Rapid Setting Repair Mortar Presented by: Navin Shewani Master Builders Solutions
EN 1504 Introduction & General principles EN 1504: The documents It consist of 10 main parts (EN 1504-1 to EN 1504-10) which covers about 65 standards for test methods for atmospherically exposed, buried and submerged concrete structures. The standards includes the Definitions Definition of technical performance of products and systems as well as the CE marking Quality control (production plant) and evaluation of conformity Key stages in the repair process and the strategies of protection and repair (Principles and methods) Site application of products and systems and quality control of works. EN 1504-1 EN 1504-2 to 7 EN 1504-8 EN 1504-9 EN 1504-10 2 11.03.2015
EN 1504 Introduction & General principles EN 1504: The documents Document number EN 1504-1 EN 1504-2 EN 1504-3 EN 1504-4 EN 1504-5 EN 1504-6 EN 1504-7 EN 1504-8 ENV 1504-9 EN 1504-10 Description Describes terms and definitions within the standard Provides specifications for surface protection products/systems for concrete Provides specifications for the structural and non-structural repair Provides specifications for structural bonding Provides specifications for concrete injection Provides specifications for anchoring of reinforcing bars Provides specifications for reinforcement corrosion protection Describes the quality control and evaluation of conformity for the manufacturing companies Defines the general principles for the use of products and systems, for the repair and protection of concrete Provides information on site application of products and quality control of the works 3 11.03.2015
EN 1504 Introduction & General principles Concrete Degradation Mechanical Chemical Physical Impact Overload Movement (e.g. settlement) Explosion Vibration Alkali-aggregate reaction Aggressive agents (e.g. sulphates, soft water, salts) Biological activities Freeze / Thaw Thermal Salt crystallization Shrinkage Erosion Wear 11.03.2 015 4
EN 1504 Introduction & General principles Principles 1-6 associated with repairing / protecting the concrete matrix Principle code and name Principle description and objective PI Protection against ingress Reducing or preventing the ingress of aggressive agents, e.g. water, other liquids, vapour, gas, chemicals and biological. MC Moisture Control Adjusting and maintaining the moisture content in the concrete within specified range of values CR SS Concrete repair or restoration Structural Strengthening described as Restoring the original concrete of an element of the structure to the originally specified shape and function Increasing or restoring the structural load bearing capacity of an element of the concrete structure PR Physical resistance Increasing the resistance of the concrete to physical or mechanical attack RC Resistance against chemicals Increasing the resistance of the concrete surface to deterioration by chemical attack 11.03.2 015 5
EN 1504 Introduction & General principles Degradation due to Reinforcement Corrosion Carbonation Chloride attack Stray currents mixed-in chlorides de-icing salts Other contaminants 11.03.2 015 6
EN 1504 Introduction & General principles Principles 7-11 associated with directly protecting the reinforcing steel Principle code and name Principle description and objective RP Preserving or restoring passivity of steel Creating chemical conditions in which the reinforcing steel is maintained in, or is returned to, a passive condition IR Increasing resistivity of concrete Reducing or halting corrosion by limiting moisture content thus reducing the amount of electrolyte and increasing the electrical resistivity of the concrete CC CP Cathodic Control Cathodic Protection described as Creating conditions in which potentially cathodic areas are unable to drive the anodic reaction e.g. reducing oxygen flow to the cathode Applying an electrical current to polarize the reinforcing steel into a cathodic condition thus preventing the formation of any anodes on the steel and thus preventing corrosion CA Control of Anodic reactions Creating conditions in which potentially anodic reactions of reinforcement are unable to take part in the corrosion reaction 11.03.2 015 7
EN 1504 Introduction & General principles Principle 3: Concrete Restoration Method 3.1 Principle N Principle Definition Methods based on principle Principle 3 [CR] Concrete Restoration 3.1 Applying mortar by hand Method 3.2 - Restoring the original concrete of an element of the structure to the originally specified shape and function - Restoring the concrete structure by replacing part of it. 3.2 Recasting with concrete 3.3 Spraying concrete or mortar 3.4 Replacing elements Method 3.3 8 11.03.2015
Repair Mortars - Performance Requirements Performance requirements for cementitious structural and non-structural repair products * Performance Test Requirement (Table 3 in EN 1504 part 3) characteristics method Structural Non-Structural Class R4 Class R3 Class R2 Class R1 Compressive strength EN12190 45 MPa 25 MPa 15 MPa 10 MPa Chloride ion content EN1015-17 0.05% 0.05% Adhesive bond EN1542 2 MPa 1.5 MPa 0.8 MPa Restrained shrinkage/expansion EN12617-4 Bond strength after test 2 MPa 1.5 MPa 0.8 MPa No requirement Durability - Carbonation Resistance EN13295 d k control concrete No requirement (1) Durability - Thermal compatibility Freeze/thaw EN13687-1 Bond strength after 50 cycles 2 MPa 1.5 MPa 0.8 MPa Visual inspection Durability - Thermal compatibility Thunder/Shower EN13687-2 Bond strength after 30 cycles 2 MPa 1.5 MPa 0.8 MPa Visual inspection Durability - Thermal compatibility Dry Cycling EN13687-4 Bond strength after 30 cycles 2 MPa 1.5 Mpa 0.8 MPa Visual inspection Elastic Modulus EN13412 20 GPa 15 GPa No requirement Skid resistance EN13036-4 Class I: > 40 units wet tested Class II: > 40 units dry tested Class III: > 55 units wet tested Class I: > 40 units wet tested Class II: > 40 units dry tested Class III: > 55 units wet tested Capillary absorption EN13057 0.5 kg.m -2.h -0.5 0.5 kg.m -2.h 0.5 No requirement 9 11.03.2015
Repair Mortars: Test Methods Performance requirements for cementitious structural and non-structural repair products * Performance Test Requirement (Table 3 in EN 1504 part 3) characteristics method Structural Non-Structural Class R4 Class R3 Class R2 Class R1 Compressive strength EN12190 45 MPa 25 MPa 15 MPa 10 MPa Principle For PC, PCC and HC mortar the principle of the test method is to determine the cube compressive strength of 40 mm specimens. An alternative method is to use the equivalent cube method based on prismatic test specimens of 40 mm / 40 mm / 160 mm in size. For prisms of PC mortar, the compressive strength shall only be determined after preparing the sample by cutting into 40 mm cube specimens. 10
Repair Mortars: Test Methods Performance requirements for cementitious structural and non-structural repair products * Performance Test Requirement (Table 3 in EN 1504 part 3) characteristics method Structural Non-Structural Class R4 Class R3 Class R2 Class R1 Adhesive bond EN1542 2 MPa 1.5 MPa 0.8 MPa Substrate Principle This Standard describes a method for measuring the tensile bond strength of repair products and systems applied to standard reference concrete specimens prepared according to pren 1766. The method of test is by direct dolly pull-off using a dolly bonded to the surface of the repair product or system, with the test area having been defined by coring through the surface. Bond Tester 11 11.03.2015
Repair Mortars: Test Methods Performance requirements for cementitious structural and non-structural repair products * Performance Test Requirement (Table 3 in EN 1504 part 3) characteristics method Structural Non-Structural Class R4 Class R3 Class R2 Class R1 Elastic Modulus EN13412 20 GPa 15 GPa No requirement Principle The principle of this test is to measure the secant modulus of the specimen by the application of a controlled axial compressive load to a prism of 4:1 aspect ratio and relating longitudinal compressive strain to the compressive stress inducing it 12 E-modulus strain gauge 11.03.2015
Repair Mortars: Test Methods Performance requirements for cementitious structural and non-structural repair products * Performance Test Requirement (Table 3 in EN 1504 part 3) characteristics method Structural Non-Structural Class R4 Class R3 Class R2 Class R1 Durability - Thermal compatibility Thunder/Shower EN13687-2 Bond strength after 30 cycles 2 MPa 1.5 MPa 0.8 MPa Visual inspection 15min 5.45h 5.45h Principle A layer of the repair product or system or surface protection system is applied to a reference concrete test specimen prepared according to EN 1766.After curing, the test specimen is subjected to thermal shock cycling between 60 C and 12 C. Following the temperature cycling, visible defects are recorded and the adhesion of the repair product or system to the concrete substrate is determined by pull-off test. PCI self made construction Sample 13 11.03.2015
Rapid Setting Repair Mortar with Class R4 Performance Parameters: High-strength, shrinkage compensated, fibre reinforced, structural repair mortar with active corrosion inhibition Meets the requirements of the new European Norm EN 1504 part 3 class R4 Suitable for vertical and overhead applications with hand trowel or spray 14
Rapid Setting Repair Mortar with Class R4 Recommended Uses: Columns, piers and cross beams of all bridges Cooling towers and chimneys and other industrial environments Marine structures, water treatment and sewerage facilities Tunnels, pipes, outfalls and all below ground construction especially in harsh ground conditions 15
Rapid Setting Repair Mortar with Class R4 Performance Test Requirement (Table 3 in EN 1504 part 3) Rapid Setting Repair Mortar characteristics method Structural Structural Class R4 Class R4 Compressive strength EN12190 45 MPa 65 MPa Adhesive bond EN1542 2 MPa 2.2 MPa Durability - Thermal compatibility Freeze/thaw EN13687-1 Bond strength after 50 cycles 2 MPa Bond strength after 50 cycles 3.0 MPa Durability - Thermal compatibility Thunder/Shower EN13687-2 Bond strength after 30 cycles 2 MPa Bond strength after 30 cycles 3.9 MPa Durability - Thermal compatibility Dry Cycling EN13687-4 Bond strength after 30 cycles 2 MPa Bond strength after 30 cycles 3.7 MPa Elastic Modulus EN13412 20 Gpa 23.5 GPa Capillary absorption EN13057 0.5 kg.m -2.h -0.5 0.14 kg.m -2.h -0.5 16 11.03.2015
Rapid Setting Repair Mortar with Class R4 Application Friendly: Easy to Mix Non-Sag Rheology Application thickness up to 30mm Can be pumpable, spray able or hand applied Rapid Setting (Saves Time) 16 Mpa. in 3 Hrs. 17
Project Reference: Ingula Pump Storage Scheme, KwaZulu-Natal 18
Project Reference: Bosmans Place, Johannesburg 11.03.2015 19
Project Reference: Arnot Power Station, Mpumalanga 11.03.2015 20
Project References: BASF Head Office, South Africa 11.03.2015 21
Experience and know-how gained from construction projects worldwide One World Trade Center, NYC: Green Sense Concrete Caterpillar, Peoria, US: Admixture systems Google, Zurich, Switzerland: Mastertop Marmaray Tunnel, Istanbul, Turkey: GleniumSKY Nestlé, Una, India: Ucrete Bird s Nest, Beijing, China: Admixture systems Shanghai Tower: RheoMATRIX Largest Football Stadium in the US, Arlington: Admixture systems/ Waterproofing East-West Highway through Algeria: Emaco Marina Bay Sands Hotel, Singapore: Waterproofing Santo Antônio hydropower plant, Porto Velho, Brazil: Glenium Lekki-Ikoyi Bridge, Lagos, Nigeria: Pozzolith / Rheobuild Wemmershoek Dam, Cape Town: Emaco / Masterseal Burj Khalifa, Dubai: GleniumSKY North Parkes Mine, New South Wales, Australia: Underground Construction Sydney Opera House: Master Builders 22