RT - 050 - 01 Structural Concrete Repairx

TECHNICAL RECOMMENDATION
Structural Concrete Repair

TECHNICAL DEPARTMENT
R-IT-06/04

RT-050-01

DRIZORO S.A.U. C/Primavera, 50-52. 28850 Torrejn de Ardoz-Madrid (SPAIN)
Tel./Phone: +34 916766676 Fax: +34 916776175
e-mail: info@drizoro.com Web site: www.drizoro.com

n 6003176 / 6003176-MA

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INDEX
1. Introduction
2. Application field
3. Scope
4. Inspection and diagnosis
4.1 Visual inspection. Environment analysis
4.2 Surface tensile strength
4.3 Carbonation depth measurement
4.4 Chloride content
4.5 Sulphate content
4.6 Temperature y surface moisture
5. Previous jobs and products description
5.1 Substrate preparation
5.2 Reinforcement steel treatment
5.3 Structural bonding agents
5.4 Structural repairing mortars
5.4.1 Thixotrophic mortars.
5.4.2 Grout mortars for structural repair.
5.4.3 Selection table for structural repairing mortars.
5.5 Protective coatings
6. Application procedure
6.1 Mixing
6.2 Application of structural repairing mortars
6.2.1 Hand application of thixotrophic mortars.
6.2.2 Mechanical application of thixotrophic mortars.
6.2.3 Fluid mortars applied by pouring or injection.
6.3 Curing
6.4 Protection
7. Application conditions
8. Products information
9. Quality control
9.1 Product delivery control
9.2 Stock control
9.3 Substrate preparation control
9.3.1 Cleaning of the element to be repaired.
9.3.2 Moisture content before bonding agent application.
9.3.3 Substrate temperature.
9.3.4 Minimum tensile strength of the substrate.
9.3.5 Oxide elimination.
9.4 Application control of the bonding agents
9.5 Application control of the repairing mortars
9.6 Final Job control
9.6.1 Adherence control by pull out test.
9.6.2 Probe performance.
9.6.3 No hollow areas checking.
9.6.4 Thickness control
9.7 Control of emptied packaging.
10. Maintenance
11. Technical drawings

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1. INTRODUCTION

This document reports the different DRIZORO systems of structural repair for concrete repairing
and restoration due to its deterioration caused by the effect of mechanical or/and chemical agents
which carry the lost of structural integrity that affects the performance of functions for which resistance
was designed.

2. APPLICATION FIELD

The procedure is applicable to concrete elements which have lost some of its original features
due to structural, chemical or physical pathologies, included in normative UNE-EN 1504.

3. SCOPE

The scope of the concrete repairing job is to return the concrete element its structural capacity
and original geometry by removing the concrete in poor condition and replacing it with a structural
mortar with improved physical features and higher performance against chemical agents, finishing
with a protective coating applied to match the durability of the repaired areas with undisturbed areas
depending on the required needs.

4. INSPECTION AND DIAGNOSIS

To achieve a reliable diagnosis of the real condition of the concrete in order to be able to select
the most suitable material to use in the repairing, it is recommended to perform a number of previous
inspections and tests.

4.1. Visual inspection. Environment Analysis

Based on the local normative and regulations, the ambient in which the structural element is
servicing, need to be classified.

4.2. Surface tensile strength

Tensile strength must be tested according to EN 1542 or equivalent.

4.3. Carbonation depth measurement

Carbonation depth in concrete shall be checked using the phenolphthalein method or test in
such way that all areas showing a purple colour will be taken as a concrete with a pH higher than 12
and thus the steel rebars are protected, in the other hand a violet colour will be taken as a concrete
with a pH lower than 12 and thus the carbonation process has began and the areas which has no
colour variation will be taken as a concrete with a pH very low showing high level of carbonation and
with no protection for the steel reinforcement.

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By using this method is possible to have an idea of the carbonation progress into the concrete
and so it is possible to remove it around the steel reinforcement and replace applying structural
mortars in order to recover the appropriate level of pasivation in the steel reinforcement avoiding the
corrosion risk.

4.4. Chloride content

If suspected chloride ingress, a pathology which may cause degradation of concrete, some core
testing at different levels and depths shall be carry out in order to establish a survey to perform a
correct diagnosis.

When the amount of chloride detected are higher than the values given in the local normative or
regulations, the chloride contaminated concrete must be removed with special care around of the
steel reinforcement.

4.5. Sulphate content

As in the above situation, some core testing must be performed in the concrete under study in
order to survey the amount of sulphates in the concrete.

4.6. Temperature and surface moisture control

Temperature and moisture values must be controlled both at concrete surface and surrounding
environment with a moisture device and contact thermometer to ensure the application of materials is
within of the recommended range of temperature and moisture.

For more accuracy is recommended to use a device for moisture measurement based on
Calcium Carbide.

5. PREVIOUS JOBS AND PRODUCT DESCRIPTION

5.1. Substrate preparation

The preparation of the concrete surface is the main task of providing the support conditions for
the subsequent application of repair materials and protective coating, so that the combination of the
repair material along with support to behave accordance with the requirements of previously
established resistance and adhesion.

For this reason, the preparation of the surface largely determines the success of the repair.

When deciding on the method used for the preparation of the support should take into account
the material of choice for repair, the extent of the surface being treated, the degree of surface
roughness necessary for the application of repair material and other factors affecting the time to take

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the decision as are the ventilation of the area of operation with systems that create dust or
accessibility to use mechanical or manual means.

The surface preparation begins with the removal of the unsound and loose concrete, cleaning
up the degraded and unsound concrete by removing the parts that have low resistance, are degraded
or contaminated by chemicals such as chlorides or sulphates until reach an area structurally resistant.

Concrete surface must have cohesion higher than 1.0 MPa as measured by the method of
direct pull out, and must be porous enough and with roughness to promote adhesion of the structural
repair mortars. Concrete must be recess so that the thickness of mortar in the worst point is above
the minimum thickness recommended for each type of repair mortar, avoiding wedge shapes for
optimum transmission of forces.

The steel reinforcement affected by corrosion must be discovered completely for an effective
cleaning, looking at the possible loss of section. If necessary a possible strengthening with more steel
rebars or carbon fibber materials shall be considered.

The surface of the concrete and steel reinforcement should be cleaned by removing substances
that may have a negative influence on the adhesion of the materials applied to concrete or promote
corrosion of reinforcing steel. It should be removed fats, oils, efflorescence, loose particles, dust,
laitance and traces of paint and rust from reinforcement with steel wire brush, sand blasting, needle
gun, and so on. Depending on the steel reinforcement protection system selected.

5.2. Reinforcement steel treatment

DRIZORO materials are intended to provide lasting protection against future aggressive
chemicals attacks to steel reinforcement, so the following products may be used:

Product Product type Appearance CE marking
Steel
reinforcement
preparation
Consumpti
on
MAXREST

PASSIVE
Oxide converter
Water base one
component liquid
EN 1504-7
P11(CA)11.1-2
St-2: 0,30 kg/m
2

MAXRITE

PASSIVE
Oxide inhibitor
slurry
Fluid coating
Mortar
EN 1504-7
P11(CA) 11.1-2
St-3: 2,60 kg/m
2

MAXEPOX

AC
Epoxy primer with
oxide inhibitors
Two component
Liquids
--- Sa2 : 0,50 kg/m
2

Principles
P11 (CA) = Principle 11. Control of Anodic Areas
-----
Methods
11.1.= Control of anodic areas by painting reinforcement with coatings containing active pigments
11.2.= Control of anodic areas by painting reinforcement with barrier coatings containing active
pigments

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5.3. Structural bonding agents

Before the start of the repairing job is necessary to apply a bonding agent to enhance the
adherence between existing concrete and the repairing material to optimize the transmission of forces

One of the great advantages of DRIZORO thixotrophic mortars is that the bonding agent is a
slurry prepared with the same repairing mortar by adding 10% more water than is needed for semi-dry
mortar consistency, since in his formulation are included additives which improve the adherence
significantly. Prior to applying the bonding slurry, you should wet the concrete surface to saturation.
The slurry should be applied by brush or broom spreading it over the surface in thin layer preventing
the accumulation of excessive thickness of material on the surface. Should be allowed to tarnish the
slurry prior to application of repair mortar, but should still be cool to the touch. If the slurry dries, you
must reapply.

In the case of concrete with chlorides attack pathology, in which the contents of these are
higher than the maximum allowed by the local regulations, it is necessary to apply an epoxy bonding
agent to isolate the repair mortars and the steel reinforcement from the diffusion of the chlorides
present in concrete. The epoxy bonding agent must be applied by brush or spray on all surface. The
repair mortar should be applied during the open time, while the epoxy bonding agent has stickiness.
In case the epoxy bonding agent dries, the epoxy bonding agent must again be applied to the existing
one.

Product Product type
Open time at
20 C
Consumption
bonding slurry
Fluid slurry made up from the repairing
mortar
h 2,00 kg/m
2

MAXEPOX
BOND Epoxy bonding agent for dry surfaces 2 h 0,3-1,0 kg/m

2

MAXEPOX
BOND S
Epoxy bonding agent for dry surfaces and
suitable for spraying methods
2 h 0,3-1,0 kg/m
2

MAXEPOX
BOND -W Epoxy bonding agent for wet surfaces 2 h 0,3-1,0 kg/m

2

5.4. Structural repairing mortars

This section presents the different structural repair mortars with the scope to rehabilitate the
concrete element, restoring all mechanical capabilities for structural servicing, geometry and the
original state. DRIZORO products for this purpose are made with special cements, selected siliceous
aggregates, additives and additions of polymers and synthetic fibbers. They are non-shrink mortar
with excellent adhesion to the substrate and high mechanical strength. They have excellent
compatibility with the concrete due to its cement-based composition. Its properties are similar in
coefficient of thermal expansion in order to not create tensions due to volume changes and the
modulus of elasticity is slightly lower for compatibility of deformations providing a monolithic
behaviour, achieving structural integrity and a proper stress transfer between concrete and steel
reinforcement. DRIZORO mortars have good resistance to environmental agents which causes most
of the concrete pathologies; such as sulphates, freezing and thawing cycles, etc. They have good
resistance against carbonation and reduce the chloride penetration, are compact and with very low
permeability coefficients.

Mortars for structural repair may be divided in:
- Thixotrophic mortars for structural repair.
- Fluid mortars for structural repair.

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5.4.1. Thixotrophic mortars

Thixotrophic do not require concrete formworks for its application. Its application can be done
manually with a trowel or palette and some of them allow commissioning work by wet spraying
methods.

The most suitable repair mortar will be given by several criteria, mechanical performance,
aggressiveness of the medium or type of exposure, layer thicknesses range, initial and final setting
time, temperatures, extent of repair, performance, etc..

Depending on the needs of the project and commissioning work, it may be chosen quick,
medium or normal setting mortars.

MAXREST
is a mortar admixture with micro silica, thixotrophic, without shrinkage for structural
repairs.

MAXRITE
500 y MAXRITE
700 are mortars modified with polymers and reinforced with

synthetic fibbers incorporating corrosion inhibitors, giving structural mortars with higher mechanical
performance, compatible modules of elasticity, excellent adhesion and greater resistance in
aggressive environments, also allowing more thickness of application per layer and thereby facilitating
the job.

The structural mortars MAXRITE
S, MAXRITE
HT and MAXRITE
F are mortars specifically

designed and formulated for applications of large areas or volumes by wet spraying methods.

Some minor repairs that need to be performed in short time , can be performed using quick-
setting time mortar as MAXREST
or MAXRITE
500, enabling to finish the repairing job rapidly

after successive applications.

When ambient temperatures exceed 30 C, the time a vailable for the application of a mortar
may be too short for quick-setting time mortars, or in some jobs with large repairing areas in which
might be interesting to apply medium or normal setting time mortars by spraying methods as with the
mortars MAXRITE
700, MAXRITE
S, MAXRITE
HT or MAXRITE
F.

The finish surface of the repair mortar can be given either by notched trowel or hard hair brush.
The texture should be slightly roughened to facilitate the adherence of the final protective coatings.

5.4.2. Grout mortars for structural repair

DRIZORO fluids mortars are non-shrink and slightly expansive grouts for repairing, filling and
reinforcement of large volumes by pouring or injection into the formwork for rebuilding of concrete in
pillars, beams, etc. Its use is also indicated for structural anchoring with large requests. The
properties highlighted in these mortars are their high mechanical strength, excellent adhesion to
concrete, steel reinforcements and steel plates, showing a mechanical behaviour very similar to
concrete in their thermal expansion coefficient and elastic modulus.

These fluid mortars achieve high early strength, are resistant to repeated loads and impact,
presenting a low water absorption by capillarity due to its compactness. Its high fluidity allows them to
fill spaces in areas inaccessible, deep or narrow locations or when the large amount of steel

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reinforcement left little space between the rebars. Like DRIZORO thixotrophic mortars, there are also
available, depending on the needs of the job, fast setting fluid mortars and normal fluid mortars.

Due to its mechanical performance, MAXGROUT
and MAXRITE
INJECTION are the more

resistant mortars. MAXRITE
INJECTION is a high performance mortar with corrosion inhibitors

incorporated and modified with polymers to achieve improved adhesion to metallic surfaces.

DRIZORO range of fluid grouts is completed with MAXGROUT
HR, a fluid mortar with high

structural strength and fast setting time and with MAXGROUT
INJECTION, a high fineness mortar

with normal setting time for consolidation of walls and crack repair by injection.

5.4.3. Selection table for structural repairing mortars

Product
P
o
l
y
m
e
r
s

F
i
b
b
e
r
s

I
n
h
i
b
i
t
o
r
s

Thickness Application
method
Setting
time
Class
UNE EN-1504-3

(mm)
(MPa)
T
h
i
x
o
t
r
o
p
h
i
c

MAXREST
X 10 30 By hand Quick R4
MAXRITE
500 X X X 5 50 By hand Quick R4

MAXRITE
700 X X X 5 50
By hand
Sprayed
Medium R4
MAXRITE
HT X X X 5 100
By hand
Projection
Normal R3
MAXRITE
S X 5 50
By hand
Sprayed
Normal R4
MAXRITE
F X X 5 40
By hand
Sprayed
Normal R4
F
l
u
i
d
s

MAXGROUT
* X 10 50
Pouring
Injection
Normal R4
MAXGROUT
*
HR X 10 50
Pouring
Injection
Quick R4
MAXRITE
*
INJECTION
X X 10 50
Pouring
Injection
Normal R4
MAXGROUT
*
INJECTION
X 2 50
Pouring
Injection
Normal n/n
* For thicker applications add 8 kg de of 3-5 mm aggregates per each paper bag of DRIZORO
AGGREGATES 3050.

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Products and systems for the protection and repair of concrete structures.
Structural and non-structural repair. EN 1504-3

Principles and Methods Type Class

CONCRESEAL
-3 P3 (CR) 3.1 PCC R2

CONCRESEAL
-5 P3 (CR) 3.1 PCC R2

MAXEPOX
CEM P3 (CR) 3.1 PCC R2

MAXREST
P3 (CR) 3.1 P4 (SS) 4.4 P7 (RP) 7.17.2 CC R4

MAXRITE
-F P3 (CR) 3.1-3.3 P4 (SS) 4.4 P7 (RP) 7.17.2 PCC R4

MAXRITE
-S P3 (CR) 3.1-3.3 P4 (SS) 4.4 P7 (RP) 7.17.2 PCC R4

MAXRITE
-HT P3 (CR) 3.1-3.3 P4 (SS) 4.4 P7 (RP) 7.17.2 PCC R3

MAXRITE
500 P3 (CR) 3.1 P4 (SS) 4.4 P7 (RP) 7.17.2 PCC R4

MAXRITE
700 P3 (CR) 3.1-3.3 P4 (SS) 4.4 P7 (RP) 7.17.2 PCC R4

MAXGROUT
P3 (CR) 3.1-3.2 P4 (SS) 4.4 P7 (RP) 7.17.2 CC R4

MAXGROUT
-HR P3 (CR) 3.1-3.2 P4 (SS) 4.4 P7 (RP) 7.17.2 CC R4

MAXRITE
INJECTION P3 (CR) 3.1-3.2 P4 (SS) 4.4 P7 (RP) 7.17.2 PCC R4

Principles
P3 (CR) = Principle 3. Concrete Restoration
P4 (SS) = Principle 4. Structural Strengthening
P7 (RP) = Principle 7. Preserving or Restoring Passivity
-----
Methods
3.1.= Concrete restoration by applying mortar by hand
3.2.= Concrete restoration by recasting with concrete
3.3.= Concrete restoration by spraying mortar or concrete
4.4.= Structural strengthening by adding mortar or concrete
7.1.= Preserving or restoring passivity by increasing cover to reinforcement with mortar or
concrete
7.2.= Preserving or restoring passivity by replacing contaminated concrete
-----
Types and Classes
CC = Hydraulic cement mortars
PCC = Polymer modified hydraulic cement mortars
R1-R2= Non-structural repair products
R3-R4= Structural repair products

5.5. Protective coatings

High-build coating are materials with a dry thickness greater than 0,25 mm and less than 5 mm
applied to concrete surface. This bigger thickness provides a better protection to concrete against
water and pollutants. The base polymers of such products include, but are not limited to, acrylics,
styrene-butadiene, polyvinyl acetates, etc. In addition, often contain special additives such as mildew-
resistant chemicals. Since these products are water-resistant, they are highly resistant to freeze-thaw
cycles; they eliminate water penetration that might freeze and cause scaling of concrete.

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Coatings will alter the appearance of the surface and will partially mask blemishes in the
concrete surface due of the fact of these materials will have both high hiding power and some ability
to fill in irregularities and level prepared surfaces. These products may be applied with brush, roller, or
spray.

Resins used in waterproofing coatings allow enveloping a surface with a sufficient dry film
thickness to produce a covering barrier that is watertight and breathable.

Advantages for coatings:

Water permeability.
- Coatings have very low water absorption so they withstand freeze-thaw cycles.

Vapour permeability.
- Resins used in elastomeric coatings are breathable. They allow moisture-vapour
transmission from substrate to escape through the coating without any blisters, bubbles or
peeling-off. This is a favourable characteristic for construction details at undersides of
cooling towers that are subjected to possible negative moisture drive.

Crack bridging.
- Elastomeric acrylic coatings with application thickness from 0,25-0,75 mm have the ability
to elongate of 300% approximately, i.e. these products have the ability of expand and
recovery to its original shape with no cracking or splitting. Therefore, coatings provide
waterproofing and protection to existing or future cracks, fully avoiding the dangerous risk
of reinforcement corrosion by pitting process on critical points.

Protection to reinforcement corrosion.
- The low water permeability and the high vapour permeability for elastomeric coatings lead
a very good resistance of concrete reinforcement corrosion.
- Elastomeric coatings are recognized as effective means of preventing substrate
deterioration due to industrial environment. They prevent deterioration from air and water
pollutants and from dirt and other contaminants by not allowing the pollutants to be
absorbed into a concrete substrate.
- Coatings prevent chloride ion penetration into a substrate and prevent damage from pitting
corrosion.
- Create a physical barrier against industrial pollutant ingress, salts and other aggressive
chemicals for concrete.

Carbon dioxide barrier
- Excellent protection against reinforcement corrosion by carbonation process because it
does not allow the carbon dioxide ingress to concrete. i.e. diffusion of carbon dioxide gas
will be inhibited so the amount of gas able to penetrate the concrete will be reduced.
Laboratory tests have established that although acrylic coating allow water vapour
diffusion, carbon dioxide gas is dramatically reduced when compared to a reference
concrete without protection.

Durability
- Provides higher and long-lasting solution and weathering resistance compared to sealers
(H & I).

Based product.

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- Water-based product, i.e., environmental friendly, non-flammable product suitable for both
outdoor and indoor applications that require big quantities of material.

Appearance.
Coatings are available in a wide range of textures and almost any colour. These products have
excellent UV stability, non-yellowing process and low dirt pickup.

DRIZORO protective systems classified as coatings

Appearance of
dry product
Base Chemistry Application Fields
MAXSEAL

-/FLEX Rough coat -- Cement
Indoor/Outdoor (UV)
+/- hydrostatic pressure
MAXSHEEN
-/ELASTIC Smooth coat Water Acrylic

Indoor/Outdoor (UV)
+/- (low) hydrostatic pressure
MAXURETHANE
range Smooth coat Solvent Polyurethane

Indoor/Outdoor (UV)
+ hydrostatic pressure
MAXEPOX
FLEX Smooth coat -- Epoxy

Indoor/Outdoor (UV)
+ hydrostatic pressure

Products and systems for the protection and repair of concrete structures.
Surface protection systems for Concrete, EN 1504-2

Principles, Methods y Types
Cement-based products
MAXSEAL
+MAXCRYL P1(PI) 1.3 (C) P2 (MC) 2.2 (C) P8 (RI) 8.2 (C)
MAXSEAL
FLEX P1(PI) 1.3 (C) P2 (MC) 2.2 (C) P8 (RI) 8.2 (C)
Acrylic-based products
MAXSHEEN
P1(PI) 1.3 (C) P2 (MC) 2.2 (C) P8 (RI) 8.2 (C)

MAXSHEEN
ELASTIC P1(PI) 1.3 (C) P2 (MC) 2.2 (C) P8 (RI) 8.2 (C)
Epoxy-based products
MAXEPOX
FLEX P1(PI) 1.3 (C) P2 (MC) 2.2 (C)

Polyurethane-based products
MAXURETHANE
P1(PI) 1.3 (C) P2 (MC) 2.2 (C)

MAXURETHANE
2C P1(PI) 1.3 (C) P2 (MC) 2.2 (C)

MAXURETHANE
TOP P1(PI) 1.3 (C) P2 (MC) 2.2 (C)

Principles
P1 (PI) = Principle 1. Protection against Ingress
P2 (MC) = Principle 2. Moisture Control
P8 (RI) = Principle 8. Increasing Resistivity by limiting moisture content
-----
Methods y Types
1.3 = Protection against ingress by coating (C)
2.2 = Moisture control by coating (C)
8.2 = Increasing resistivity by coating (C)

For details on application of protective coatings consult RT 078 SURFACE PROTECTIVE
SYSTEMS. PART II: COATINGS

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6. APPLICATION PROCEDURE

6.1. Mixing

Repair mortars must be mixed with the quantity of water indicated in the corresponding Product
Technical Bulletin. Do not exceed the recommended amounts of water. Do not use the remains of
previous mixings to make a new mix, neither add fillers, aggregates, and others cements in order to
increase the application volume unless otherwise specified.

For mixing, manual means are recommended only for small amounts. For mixing a whole paper
bag is preferable to use mechanical means such as low-speed mixer, 400 to 600 rpm, equipped with
a mixer. The mixing time is about 3 minutes until obtain a homogeneous mortar in colour and
appearance and free of lumps. In no case knead a structural repair mortar using violent mechanical
agitators or high-speed mixer; neither kneads it for too long.

For quick-setting time mortars should only prepare the amount of material that may be placed
before the initial setting time, which depends on temperature and humidity.

6.2. Application of structural repairing mortars

Following is explained the method of application for the different structural repairing mortars.
- Thixotrophic mortars applied by hand.
- Thixotrophic mortars applied by wet spraying methods.
- Fluid mortars applied by pouring or injection.

6.2.1. Hand application of thixotrophic mortars

Apply the bonding agent for an optimum adherence, as stated in paragraph 5.3.

If the bonding agent is product slurry, wet the concrete surface to saturation and apply the slurry
with hard hair brush on the surface to be repaired and on the steel reinforcement, filling all pores,
voids and gaps. Wait until the surface loss the shine, and with the slurry still fresh, apply the
thixotrophic mortar in layers with the maximum recommended thickness for each product. Scratch
the surface of each layer with the spatula before apply the next layer in order to improve the
adherence on each layer applied. Observe the waiting time between layers. If the layer warm up,
slightly spray some clean and fresh water.

If the bonding agent is an epoxy bonding agent, apply the bonding agent and wait the
recommended time for the product and apply the structural repairing mortar pressing on the surface of
the epoxy bonding agent before its gets tack free.

Do not apply structural repairing mortars if the material slurry or the epoxy bonding agent has
lost its properties. In such situation apply again the bonding agent, and apply the structural repairing
mortar within the interval recommended.

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6.2.2. Mechanical application of thixotrophic mortars

When applying the structural repairing mortars by wet spraying methods, is not necessary to
apply a bonding agent, but still is necessary to wet the surface to saturation. If were necessary to
apply the bonding agent, follow the instructions given in paragraph 5.3 and 6.2.1

Spray the mortar on the surface according to the maximum thickness recommended per layer in
such way that the sprayed mortar gets compact, with regular thickness and with the minimum
rebound possible. If needed a smooth or trowelled finishing, it must be performed immediately after
spraying the last layer of mortar.

6.2.3. Fluid mortars applied by pouring or injection.

Application of fluid structural repairing mortars shall be performed by pouring or injection
methods. To do so, is necessary to build up formwork to retain the poured product.

Application by pouring is performed simply by gravity, pouring directly from the mixer in a
continuous way and if possible from the same point in order to avoid cold joints formation and reduce
the risk of air bubbles occluded. If necessary a vibrating tool may be used to fill the requested volume,
some care must be take because too much vibration might cause segregation of the solid particles
and add air bubbles into the material.
When grouting below anchoring plates, remember to practice holes to purge the air in the
volume to be filled. When injecting with pumps, it should be done at low pressure and at low rate to
allow the air pressure dissipation, otherwise uncontrolled pressures might cause the fracture of the
element under reparation and like stated above, some holes must be drilled to purge the air volume
inside the formwork or element.

6.3. Curing

Once the job is finished, observe the standards cautions for a good curing, such as spray clean
and fresh water, cover with plastics or wet burlaps, etc...Also the curing process shall be improved
using the curing agent MAXCURE
.

Protect from rain showers, sunlight and freeze during the first 24 hours and avoid a fast drying
due to high temperatures, wind, etc.

6.4. Protection

The repairing job shall be finished using a waterproofing and protecting cement based coating
MAXSEAL
MAXSEAL

FLEX, or with an acrylic based anti carbonation coating MAXSHEEN
or
MAXSHEEN

ELASTIC.

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7. APPLICATION CONDITIONS

Do not apply in rain or when rain, contact with water, condensation, dampness and dew is
expected within the first 24 h after the application. Do not apply on substrates vitrified or enamelled,
or treated with water repellent agents. Do not apply on bituminous materials, metals, wood, plasters
or paints.

The optimum temperature range for application is from 10 C to 30 C. Do not apply with
substrate and/or ambient temperature is at or below 5 C, or when temperatures are expected to fall
below 5 C within 24 h after application. Do not ap ply to frozen or frost-covered surfaces.

For applications at hot temperatures, low relative humidity and/or windy conditions, i.e. summer
time, surface must be wet thoroughly with plenty of water prior to application. Avoid applications in
areas exposed directly to the sunlight with high temperatures.

Setting time data is measured at 20 C. Lower temperatures and/or higher R.H. values increase
this value.

With low temperatures keep the product in a warm place. With hot temperatures keep the
product in a cool place, wet the different layers and, mix small batches of material and apply
immediately

Store in a cool, dry and covered place, protected from moisture, freezing and away from direct
exposure to sunlight at temperatures above 5 C.

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8. PRODUCT INFORMATION

The repairing materials included in the Technical Recommendation are:
- Steel reinforcement treatment: MAXREST
PASSIVE, MAXRITE
PASSIVE & MAXEPOX

AC
- Bonding agents: MAXEPOX
BOND, MAXEPOX
BOND S & MAXEPOX
BOND W.
- Thixotrophic structural mortars: MAXREST
, MAXRITE
, MAXRITE
500, MAXRITE
700,
MAXRITE
HT, MAXRITE
F & MAXRITE
S.
- Fluid structural mortars: MAXGROUT
, MAXGROUT
HR, MAXRITE
INJECTION &
MAXGROUT
INJECTION.
- Protective coatings: MAXSEAL
, MAXSEAL
FLEX, MAXSHEEN
, MAXSHEEN
ELASTIC,
MAXURETHANE
, MAXEPOX
FLEX, MAXQUICK

For further information, consult the Technical Bulletins and the Safety Data Sheet for each
product.

9. QUALITY CONTROL

All repair jobs must be executed according to a detailed quality control planning for each of the
proceedings performed during the repairing jobs. The number of control test will be established to
evaluate the quality of the performed jobs. The type and number of test will be established according
to UNE EN-1504-10 standards.

9.1 Product delivery control

All materials will be checked at its reception in the job site, verifying and recording the following
parameters:

Total amount of materials.
Name and classification of each material with a correct identification.
Proper packaging, returning all damaged packages or containers.
Expiration date of the products.

9.2 Stock control

All products will be stored in a cool, dry and covered place, protected from moisture, freezing and
away from direct exposure to sunlight at temperatures above 5 C and below 30 C in its unpackaged
containers and without direct contact with the ground.

After each workday must be checked the storage of each material.

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9.3 Substrate preparation control

9.3.1 Cleaning of the element to be repaired

Surface must be checked to verify that accomplish the necessary condition for the product
application.

The control will be performed by visual inspection, verifying:

Cleaning and repairing of the substrate: Check that the substrate accomplishes with the
specifications in section 5.1.

Surface must be clean, without dust and loose particles (bare hand checking) after surface
preparation and before coating application.

Verify that substrate is absorbent and without rest of demolding agents, grease or oils,
determined by water spraying before coating application.

Substrate temperature: Verify at the moment of application that substrate temperature is
within the range established in the Technical Bulletin of each product.

9.3.2 Moisture content before bonding agents application

In the case of application of mortar slurry, you should check that the surface is saturated with
water and there are no negative pressures of water through the surface.

If the bonding agent is epoxy base, the moisture on surface must not be higher than 4 %. Verify
with moisture control device.

9.3.3 Substrate temperature

Check temperature at the moment of application to verify is within the optimum range for each
product.

9.3.4 Minimum tensile strength of the substrate

Check minimum strength with pull out test to verify the substrate cohesion is higher than 1.0
MPa, according to paragraph 5.1. (Standard ISO 4624 or similar as described in the European
Standard EN 1542)

9.3.5 Oxide elimination

Check the steel reinforcement using the models for steel preparation to verify the steel surface
accomplish with the indicated in the technical bulletin of the selected product for the treatment of the
steel rebars.

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9.4 Application control of the bonding agents

Check that application of the bonding agent is homogeneous and continuous, without exceeding
the recommended thickness. Verify that at the moment of application the bonding agent still is fresh
and tacky.

9.5 Application control of the repairing mortars

Verify during application the following:

Quality of the mixing water used according to local regulations
Percentage of mixing water used
Mixing methods used for blend or knead the mortar (as indicated in the Technical Bulletins of
each product), verifying the proper mixing time.
Check the fresh mortar is homogeneous and free of lumps.
Verify thickness and waiting time between layers according to specifications on Technical
Bulletins.
Verify that at the moment of application the bonding agent still is fresh and tacky.

9.6 Final job control

9.6.1. Adherence control by Pull Out test

Pull out test as in Standard ISO 4624 or similar as described in the European Standard EN
1542. Acceptance: Minimum value 1,0 MPa. Whenever failure is in the concrete interface, other
failure mechanism might be accepted if the minimum value is 1,0 MPa.

9.6.2. Probe performance

Test specimens must be taken during application according to UNE 12190 or similar.

9.6.3. No hollow areas checking

The beating on the concrete surface can be performed through light mallet or echo test
equipment by impact with the aim of identifying areas detached from the concrete structure or loose
individual aggregates on the surface of the concrete substrate.

9.6.4. Thickness measurement

Thickness measurement by method of profile measurement or wedge cut method according to
standard ISO 2808. Acceptance: 80% of the requested value.

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9.7 Control of empty packages

Before used packaging disposal, the empty packages must be checked, verifying the hardening
of the leftovers in the containers.

10. MAINTENANCE

Details of the method of execution of the repair and protection, quality control results and other
information applicable to the subsequent maintenance of the structure must be registered and provide
the right person.

Due to the nature of all mineral products used, the durability, efficiency and stability of the
applied products is very high. Therefore, these products require no special maintenance.

Every five years or sooner if necessary, proceed to the visual inspection to verify new cracks or
degradation on the protective coating or in the structural elements repaired. If an abnormality is found
shall be repaired immediately to prevent its spread.

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11. TECHNICAL DRAWINGS

1.- Substrate preparation
2.- Steel reinforcement treatment
3.- Bonding agent
4.- Thixotrophic structural repairing mortar
5.- Coating for concrete surface protection
11.1 Repair of pillars and columns using thixotrophic mortars

3.- Bonding agent
4.- Setting of formworks
5.- Pour of the fluid structural grout
6.- Concrete coating for waterproofing and protection
11.2 Fluid structural grout for pillars and columns repairing

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3.- Pasivation of steel reinforcement
4.- Application of structural repairing mortar
5.- Concrete coating for waterproofing and
protection
11.3 Structural mortars for beams repairing

3.- 1 Layer of structural mortar and scratching of surface
4.- 2 Layer of structural mortar and trowelling of surface
5.- Concrete coating for waterproofing and protection
11.4 Structural mortars applied by wet spreading methods for wall repairing

1
2
3
4
5

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TECHNICAL RECOMMENDATION

Structural Concrete Repair

BOND Epoxy bonding agent for dry surfaces 2 h 0,3-1,0 kg/m

BOND -W Epoxy bonding agent for wet surfaces 2 h 0,3-1,0 kg/m

700 are mortars modified with polymers and reinforced with

F are mortars specifically

500, enabling to finish the repairing job rapidly

INJECTION are the more

INJECTION is a high performance mortar with corrosion inhibitors

HR, a fluid mortar with high

INJECTION, a high fineness mortar

500 X X X 5 50 By hand Quick R4

-3 P3 (CR) 3.1 PCC R2

-5 P3 (CR) 3.1 PCC R2

CEM P3 (CR) 3.1 PCC R2

P3 (CR) 3.1 P4 (SS) 4.4 P7 (RP) 7.17.2 CC R4

-F P3 (CR) 3.1-3.3 P4 (SS) 4.4 P7 (RP) 7.17.2 PCC R4

-S P3 (CR) 3.1-3.3 P4 (SS) 4.4 P7 (RP) 7.17.2 PCC R4

-HT P3 (CR) 3.1-3.3 P4 (SS) 4.4 P7 (RP) 7.17.2 PCC R3

500 P3 (CR) 3.1 P4 (SS) 4.4 P7 (RP) 7.17.2 PCC R4

700 P3 (CR) 3.1-3.3 P4 (SS) 4.4 P7 (RP) 7.17.2 PCC R4

P3 (CR) 3.1-3.2 P4 (SS) 4.4 P7 (RP) 7.17.2 CC R4

-HR P3 (CR) 3.1-3.2 P4 (SS) 4.4 P7 (RP) 7.17.2 CC R4

INJECTION P3 (CR) 3.1-3.2 P4 (SS) 4.4 P7 (RP) 7.17.2 PCC R4

-/ELASTIC Smooth coat Water Acrylic

range Smooth coat Solvent Polyurethane

FLEX Smooth coat -- Epoxy

P1(PI) 1.3 (C) P2 (MC) 2.2 (C) P8 (RI) 8.2 (C)

FLEX P1(PI) 1.3 (C) P2 (MC) 2.2 (C)

P1(PI) 1.3 (C) P2 (MC) 2.2 (C)

2C P1(PI) 1.3 (C) P2 (MC) 2.2 (C)

TOP P1(PI) 1.3 (C) P2 (MC) 2.2 (C)

PASSIVE & MAXEPOX

BOND S & MAXEPOX

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