Repair Mortar(M)

DESCRIPTION:

AT-REPAIR MORTAR (M) is a high strength and high build dual compensated shrinkage structural repair mortar. AT-REPAIR MORTAR (M) is designed to be used for both vertical and horizontal applications. AT-REPAIR MORTAR (M) has high ultimate compressive strength and high abrasion resistance. The specially selected cement and polymers contained in AT-REPAIR MORTAR (M) provide a mortar with strong adhesion to concrete and masonry work on vertical and horizontal substrates with negligible shrinkage. AT-REPAIR MORTAR (M) is ready to use and requires only addition of water.

USES:

• AT-REPAIR MORTAR (M) is highly recommended for vertical and horizontal structural high build repairs. Typical applications are:
  • Also suitable for repairs that demand high compressive strength
  • Repairing damaged concrete panels where structural strength is required
  • High build repair applications 5 mm to 80 mm for vertical surfaces
  • May be applied in verticals up to 160 mm in small pockets or with the aid of formwork
  • Repairs to spalled concrete or deteriorated concrete caused by corrosion of steel reinforcement
  • Repairs requiring low permeability and high resistance to chlorides and carbon dioxide
  • Can be applied up to 180 mm in horizontal surfaces

FEATURES & ADVANTAGES:

• AT-REPAIR MORTAR (M) ensures high ultimate compressive strength
• High build repairs achievable in a single application
• Low permeability providing protection from chloride attack and carbonation
• High strength and high abrasion resistance
• Dimensionally stable
• Excellent workability
• Shrinkage compensated allowing for long term dimensional stability
• Eliminates the need for formwork
• Shrinkage compensated
• Can be applied by dry or wet process, achieving high build with exceptional compaction and enhanced performance
• May be coated with acrylic protective coatings
• Exceptional bond strength to concrete substrates
• Internal or external applications
• Pre-bagged eliminates any on-site mixing variation
• Easy to use- simply add water and mix

APPLICATION INSTRUCTION:

• SURFACE AND SUBSTRATE PREPARATION
  • All surfaces must be free of oil, grease, dust, plaster, paint and any other contamination that will inhibit the bond
  • Any cracked or weakened surface should be removed and repaired to provide a solid foundation
  • It is recommended that for large areas a minimum depth of 5mm be prepared as to avoid excessive feather edging or skim coating
  • Break out the repair area to a minimum of 5mm up to the saw cut edge
  • Scabbing or high pressure water blasting should be used to remove laitance and provide a mechanical key
  • If any corroded steel is present remove all loose scale and corrosion/rust deposits. Grit blasting is effective in removing corrosion, and all steel including re-bars should be cleaned to a bright condition

• PRIMING
  • Concrete/Masonry: Priming is necessary
  • The substrate should be pre-soaked with water
  • For very porous substrates all masonry surfaces should be primed with AT-GARD PRIMER
  • Allow the primer to reach a tacky consistency before applying AT-REPAIR MORTAR (M)
  • Steel/Rebar:
    • Remove all loose corrosion deposits on steel. Steel should be cleaned to a bright condition

NOTE: If AT-GARD PRIMER dries prior to application of AT-REPAIR MORTAR (M), it is imperative that AT-GARD PRIMER is to be re-applied and allowed to reach a tacky consistency prior to the application of AT-REPAIR MORTAR (M). If AT-GARD PRIMER is too wet, then ultimate build-up of AT-REPAIR MORTAR (M) will be difficult; as slump will occur on the interface of the concrete substrate and repair mortar. In the case where AT-GARD PRIMER is used as a primer, then AT-GARD PRIMER MUST BE TACKY AND NOT DRY prior to the application of the AT-REPAIR MORTAR (M).

• MIXING
  • AT-REPAIR MORTAR(M) is ready to use- simply add the powder to 2.6-2.9 litres of water and mix using a mechanical forced action mixer with a high shear spiral mixing paddle.
  • DO NOT USE FREE FALL MIXERS
  • Always add the powder to the pre-measured water and mix until a homogenous mix is obtained which is lump free
  • Mixing normally takes 3-5 minutes
  • Any shorter mixing time will result in an inconsistent mix
  • DO NOT MIX PART BAGS
  • DO NOT MIX BY HAND
  • DO NOT ADD EXCESS WATER
  • DO NOT ADD MORE THAN 2.9 LITRES OF WATER
  • Excess water will reduce the ultimate (final) strength and extend the drying time of the product. Additional or excess water will increase the sag and reduce the build-up of the mortar
  • Only mix the quantity of material that can be used within the set time of the material
  • Discard partially set or hardened material

• APPLICATION
  • Thoroughly compact the mortar into the prepared and primed substrate and around the exposed steel reinforcement and re-bars.
  • A smooth surface can be obtained using a steel trowel.
  • DO NOT OVERWORK THE SURFACE
  • Spray Application
    • AT-REPAIR MORTAR (M) can be applied using wet application technique. The mortar is pre-mixed with the required dosage of water and then pumped through a delivery hose through a spray gun with a suitable nozzle.
  • Low Temperature Application
    • Do not apply at temperatures below 5º C and falling. All temperatures of 5º C and below, the use of warm water is recommended.
  • High Temperature Application
    • Do not apply at temperatures above 35º C as initial set will commence early and the product will be difficult to apply. It is recommended that chilled/cold water be used to mix the product./li>

• CURING
  • Curing should be conducted is accordance to good concrete practise and ADO recommend the use of suitable curing compound, AT-CURE(AC), applied in accordance to Technical Data Sheet.

• OVER COATING WITH PROTECTIVE COATINGS
  • AT-REPAIR MORTAR (M) can be over coated with all type of decorative and protective coatings. All coatings may be applied over the AT-CURE (AC); hence removal of the curing compound is not necessary.

TYPICAL PERFORMANCE PROPERTIES (obtained by using 2.6 ltr of water per 20 kg bag, under laboratory condition)

APPLICATION INFORMATION

YIELD

DYING SHRINKAGE (Tested as per AS 1012.13)

ABRASION RESISTANCE [Tested to ASTM C501 – 1984 (Tested Abrasion) (Reapproved 1996)]

PRECAUTION:

• Addition of excess water, other than specified will lead to extended cure time and low strength
• If the substrate into which the AT-REPAIR MORTAR (M) is applied moves or cracks, reflective cracking will occur in AT-REPAIR MORTAR (M)
• Ensure existing concrete surfaces / substrates are at least 21 days old prior to application of AT-REPAIR MORTAR (M)
• Do not apply AT-REPAIR MORTAR (M) in areas less than 5 mm thick, occasional thickness less than 5 mm is acceptable only in very localized areas
• In application where high winds and exposed areas are present, ensure curing compound is applied after final trowel
• Protect from direct sunlight/ heat
• Ensure AT-REPAIR MORTAR (M) does not come in contact with water or rain for a minimum period of 24 hours post application
• AT-REPAIR MORTAR (M) should not be used when temperatures are below 5˚C and greater than 35˚C
• If AT-REPAIR MORTAR (M) is to be used in immersed conditions- AAT-GARD PRIMER must be used.

CLEAN UP:

• Wash all tools and equipment with fresh, clean water immediately after use
• AT-REPAIR MORTAR (M) can only be removed mechanically

PACKAGING & STORAGE:

• AT-REPAIR MORTAR (M) is available in
  • 20 kg HDPE bag
• AT-REPAIR MORTAR (M) has shelf life of 6 months if stored in the original sealed packaging in dry, low humid environments
• Keep bags in sealed condition when not in use and away from moisture
• Storing of bags over palette platforms is recommended

HEALTH & SAFETY:

• Protect hands with rubber gloves and eyes with goggles.
• Accidental splashes to the skin or eyes must be rinsed immediately with clean water.
• Store in well-labeled containers.