RELATED MATERIALS
- FERROSEAL: Cement mortar that protects steel reinforcement against corrosion and acts as a bonding layer between old and new concrete.
- MEGACRET-40: Fibre-reinforced high-performance repair mortar.
- MEGACRET-30: Polymer-modified repair mortar.
- ADIPLAST: Polymer latex admixture for improving mortar bonding.
- EPOXYPRIMER-500: Two-component epoxy primer for bonding old and new concrete.
- AQUAFIX or RAPICRET: Fast-setting repair mortar for sealing formwork joints.
I. NATURE OF THE PROBLEM – REQUIREMENTS
Exposure of reinforcing steel due to carbonation or corrosion reduces the cross-section of the bar and causes concrete spalling. Repair requires removal of deteriorated concrete, protection of steel reinforcement against further corrosion, and restoration of the cross-section with a repair mortar that adheres well to concrete and steel.
II. SOLUTION
Clean and derust the exposed reinforcing bars and coat them with FERROSEAL cement mortar in two layers. FERROSEAL provides corrosion protection and improves the bond between new mortar and the existing concrete. Restore the concrete with MEGACRET-40 or MEGACRET-30 fibre‑reinforced repair mortars modified with ADIPLAST polymer. For heavy loads or dynamic stresses, apply EPOXYPRIMER-500 epoxy primer before placing the repair mortar. Use AQUAFIX or RAPICRET to seal formwork joints when casting deep repairs.
III. APPLICATION
1. Remove all deteriorated and loose concrete until sound substrate is reached. Expose corroded steel reinforcement and clean it from rust and scale by wire brushing or sandblasting.
2. Brush the first coat of FERROSEAL onto the cleaned reinforcement and adjacent concrete. When it has dried (about 2 hours), apply a second coat.
3. Mix MEGACRET-40 or MEGACRET-30 with water and ADIPLAST according to the manufacturer’s instructions until a homogeneous mortar is obtained.
4. Pre-wet the substrate without leaving standing water. Apply the mortar with a trowel, pressing it firmly around and behind the reinforcing bars. Build up the repair in layers if necessary, finishing the surface as required.
5. Protect the repaired area from rapid drying. Keep it moist for at least 48 hours or cover with curing cloths or film.
IV. REMARKS
- Application temperature should be between +5 °C and +35 °C.
- Maximum layer thickness per pass depends on the repair mortar (usually up to 40 mm). Apply in multiple layers for thicker repairs.
- Do not rework mortar that has begun to set; prepare only the quantity that can be used within the working time.
- Protect the repair from frost, rain and high temperatures until adequate strength is achieved.
- Wear gloves and goggles during mixing and application; avoid contact with skin and eyes.
- FERROSEAL: Cement mortar that protects steel reinforcement against corrosion and acts as a bonding layer between old and new concrete.
- MEGACRET-40: Fibre-reinforced high-performance repair mortar.
- MEGACRET-30: Polymer-modified repair mortar.
- ADIPLAST: Polymer latex admixture for improving mortar bonding.
- EPOXYPRIMER-500: Two-component epoxy primer for bonding old and new concrete.
- AQUAFIX or RAPICRET: Fast-setting repair mortar for sealing formwork joints.
I. NATURE OF THE PROBLEM – REQUIREMENTS
Exposure of reinforcing steel due to carbonation or corrosion reduces the cross-section of the bar and causes concrete spalling. Repair requires removal of deteriorated concrete, protection of steel reinforcement against further corrosion, and restoration of the cross-section with a repair mortar that adheres well to concrete and steel.
II. SOLUTION
Clean and derust the exposed reinforcing bars and coat them with FERROSEAL cement mortar in two layers. FERROSEAL provides corrosion protection and improves the bond between new mortar and the existing concrete. Restore the concrete with MEGACRET-40 or MEGACRET-30 fibre‑reinforced repair mortars modified with ADIPLAST polymer. For heavy loads or dynamic stresses, apply EPOXYPRIMER-500 epoxy primer before placing the repair mortar. Use AQUAFIX or RAPICRET to seal formwork joints when casting deep repairs.
III. APPLICATION
1. Remove all deteriorated and loose concrete until sound substrate is reached. Expose corroded steel reinforcement and clean it from rust and scale by wire brushing or sandblasting.
2. Brush the first coat of FERROSEAL onto the cleaned reinforcement and adjacent concrete. When it has dried (about 2 hours), apply a second coat.
3. Mix MEGACRET-40 or MEGACRET-30 with water and ADIPLAST according to the manufacturer’s instructions until a homogeneous mortar is obtained.
4. Pre-wet the substrate without leaving standing water. Apply the mortar with a trowel, pressing it firmly around and behind the reinforcing bars. Build up the repair in layers if necessary, finishing the surface as required.
5. Protect the repaired area from rapid drying. Keep it moist for at least 48 hours or cover with curing cloths or film.
IV. REMARKS
- Application temperature should be between +5 °C and +35 °C.
- Maximum layer thickness per pass depends on the repair mortar (usually up to 40 mm). Apply in multiple layers for thicker repairs.
- Do not rework mortar that has begun to set; prepare only the quantity that can be used within the working time.
- Protect the repair from frost, rain and high temperatures until adequate strength is achieved.
- Wear gloves and goggles during mixing and application; avoid contact with skin and eyes.
