Mapegrout FMR-PP. WHERE TO USE Repairing vertical surfaces, horizontal surfaces and ceilings in deteriorated concrete structures.

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1 IN COMPLIANCE WITH EUROPEAN STANDARD EN R4 REPAIR MORTAR Mapegrout FMR-PP EN Shrinkage-compensated, sulphate-resistant thixotropic mortar with work-hardening behaviour reinforced with structural polymer fibres, particularly suitable for repairing concrete structures where high ductility is required WHERE TO USE Repairing vertical surfaces, horizontal surfaces and ceilings in deteriorated concrete structures. Some application examples Repairs to areas of concrete damaged by oxidised rebar. Reintegrating concrete around rebar in reinforced concrete structures. Repairs to surfaces subject to high wear and impact (channels, industrial floors, access ramps, etc.). Levelling off diaphragm walls and tunnel walls. Repairs to motorway, road and railway viaduct piles. Repairs to spillways. Repairs to drain systems. TECHNICAL CHARACTERISTICS Mapegrout FMR-PP is a ready-mixed powdered mortar made from high-strength cement, selected aggregates, special admixtures and structural polymer fibres according to a formula developed in the MAPEI research laboratories. The alkali-resistant structural polymer fibres, thanks to their special shape, guarantee their strong adherence to the cementitious paste and their even distribution throughout the mortar. They also give the mortar a high level of flexural strength and considerably improve its resistance to impact. When Mapegrout FMR-PP is mixed with water, it forms mortar with a thixotropic consistency which is very easy to apply on vertical surfaces and floors in layers from 1 to 5 cm thick without using formwork or electrowelded mesh. When applied on ceilings electro-welded mesh must be used; make sure the layer of mortar over the mesh is at least 2 cm thick. To allow the product s expansive properties to develop fully and correctly, Mapegrout FMR-PP must be cured in a damp environment. Mapegrout FMR-PP may also be admixed with 0.25% of Mapecure SRA, a special product that has the capacity to improve the volumetric stability of the system. Mapecure SRA guarantees better curing of the mortar by reducing surface tension in the pores and delaying evaporation of the mixing water, thereby enhancing the development of hydration reactions. Mapecure SRA acts as an internal curing agent and, by interacting with some of the main components in the cement, reduces final shrinkage by 20 to 50% compared with the same product without the admixture, thereby reducing the risk of micro-crack formation. Once hardened, Mapegrout FMR-PP has the following properties: high flexural and compressive strength; high ductility; modulus of elasticity, thermal expansion coefficient and permeability coefficient similar to high quality concrete;

2 Mapegrout FMR-PP impermeable to water; excellent adhesion to old concrete, as long as it is roughened (surface roughness > 5 mm) and sprinkled with water prior to application, and to rebar, especially when treated with Mapefer or Mapefer 1K. Mapegrout FMR-PP complies with the principles defined in EN ( Products and systems for protecting and repairing concrete structures: definitions, requirements, quality control and conformity assessment. General principles for the use and application of systems ), and the minimum requirements of EN ( structural and non-structural repairs ) for R4-class structural mortars. As with all the other products in the Mapegrout line, the expansion rate of Mapegrout FMR-PP has been calculated to compensate for the successive hygrometric shrinkage of the product. In order for this process to be carried out efficiently, however, it must be restrained by having a particularly rough surface on the substrate. This kind of condition is required because, in the mortar, internal coercion is generated through its high adhesion and high fibre content, a similar concept to that of pre-stressed concrete. Thanks to this effect, therefore, Mapegrout FMR-PP may be applied in layers up to 5 cm thick without inserting electro-welded restraining mesh (which is required when using normal repair mortars). RECOMMENDATIONS Do not apply Mapegrout FMR-PP on smooth concrete surfaces: create a very rough surface for the mortar. Do not add water once the mix has started to set. Do not apply Mapegrout FMR-PP if the temperature is lower than +5 C. Do not use Mapegrout FMR-PP if the bag is damaged or if it has been opened previously. Do not add cement or admixtures to Mapegrout FMR-PP. Do not use Mapegrout FMR-PP for repairs requiring casting into formwork (use Mapegrout Hi-Flow). Do not use Mapegrout FMR-PP for anchoring elements accurately in place (use Mapefill). APPLICATION PROCEDURE Preparation of the substrate Remove all deteriorated and loose concrete to create a sound, strong substrate with a surface roughness of at least 5 mm. Any areas previously repaired and which are not perfectly bonded must be removed. Remove all dust, rust, cement laitance, grease, oil and old paint from the concrete and rebar by sandblasting. After sandblasting, treat the rebar with Mapefer or Mapefer 1K anti-corrosion cementitious mortar according to the procedure illustrated in the Technical Data Sheet for each product. Wait until the Mapefer or Mapefer 1K is completely dry and saturate the substrate with water. Before applying Mapegrout FMR-PP, wait until any excess surface water has evaporated off. Use compressed air to accelerate this process if required. Preparation of the mortar Pour water into a cement mixer to form the consistency required ( litres, 16-18% of the amount of powder) and slowly add Mapegrout FMR-PP in a constant flow. If better air curing is required, add Mapecure SRA at a rate of 0.25% of the weight of the mortar immediately after mixing (0.25 kg every 100 kg of Mapegrout FMR-PP). Mix for 1-2 minutes, remove any powder which has stuck to the sides of the mixing drum and mix again for 2-3 minutes to form a homogeneous, lump-free mix. A mortar mixer or drill with a mixer fitting may also be used, depending on the amount of mortar to be prepared. Mix at a low speed to prevent entraining air into the mix. Only under exceptional circumstances should the mix be prepared by hand. In this case, prepare only small batches each time and mix for at least 5-6 minutes to form a completely homogenous blend. Please be advised that, if the mortar is prepared by hand, more water will be required. This will lead to lower performance figures for some of the characteristics, such as mechanical strength, shrinkage, waterproofing capacity, etc. Mapegrout FMR-PP remains workable for approximately one hour at +20 C. When integrating areas of concrete with layers of Mapegrout FMR-PP more than 5 cm thick without formwork, place additional rebar dolly-bars and make sure the thickness of mortar applied complies with Eurocode 2, according to the exposure classes in EN 206/1. Thinner layers may be applied if there is no reinforcement but the surface of the substrate must be very rough prior to application to contrast any expansion. The expansive action of the mortar takes place during the first few days of hardening. Application of the mortar Mapegrout FMR-PP is generally applied by spray with a piston or worm-screw type rendering machine, such as a Turbosol or Putzmeister (continuous-feed type machines are not suitable). Mapegrout FMR-PP may also be applied in layers up to a maximum of 50 mm thick with a spreader or trowel without using formwork. If a second layer of Mapegrout FMR-PP is required, it must be applied before the first layer has completely set. If the second layer is applied after the first layer has already set, we recommend roughening the surface of the first layer and to wet the surface with water.

3 TECHNICAL DATA (typical values) PRODUCT IDENTITY Strength class according to EN : Type: Consistency: Colour: R4 CC powder grey Maximum size of aggregate (EN ) (mm): 2.5 Bulk density (kg/m³): 1,350 Dry solids content (%): 100 Ion chloride content: minimum requirement 0.05% according to EN (%): 0.05 APPLICATION DATA (at +20 C - 50% R.H.) Colour of mix: Mixing ratio: Consistency of mix: grey 100 parts of Mapegrout FMR-PP with parts of water ( litres of water every 25 kg bag) plastic-thixotropic Density of mix (EN ) (kg/m³): 2,100 ph of mix: > 12.5 Application temperature: Pot life of mix: +5 C to +35 C approx. 1 hour Waiting time between each layer: FINAL PERFORMANCE (17% mixing water) Performance characteristic Test method max. 1-2 hours Requirements according to EN for R4 class mortar Compressive strength (MPa): EN (28 days) Characteristic compressive strength on a 40 x 40 x 160 mm test sample - Rck (MPa): Performance of product > 20 (after 1 day) > 50 (after 7 days) > 65 (after 28 days) EN (after 28 days) Flexural strength (MPa): EN 196/1 8 (after 1 day) 9 (after 7 days) 13 (after 28 days) Compressive modulus of elasticity (GPa): EN (after 28 days) 27 (after 28 days) Adhesion to concrete (substrate in MC 0.40 type concrete - w/c ratio = 0.40) according to EN 1766 (MPa): Contrasted expansion (µm/m): EN (after 28 days) > 2 (after 28 days) UNI 8147 method A Resistance to accelerated carbonation: EN depth of carbonation than the reference concrete (MC 0.45 type water/cement ratio = 0.45) according to UNI after 1 day Capillary absorption (kg/m² h 0.5 ): EN < 0.08 Impermeability to water penetration depth - (mm): Thermal compatibility measured as adhesion according to EN 1542 (MPa): freeze-thaw cycles with de-icing salts: storm cycles: dry heat cycles: EN 12390/8 < 5 EN 13687/1 EN 13687/2 EN 13687/4 2 (after 50 cycles) 2 (after 30 cycles) 2 (after 30 cycles) Exposure class: EN 206/1 > 2 > 2 > 2 X0, XC1, XC2, XC3; XC4 XD1, XD2, XD3 XS1, XS2, XS3 XF1, XF2, XF3, XF4 XA1 Initial crack resistance f lf (MPa): UNI 11039/2 5.1 Ductility index: D1 ( mm): UNI 11039/2 1.1 Class D H0 Limit-proportionality (LOP) (MPa): EN fct,l 5,4 Residual flexural strenght (MPa): CMOD1 = 500 µm: CMOD2 = µm: CMOD3 = µm: CMOD4 = µm: EN Reaction to fire: EN Euroclass E fr1 4,0 fr1 6,4 fr1 6,7 fr1 6,0 Notes: because of the structural polymer fibres contained in the mix, special care must be taken when preparing samples for flexural strength tests to ensure the fibres are distributed evenly and uniformly

4 Finish off the surface of the mortar as soon as it starts to set with a float. If the surface then needs to be skimmed, we recommend removing any fibres protruding from the surface with a flat trowel and cleaning the surface with high pressure water jets beforehand. PRECAUTIONS TO BE TAKEN DURING AND AFTER APPLICATION Prepare the mix using sealed bags of Mapegrout FMR-PP which have been stored on their original pallets. In hot weather, store the product in a cool area and use cold water to prepare the mix. In cold weather, store the product in a closed area at a temperature of +20 C and protect from frost. Use lukewarm water to prepare the mortar. After application, particularly in hot or windy weather, we recommend curing Mapegrout FMR-PP very carefully to prevent the mixing water evaporating too quickly, otherwise surface cracks may appear due to plastic shrinkage. Spray water on the surface 8-12 hours after applying the mortar and repeat this operation at regular intervals (every 3-4 hours) for at least the first 48 hours. Alternatively, after floating the mortar, apply Mapecure E anti-evaporation agent in watery emulsion with a low pressure pump, Mapecure S filmforming curing agent for mortar and concrete or Elastocolor Primer, a high-penetration solvent fixing agent for absorbent surfaces and curing agent for repair mortar. As with all the best products in this category available on the market, Mapecure E and Mapecure S impede a good bond with successive layers. Therefore, if a smoothing layer or paint is to be applied after curing, they must be completely removed by sandblasting. If Elastocolor Primer is used to prevent evaporation, on the other hand, the final protective layer of Elastocolor Paint or Elastocolor Rasante may be applied directly on the surface without removing it. PERFORMANCE DATA Mapegrout FMR-PP mortar is reinforced with structural polymer fibres and has the capacity to improve the post-cracking behaviour of repaired concrete members. This type of mortar forms a ductile failure mechanism, in which ductility refers to the capacity of the mortar to maintain its strength characteristics as the cracking process progresses. This is why this type of product is particularly recommended for repairing structures subjected to dynamic loads. The special characteristics of the fibres, along with their high shape ratio, allow the fibres to be dispersed more easily and more evenly in the cementitious matrix and, as a result, improve its rheological properties. They also give the product excellent workability and make it easy to pump. The ductility classification adopted is the one defined in UNI and UNI standards and UNI in particular classifies ductility based on the following measurements: resistance to initial cracking f lp : conventional flexural strength of mortar calculated according to the amount of load recorded against the average opening at the tip of the cut in the test sample; ductility index D 1 : ductility of mortar in the range of average crack opening between 0.6 and 3 mm. The product is classified according to UNI standards by calculating the values mentioned above. The ductility index D 1 for Mapegrout FMR-PP, as shown in the Technical Data table, is higher than 1.1 and, therefore, according to UNI standards, the mortar has a workhardening type of behaviour characterised by a gradual increase in strength as the average crack opening value increases. The graph in figure 1 shows the loaddisplacement curve for Mapegrout FMR-PP according to EN which, thanks to its content of structural polymer fibres, is able to mantain the same initial crack resistance load until a crack-tip opening value of 3.5 mm. The structural polymer fibres contained in Mapegrout FMR-PP also give the mortar excellent behaviour in the event of fire. In fact, if there is a fire, the increase in temperature leads to a change in state of the water in the mortar (moisture): it changes from a liquid state to a gaseous state (water vapour). The water vapour that is formed, however, causes a build up of pressure within the mortar that could lead to it becoming detached from the rebar (spalling effect). This type of behaviour is improved thanks to the polymer fibres in the mortar which, at around C, lift up to leave capillary pores inside the mortar, thereby allowing the water vapour to release the pressure externally and prevent the mortar detaching. Cleaning Wash mortar from tools with water before it hardens. Once hardened cleaning is much more difficult and it must be removed mechanically. CONSUMPTION 18 kg/m² per cm of thickness.

5 Load (kn) CMOD (μm) Figure 1: Load-displacement diagram for Mapegrout FMR-PP according to EN PACKAGING Mapegrout FMR-PP is supplied in 25 kg bags. STORAGE Mapegrout FMR-PP may be stored for 12 months in its original packaging. The special 25 kg vacuum-packed polyethylene bags may be stored outside for the entire duration of the site. Rain has no effect on its characteristics. This product conforms to the prescriptions of Reg. (EC) N. 1907/2006 (REACH) Annex XVII, item 47. SAFETY INSTRUCTIONS FOR PREPARATION AND APPLICATION Mapegrout FMR-PP contains cement that when in contact with sweat or other body fluids causes irritant alkaline reactions and allergic reactions to those predisposed. It may damage the eyes. When applying the product it is recommend to use protective gloves and goggles and to take the usual precautions for handling chemicals. If the product comes in contact with the eyes or skin, wash immediately with plenty of water and seek medical attention. For further and complete information about the safe use of our product please refer to the latest version of our Material Safety Data Sheet. PRODUCT FOR PROFESSIONAL USE. WARNING Although the technical details and recommendations contained in this product data sheet correspond to the best of our knowledge and experience, all the above information must, in every case, be taken as merely indicative and subject to confirmation after long-term practical application; for this reason, anyone who intends to use the product must ensure beforehand that it is suitable for the envisaged application. In every case, the user alone is fully responsible for any consequences deriving from the use of the product. Please refer to the current version of the Technical Data Sheet, available from our website LEGAL NOTICE The contents of this Technical Data Sheet ( TDS ) may be copied into another project-related document, but the resulting document shall not supplement or replace requirements per the TDS in force at the time of the MAPEI product installation. The most up-to-date TDS can be downloaded from our website ANY ALTERATION TO THE WORDING OR REQUIREMENTS CONTAINED OR DERIVED FROM THIS TDS EXCLUDES THE RESPONSIBILITY OF MAPEI. All relevant references for the product are available upon request and from

6 Mapegrout FMR-PP (GB) Any reproduction of texts, photos and illustrations published here is prohibited and subject to prosecution (GB) A.G. BETA BUILDING THE FUTURE