RELATED MATERIALS
BEVETOL-SPL - Concrete superplasticiser, type G
REOTOL-SPL - Concrete superplasticiser, type F
MEGAGROUT-100 - High-strength, non-shrinking pourable cast grout
DUREBOND - Two-component epoxy injection resin for cracks > 3 mm and bonding agent
AQUAFIX - Rapid-setting cement
RAPICRET - Fast-setting patching mortar
I. NATURE OF THE PROBLEM - REQUIREMENTS
When repairing damaged concrete elements by grouting, the filling material must have sufficient fluidity to flow and fill cavities at 8-12 cm thickness without leaving voids. For thin layers (4-8 cm) it is difficult to place concrete; therefore a very fluid, high-strength mortar is required. The new concrete or mortar must bond to the existing concrete so that the old and new materials act monolithically.
II. SOLUTION
For normal grouting at 8-15 cm thickness use concrete enhanced with BEVETOL-SPL or REOTOL-SPL superplasticiser to achieve high fluidity and strength. For thin layers (4-8 cm) use MEGAGROUT-100, a high-performance grout with very high fluidity and strength.
III. APPLICATION
Substrate preparation:
1. Remove damaged concrete and create cavities to improve bonding.
2. Expose reinforcement where necessary and roughen the surface mechanically (e.g. sand-blasting).
3. Wash the existing concrete thoroughly with water under pressure.
4. Prepare the formwork and place new reinforcement according to the structural design, joining it to the old reinforcement with pegs and dowels.
5. Where possible, coat the old concrete surface with DUREBOND epoxy resin to ensure a good bond.
Normal grouting (8-15 cm):
- Following the preparation, cast concrete with BEVETOL-SPL (0.6-0.8% by cement weight) or REOTOL-SPL (1.2-1.7% by cement weight) until an approximate 20 cm slump is obtained. Vibrate the concrete during casting to achieve proper compaction.
Grouting at thin layers (4-8 cm):
- Seal the joints between formwork panels with AQUAFIX or RAPICRET to prevent leakage because MEGAGROUT-100 is very fluid.
- Mix the contents of a 25 kg bag of MEGAGROUT-100 with 3 kg of water using a low-speed mixer until a homogeneous mass forms; if necessary, add up to 0.5 kg more water to obtain the desired fluidity.
- Cast the mortar carefully, making sure the space between the formwork and existing structure is completely filled without entrapping air. Consumption: 21.5 kg/m² per cm of thickness (approx. 2.1 kg per litre).
- Keep exposed surfaces wet for at least 24 hours by covering them with wet linoleum or polyethylene sheets.
IV. REMARKS
- Perform work only when ambient temperature is between +5 °C and +35 °C.
- The strength of the new concrete must exceed the old concrete by at least 10 N/mm².
- Maximum aggregate size in the concrete should not exceed 20 mm.
- MEGAGROUT-100 should be applied at a maximum thickness of 10 cm per layer.
- Do not rework or soften mortar that has begun to set.
- MEGAGROUT-100 retains fluidity for about 60 minutes at 15-25 °C. At high temperatures store bags in a cool place and use cold water; at low temperatures use lukewarm water and insulate the formwork.
- The product contains cement and is classified as irritant; observe the safety precautions on the packaging.
BEVETOL-SPL - Concrete superplasticiser, type G
REOTOL-SPL - Concrete superplasticiser, type F
MEGAGROUT-100 - High-strength, non-shrinking pourable cast grout
DUREBOND - Two-component epoxy injection resin for cracks > 3 mm and bonding agent
AQUAFIX - Rapid-setting cement
RAPICRET - Fast-setting patching mortar
I. NATURE OF THE PROBLEM - REQUIREMENTS
When repairing damaged concrete elements by grouting, the filling material must have sufficient fluidity to flow and fill cavities at 8-12 cm thickness without leaving voids. For thin layers (4-8 cm) it is difficult to place concrete; therefore a very fluid, high-strength mortar is required. The new concrete or mortar must bond to the existing concrete so that the old and new materials act monolithically.
II. SOLUTION
For normal grouting at 8-15 cm thickness use concrete enhanced with BEVETOL-SPL or REOTOL-SPL superplasticiser to achieve high fluidity and strength. For thin layers (4-8 cm) use MEGAGROUT-100, a high-performance grout with very high fluidity and strength.
III. APPLICATION
Substrate preparation:
1. Remove damaged concrete and create cavities to improve bonding.
2. Expose reinforcement where necessary and roughen the surface mechanically (e.g. sand-blasting).
3. Wash the existing concrete thoroughly with water under pressure.
4. Prepare the formwork and place new reinforcement according to the structural design, joining it to the old reinforcement with pegs and dowels.
5. Where possible, coat the old concrete surface with DUREBOND epoxy resin to ensure a good bond.
Normal grouting (8-15 cm):
- Following the preparation, cast concrete with BEVETOL-SPL (0.6-0.8% by cement weight) or REOTOL-SPL (1.2-1.7% by cement weight) until an approximate 20 cm slump is obtained. Vibrate the concrete during casting to achieve proper compaction.
Grouting at thin layers (4-8 cm):
- Seal the joints between formwork panels with AQUAFIX or RAPICRET to prevent leakage because MEGAGROUT-100 is very fluid.
- Mix the contents of a 25 kg bag of MEGAGROUT-100 with 3 kg of water using a low-speed mixer until a homogeneous mass forms; if necessary, add up to 0.5 kg more water to obtain the desired fluidity.
- Cast the mortar carefully, making sure the space between the formwork and existing structure is completely filled without entrapping air. Consumption: 21.5 kg/m² per cm of thickness (approx. 2.1 kg per litre).
- Keep exposed surfaces wet for at least 24 hours by covering them with wet linoleum or polyethylene sheets.
IV. REMARKS
- Perform work only when ambient temperature is between +5 °C and +35 °C.
- The strength of the new concrete must exceed the old concrete by at least 10 N/mm².
- Maximum aggregate size in the concrete should not exceed 20 mm.
- MEGAGROUT-100 should be applied at a maximum thickness of 10 cm per layer.
- Do not rework or soften mortar that has begun to set.
- MEGAGROUT-100 retains fluidity for about 60 minutes at 15-25 °C. At high temperatures store bags in a cool place and use cold water; at low temperatures use lukewarm water and insulate the formwork.
- The product contains cement and is classified as irritant; observe the safety precautions on the packaging.
