 1
N/mm2 unless otherwise detailed by the responsible Structural Engineer.
If the strengthening work has to be performed according to fib Bulletin No.
14, then the concrete must have a minimum tensile strength of 3 N/mm 2.
Concrete substrates must generally be at least 28 days old.
If the substrate is damaged and needs to be repaired, a repetition of the
substrate strength tests is necessary after the repair is completed and
hardened.

6.2 SITE INSPECTION

On site, all aspects of the preparation, mixing, application and installation
of the strengthening materials should be continuously observed and
recorded, including at least the following:
• Surface preparation and testing
• Materials labels and batch numbers
• Mixing of the Sikadur resin materials
• Application of the resin to the substrate and the SikaWrap Fibre
Connectors
• Temperature, dew point and other environmental data
• Curing of the materials
• System testing
• Any other details required for the Strengthening System and its
specification
As SikaWrap FX Fibre Connectors are part of a SikaWrap Fabric
Strengthening System installation, all of the same rules and conditions for
SikaWrap Fabrics apply:
Upon completion of the resin curing periods the installed System should
be checked again to confirm that there are no areas where the

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impregnation resin has not fully penetrated, or where the resin has not
completely cured and hardened. Any such areas covering more than 25 x
25 mm on the surface must be repaired. Any repairs must be made
subject to the same application, curing and quality control specifications
as the original works.
Any small areas of delamination and / or bubbles can be repaired by
injecting them with a compatible Sikadur resin to re-establish bond
between the substrate and the Strengthening System.
If any large defects are found, then removal and re-application, or the
application of additional layers of SikaWrap FRP Reinforcement may be
necessary. The repair type, the preparatory works, the number of layers to
be added and the overlapping lengths must always be approved by the
responsible Structural Engineer.

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