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Home My WebLink AboutTECHNICAL GUIDELINESPrepared by the International Concrete Repair Institute December 2008 Guide' fort Surface Preparation for the .Repair of Deteriorated Concrete Resulting from Reinforcing Steel Corrosion Guideline No. 310.1 R-2008 (formerly No. 03730) Copy right 0 2008 International Concrete Repair Institute All rights reserved International Concrete Repair Institute ' 3166 S. laver Road, Suite 132, Des Plaines, IL 60018 ' Phone: 847-827-0830 Par. 847-827-0832 Web site: www.icri.org E-mail: ink alicri.org LE U MPY y,��frn� ,N-reanwrioNw� ii?IIG.liH� COerCRET5 Ri7Ant a��i;�'iNSTITUTE About ICRI Guidelines ThelriternationalConcreteRepair Iris titute (ICRI) rvasfoun ded to improve the durability ofconcrete repair and enhance its value for structure owners. The identificdtion. development, and promotion of the most promising methods and materials are printery vehicles for accelerating advances in repair technology. Working thrnugh a variety of forums, ICRI members have the opportunity to address these issues and to directly contribute to improving the practice ofconcr•ete repair: A principal component of this effort is to make carefrrllyselected information on importard repair subjects readily accessible to decision makers. Ihrring the past several decades, much has been reported in The literature oil concrete repair meiho:ls aid materials as theyho ve been developed and refined Nevertheless, it has been difficult to find critically revieived information on the state of the art condensed into easy -to -use formats. To that end, ICRI guidelines are prepared by satcn'aaed tasicgroi ps asd app?med by the. ICRI Technical Activities Committee. Bach guideline is designed to address a spec0c area of practice recognized as essential to the achievement of durable repairs. AlllCRIguideline documents ore sybjectto eontinualretaew by the membership and may be revised as approved by the Technical Activitres Committee. Technical Activities Committee Kevin Micbols, Chair Jun McDonald, Secretary Randy Beard Don Caple Bruce Collins William "Bud" Earley Don Ford' Tun Gillespie Peter Goller Peter Lipphardt David Rodler Michael Tabassi David 'Whitmore Pat Winkler Producers of this Guideline Surface Preparation Committee Pat Winkler, Char' DanAnagnos Randy Beard Bruce Collins William Bud" Earley •PeterEmnions* Andrew Fulkerson Randy Glover Fred Goodwin* Kurt Gottinger Tyson Herman Dave Homerding Bob Johnson David Karins Ken Lozen' Jim McDonald BediNewbold Jeffery Smith Sandra Sprouts Rick Toman Patrick Watson *Contributing edrtws Synopsis This guideline provides guidance on concrete removal and surface preparation procedures for the repair of deteriorated concrete caused by reinforcing steel corrosion. Removal geometry, configuration of the repair area, removal process, edge preparation, reinforcement repair, surface preparation and inspection necessary for durable repairs are discussed. Special considerations for concrete removal associated with column repair are included. Keywords anodic ring effect, bonding, bruising, corrosion, delamination, deterioration, reinforcing steel, structural repair, surface preparation. . . This document is intended as a voluntary guideline for the owner, design professional, and concrete repair contractor. It is not intended to relieve the professional engineer or designer of any responsibility for the specification of concrete repair methods, materials, orpractices. While we believe the information contained herein represents the proper means to.achieve quality results, the International Concrete Repair Institute must disclaun any liability or responsibility to those who may choose to rely on all or any part of thus guideline. 310.1R-2008 GUIDE MR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION FILE, COPY I A4491 hi /.xr/�urc 1.0 Intrnduction—...,—..—.^~~~~~.~~~—^—^~'.. :~^^.~^~~^^`~~^~—^—`' ��U � DoUni�un�.........—.,—.—~~.~~^'~~.~—~~.~~'~~~,~�—^^~~`—^`. 1 / 3.0 Exposure oi8n�foro�g8�u,........�....~.~..~~~~.,—^^..�~~.—.~.~ 4J0 Anodic 0ng(HNo)�8md............~.~~^..~^'~~..~~.~..—~_..~. 2 5.0 DommolGnomoky^.............^~.,',~~~,_~,^~~',,_,~~^~.~~_ 2 6J0 ConUyuruKonofDnpukArea ..—,...�...�~..~~,~~~'~~.~—~.—,..^.,.~ � � 78 Conm�oDemmmV8u�unePrepuru§mn...—..—....~—~...`--~.~~~—.~^~ � � 71Exposing and Undercutting ofReinforcing Steel .......... '—..—..~.~~.~~ ... ........... 3 7.2 Preparation of the Po�no�r—...~...~.~'^^—.^~.~~~~~�..~~~—// T�Qom�ngodthe Concrete Surface and Reinforcing Steel ....................................................... 4 0.0 Inspection and Repair of Reinforcing Steel ......... ............................ .'.~,~~~... ............. 5 �0 RmU8uMooe�speo�nn....,.~..---.—~.,~.~—..'~~~~..^.~.^..~~~. � 1KV Spm��Cond8�nzot Columns ................................................................................................ 8 11J) Summary......,..^.......~.~~__^—~`~~—^^~.r---^^--~~ J 1�0 ' 0dor�moox.,......_._....,..^—~_~,~^~~.~~~~_~~_~~~_~~. J 1Z1 Referenced Standards and Reports 7 IVA STEEL ounnumnw 310.iH-2088 GUDE FOR sURFACEPREPARAMON FORIHE REPAIR OFIDETERJORATED CONCRETE RESULTING FROM REINFORCING gp-4\ INTEF NAT I ON AL CORCHETA IMPAIR w 4vgyWIN ST IT UT E =� TM k�saa y L 310AR-2008 GUIDE FOR SURFACEPRFPAPAIIONFORTHEREPAIROFOEMRICRAIEDCONCRETERESULTINGFROMREINFORCINGSTEELCORROSION 1.0 Introduction This guideline provides owners, design profes- sionals, contractors, and other interested parties with a recommended practice for the removal of deteriorated concrete caused by the corrosion of reinforcing steel, including the preparation ofthe removal cavity to provide a cleats sound surface to bond a repair material. This guideline outlines removal geometry, configuration, removal process, edge preparation, reinforcement repair, surface preparation, and inspection prior to placing a repair material. An engineer should evaluate the impact of concrete removal on structural capacity prior to performing concrete removal and repair. The repair methods involve saw cutting and concrete removal using impact tools, hydrodamolition, and other removal techniques. Special caution should be taken to locate and avoid cutting or damaging embedded reinforcing bars, prestressing strands, post - tensioning tendons, or electrical conduits. Cutting into these items can be life threatening and may significantly affect structural integrity. This guideline also contains a discussion of concrete removal and preparation for the repair. of columns where the concrete is in compression Special consideration must be given to the repair of concrete in compression as the load -carrying capacity of the element may be perrianently compromised during the concrete removal and preparation process. While the procedures outlined herein have been used to successfully remove concrete and prepare the removal cavity onmany projects, the requirements for each project will vary due to many different factors. Each project should be evaluated individually to ascertainthe applicability of the procedures described herein. Refer to ACI 506R-05, "Guide to Shotcrete" for surface prepar- ation prior to shoterete application. 2.0 Definitions Angdicringeftect: Corrosionprocess in which the steel reinforcement in the concrete surrounding a repaired area begins to corrode preferentially to the steel reinforcement in the newly repaired area (sometimes referred to as the halo effect). . Bruised surface (micro -fracturing): Asurface layer weakened by interconnected microcracks in concrete substrates caused by the use of high - impact, mechanical methods for concrete removal, and surface preparation; fractured layer ��f•��lq INrERNATIONAL HiGnin C ncRrTE nrVAIR QN I N S TIT tl T E typically extends to a depth of 0.13 to 0.3E in. (3 to 10 mm) and, if not removed, frequently results in lower bond strengths as compared with surfaces prepared with nonimpact methods. Carbonation: The conversion of calcium ions in hardened cememitious materials to calcium carbonate by reaction with atmospheric carbon dioxide. Carbonation reduces the pH of the concrete and its abilityto protect reinforcing steel and embedded metal items from corrosion. . Chloride contamination: Contamination of concrete with chloride ions commonly used in deicing salts and accelerating admixtures such as calcium chloride and sodium chloride. Chloride contamination above the threshold for corrosion can result in corrosion of the reinforcing steel. Chloride thresbold: The amount of chloride required to initiate steel corrosion in reinforced concrete under a given set of exposire conditions; commonly expressed in percent of chloride ion by mass of cement. Corrosion: Degradation of concrete or steel reinforcement caused by electrochemical or chemical attack. Micro crack: Acrack too small to be seen with the unaided eye. Tensile pulloff test: A test to determine the unit stress, applied in direct tension, required to separate a hardened repair material from the existing concrete substrate. The test may also be used to determine the maxinamn unit stress that the existing concrete substrate is capable of resisting underaxial tensile loading and the near - surface terssile strength of a prepared surface (refer to ICRI Technical Guideline No. 210.3- 2004 (formerly No. 03739] and ASTM C1593). Substrate: The layer immediately under a layer of different material to which it is typically bonded; an existing concrete surface that receives an overlay, partial -depth rep air, protective coating, or some other maintenance or repair procedure. 3.0 Exposure of Reinforcing Steel The practice of completely removing the concrete (undercutting) from around the corroded reinforcement, no matter what degree of corrosion is found, is key to achieving long-termperfbnuance of surface repairs. In most cases,' complete removal of the concrete from around the. reinforcing steel is the best practice, where protection of the reinforcing steel within the GUIDE FOR SURFACE PREPARATION FOR THE REPAIR. OFOEfERIORATFi1 CONCRETER60tiINO FROM REINFORCING STEEL CORN 370.1R-200 COPY , i��3�INT'cFlNAT 10NAl SSvR. 71�'33 CCttC4LTc FOa7A1F. K N S T a T U TNuo E repair cavity is achieved. by providing auniform chemical environment around the reinforcing steel. If noncorroded reinforcing steel is exposed and the concrete is chloride contaminated, removal of the concrete around the reinforcing should occur or other corrosion -reducing means should be considered. Reinforcing steel partially embedded in chloride -contaminated concrete is susceptible to future accelerated corrosion If, for structural reasons, the concrete camrot be completely removed from around the corroded reinforcing steel or if a corrosion inhibiting system is not used, the repairmay be compromised due to continued corrosion. If there is a potential trade-off between durability and structural capacity, structural capacity should always take priority. When reinforcing steel is not fully exposed through the concrete removal and preparation process, alternative corrosion inhib- iting systems shotild be considered. These systems may include use of corrosion inhibitors, sacrificial anodes, or cathodic protection. 4.0 Anodic Ring (Halo) Effect . The existing concrete surrounding a repair area in clloride-contaminated or low pH reinforced concrete is susceptible.to accelerated corrosion This is due to the electricarpotential differential between the chloride contaminated or low pH existing concrete and the chloride -free or high pH repair material. This anodic ring effect czn result in accelerated corrosion of the surrounding reinforcing steel leading to future concrete deterioration. To assess existing concrete conditions beyond the repair area, chloride content and pH of the concrete at the level of the reinforcing steel should be determined. Where the chloride content exceeds the threshold level for the initiation of corrosion or. where the reinforcing steel is susceptible to corrosion as a. result of carbonation, a corrosion inhibiting system should be considered to minimize future corrosion. Othermeasuresmay alsobe considered, such as the application of sealers and coatings, to slow the corrosion process. In severely chloride - contaminated or carbonated concrete, the complete removal and replacement of the contaminated concrete at and beyond the repair area may be necessary to provide a successful long -tern repair. 5.0 Removal Geometry' Lxamples of the removal geometry for several different types of reinforced concrete elements are shown in Fig. 5.1 through 5.6. Repairs may be located'onitorizoatal,vertical, and/or overhead surfaces. The removal in Fig. 5.5 and 5.6 is for columns where the removal will not affect the structural capacity of the column. Removal of concrete within the reinforcing or to expose the reinforcing (concrete in compression) is a special condition and is discussed in Section 10. Fig. 5.1: Partial depth repair, slob or wall,. section Fig. 5.2: Full depth repair, stab or wall, section 2-310.111-2008 GOIDEFOR Sl1RFACEPREPAR4TIONFOR THE REPAIgOFDEFERIORATEDCONCRETE REF E$OFsltt�auay� P � { Fig. 5.3: Beam or rib repair, elevation Fig. 5.4. Beam or rib repair section Fig. 5.5. Column repair, elevation Fig. 5.6. Column repair, section S INT6 RNAT�ONAL . I N3 a T 1 T 6 T I e 6.0 Configuration of Repair Area . Deteriorated and delaminated concrete should be located and marked prior to starting the removal process. Delaminated concrete can be located using sounding or other suitable techniques. The repair area should extend a minimum of 6 in. (152 nun) beyond the actual delaminated concrete. Note that during concrete removal, repair areas can grow in size beyond the areas identified due to incipient delaminations that are not readily identifiable by sounding. Repair configurations should be kept as simple as possible, preferably square or tectangulareNillisquare comers (Pig. 6.1).This may resultin the removal of sound concrete. Reentrant, comers should be minimized or avoided, as they are susceptible to cracking. ei r... �ry�x,h4Y♦ Fig. 6.1: Arcas ofdeterioration and recommended removal configurations 7.0 Concrete Removal/Surface Preparation. 7.1 Exposing.and Undercutting of Reinforcing Steel Remove concrete from the marked areas and undercut exposed reinforcing steel (Fig. 7.1) using impact breakers, hydrodeniolition, or another suitable method. Undercutting will provide clearance under the reinforcing keel for cleaning and full bar circumference bonding to the repair material and the surrounding concrete. Bonding GLADE FOR SURFACE PREPARATION FOR THEREPAIR OF DETERIORATED CONCRETE RESULTING FROM RDNF 61N COR 3101 —2003 3 C 0 P— Y )11NTEFlNhT10NAl crtaj�j c Tn 3R � N u T 1 TUU T T E the repair material to the full circumference of the - reinfoming steelmill'secure the repair structurally. Provide aaynirnurn of 0.75 is (19 mm) clearance between eaposedreinforcing steel and surrounding concrete or 0.25 in. (6 mm) larger than the coarse aggregate in the repair material, whichever is greater. Sound concrete may have to be removed to provide propel clearance around the reinforcing steel. If impactbreakers are used for partial depth concrete removal, the breaker should not exceed 30 lb (12 kg). A 15 lb (7 kg) breaker is preferred Fig. 7.1: Remove concrete to undercut and expose reinforcing steel and ptuvide uniform repab• depth Fig. 7.2: Saw cut perimeter to provide vertical edge Fig. 7.3: Abrasive blasting rc clean substrate and reinforcing to minimize damage to the substrate, reinforcing steel, and surrounding concrete. Concrete removal should extend along the reinforcing steel until there is no further delam- ination, cracking, or significant corrosion and the reinforcing steel is well bonded to the surrounding concrete. Care should be taken to avoid significant and sudden changes in the depth of concrete removal, as the repair material is more susceptible to cracking at these locations. If noncorroded reinforcing steel is exposed during the removal process, care should be taken to not damage the bond to the surrounding concrete. if the bond between the reinforcing steel and concrete is broken, undercutting of the reinforcing steel is required. Remove all deteriorated concrete and additional concrete as required to provide the proper configuration and/or the minimum required, thickness of repair material as required by the manufacturer of the repair material and/or the project specifications. 7.2 Preparation of the Repair. Perimeter The perimeter of the repair area should be saw cut 0.75 in. (19 mm) deep to provide a vertical edge (Fig. 7.2) for the repair material. This will avoid featheredging of the repair material. Depending on the repair material selected, the depth of the existing reinforcing and the manufacturer's recommendations, a sawcut depth less than.0.75 in. (19 nun) deep may be sufficient Care should be taken to avoid cutting the existing reinforcing steel. 7.3 Cleaning of the Concrete Surface and Reinforcing Steel The use of high -impact, mechanical methods to remove deteriorated concrete will result in a surface layer weakened by interconuectedmicro- cracks in the concrete substrate. The fractured (braised) layer can extend to a depth of 0.125 to 0.375 in. (3 to 10 mm) into the resultant concrete substrate andmay resultin reducedboad strength. Remove the bruised layer and bond -inhibiting materials such as dirt, concrete slurry, and loosely bonded concrete by oil -free abrasive blasting (Fig. 7.3) or high-pressure water blasting. The 4-310AFV— 08 GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESUMNG FROM REINFORCING STEEL CORROSION COPY saw -cut edge of the repair area should also be blasted to roughen the polished vertical surface caused by the saw -cutting.' All concrete, corrosion. products, and scale should be removed from the reinforcing steel by oil -free abrasive blasting or high-pressure eater blasting. Verify that the reinforcing steel and concrete surface are free from dirt, oil, cement fines (slurry), or any material that may interfere with the bond of the repair material. Inspect the repair cavity to verify that all delvninations and deterioration have been removed. If hydro - demolition is used,.cement fines (slurry) roust be completely removed from the repair surface. A tightly-bondedlightntst build-up on the reinforcing surface is usually not detrimental to bond. If a protective coating is applied to the reinforcing steel, follow the coating manufacturer's recom- mendations for steel surface preparation. 8.0 Inspection and Repair of Reinforcing Steel Loose reinforcement should be secured in its original position by tying to secure bars or by other appropriate methods to prevent movement during placement of repair material. If reinforcing steel has lost cross -sectional area, a structural engineer should be consulted. Repair reinforcing steel by either replacing the INTERNATIONAL ;aB�siiy9 CGHC:I.ri� nLFA1R damaged/deteriorated steel or placing supple- mental reinforcing steel. in the affected section (Fig. 8.1). Supplemental reinforcing steel may be lap -spliced or mechanically spliced to existing reinforcing steel The supplemental reinforcing steel should extend (lap length) beyond the damaged/deteriorated area in accordance with ACI 318, `Building Code Requirements for Structural Concrete." 9.0 Final Surface Inspection Immediately prior to placing the repair material, inspect the repair cavity to verify that all bond - inhibiting materials (dirt, concrete slurry, loosely bonded aggregates, or any material that may interfere with the bond ofthe repairmaterial to the existing concrete) have been removed. If bond - inhibiting materials are present, the repair cavity should be recleaned as previously described. To verify the adequacy of the prepared concrete surface and completeness of bond- inhibiting•material removal, a tensile pulloff test (ICRI Technical Guideline No. 210.3-2004 or ASTM C1583) should be considered to evaluate the bond strength capacity and tensile strength of the existing concrete substrate. This testmay also be performed after the repair is complete. The pulloff strength requirement should be established by the engineer and included as a performance specification for the repair. Affected Length Loss of Cross Section 'a. V ,',a i Y5{4 $...'Yaernk{.. I,�.i; ta4.. 6.7; 4te"jA',i, Y1 lt'Ylti, ,. fEl Fl,.' i.r.l I(F ; 1 :. .. nl '.. Required Lap Required Lap tn ShppleenZal Bar — - yAffeaed.Length C O Fig. 8.1: Repair of damaged1dereriorated reinforcing p GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OFOMRIORATEO CONCRETE RESULTING FROM REINFORCING sTEELCORROSION 310.113-2000-5 N, i" T IT U T IS I 10.OSpecial Condition at Columns R.T.0 V 5 50 M*1 ggj 4 0. ,fiRA, -5, K . ..... ....... Fig. 10.1:Column loadpath ' Fig. 10.2a: Column repair Fig. 10.2b: Column section Fig. 10.3: Column load path following mpair 5:310.1R-2008 GUIDE FDR SURFACE PREPARA'DON FOR IRE REPAIR OFDETERIORATED CONCRETE RESUL7NGTROMREINFORCING STEEL CORROSION e. Undercutting of reinforcement is a best practice in tensile zones of concrete. In columns, the primary loading condition is compression. From a design perspective, the concrete section containcdwitlunthe minforchrg cageis considered to curry the compressive lends (Fig. 10.1). The concrete outside of the reinforeementis considered as protective concrete cover for fire and corrosion protection of the reinforcement. Removing the concrete within the column reinforcing steel (Fig. 10.2) can greatly increase the compressive stress in the reinforcing steel and the remaining concrete. Upon concrete removal, compressive load paths redistribute around the repair (deteriorated) sections (Fig. 10.3). Depending on the size of the concrete removal area behind the colmnn steel, buckling of the column vertical reinforcing bars can occur. In the majority of cases, shoring systems will not unload the compressive stress in the columnsection. When new repair material is placed in the prepared area, the new material cures and most materials undergo drying shrinkage, whichresults in the new material being put into a tensile stress sUite. The new material will not carry compressive loads until the original concrete compresses further, forcing the repair material into compression If further compression is beyond the capacity of the existing concrete, failure of the column may occur. This key concept; affects the concrete' preparation process. In normal concrete repair (other than colunws), removal of the concrete surrounding the corroding reinforcement (also known as undercutting) is anomial and necessary process to provide for a long-term durable repair. To remove concrete around vertical reinforcing steel in a colmmn (removing concrete inside the reinforcing bar cage) can cause the remaining concrete'and/or reinforcement in the column to become overstressed. From a structural point of view, this condition may'not be desirable. If concreteis to be removed inside thereinforcement cage, a qualified structural engineer should determine the impact of the repair on potential reinforcement buckling and overall structural capacity of the column. Note that the discussion in this section is also applicable in concept to compression zone portions of other structural members such as beams, slabs, and walls (with or without compression reinforcement) where on -going compressive stress exists and where adequate shoring cannot be installed prior to repai stopreventdisplacements andcoresponding stress redistributions during repairs. / INTEMN ATONAL �3'ci3:66�r CONCALT'e naratta I N S T I T U T E 11.0 Summary The repair of deteriorated concrete resulting from reinforcing steel corrosion is necessary to extend the service life of the structure. Performing concrete repairs using industry-bestpractices will ensure the success and longevity of the repair. Understanding the existing conditions and cause of corrosionwill assist the engineer in specifying the type and extent of the repair required, and the type of corrosion mitigation systems and/or preventative measures that should be, considered to protect the structure from future deterioration 12.0 References 12.1 Referenced Standards and Reports The following standards and reports were the latest editions at the time this document was prepared. Because these documents are revised frequently, the reader is advised to contact the proper-sponeoring group if it is desired to refer to the latest version. American Concrete Institute (ACI) ACI 506R, "Guide to Shotcrete" ACI E706 (RAP 8), "Installation of Embedded Galvanic Anodes" American Society for Testing and Materials (ASTM International) ASTM C1583, "StandardTestMethodforTensile Strengthof Concrete Surfaces and the Bond Strength or Tensile Strength of Concrete Repair and Overlay Materials by Direct Tension (Pull - off Method)" International Concrete Repair Institute (ICRI) ICRI Concrete Repair Terminology ICRI Technical Guideline No. 130.1R-2008 (formerly No. 03735), "Guide for Methods of Measurement and Contract Types for Concrete Repair Worle' I.CRI Technical Guideline No. 210.3-2004 (formerly No. 03739), "Guide for Using In -Situ Tensile Pull -Off Tests to Evaluate Bond of Concrete Surface Materials" . GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OFDETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION 310.1R-200E-7 MLL COY LD C-� per.. A (�'�'. INTERNATIONAL 1p';,1;�a'` saeeeaur[ t:�smr ICRI Technical Guideline No. 310.3-2004 (formerly No. 03737), "Guide for the Preparation of Concrete Surfaces for Repair Using Hydro - demolition Methods" ICRI Technical Guideline No. 320.2R-2008 (formerly No. 03733), "Guide for Selecting and Specifying Materials for Repair of Concrete Surfaces" These publications may be obtained from these organizations: American Concrete Institute 38800 Country Club Drive Farmington Hills, MI 49331 4wN vconcrete.org ASTM Intenu<itional 100 Barr Harbor Drive West Conshohocken, PA 19428 www.astm.org International Concrete Repair Institute 3166 S. River Road, Suite 132 Des Plaines, IL 60018 ' ivww.icri.org S'-310.1R-2005 GUIDE FOR SURFACE PREPARATION FOR THE REPAIR OF DETERIORATED CONCRETE RESULTING FROM REINFORCING STEEL CORROSION INTERNATIONAL CONCRETE REPAIR I N s -r i -r u -r r= 3165 S. River Road, Suite 102 [)as Plaines, IL 60018 Phone: 847-627-0830 Fax: 847-827-0832 Web site: www.lcd.org E-mail: lnio@icfi.c)rg C ' P �'CDOY I—-\ We create chemistry 3 030100 Maintenance of Concrete Technical Data Guide asterEmaccr S 440 Pourable and pumpable pre -extended self -consolidating repair mortar FORMERLY LA40 REPAIR MORTAR DESCRIPTION MasterEmaco S 440 is a one -component, shrinkage -compensated, self -consolidating repair mortar. It is designed for large volume repairs, including structural elements in applications from 1.5" (38 mm) to full depth. PRODUCT HIGHLIGHTS • Dual expansion system compensates for shdnkage in plastic and hardened states • High early strength allows early form removal • Low permeability protects against carbon dioxide and chloride intrusion • Excellent freeze/thaw resistance for durability in cold, wet environments • Flowability makes H ideal for placement by pumping or pouring into congested locations • Self -consolidation minimizes honeycombing without vibration APPLICATIONS • Interior and exterior • Large volume structural repairs • Repair or replacement of concrete elements SUBSTRATES • Concrete Master Bulders Solulions by BASF w ..master-builders-solullarsbasLus F \\ ,.J., ` >. t.: ^✓ HOW TO APPLY SURFACE PREPARATION CONCRETE i.Concrete must be structurally sound and fully cured (28 days). 2.Saw cut the perimeter of the area being repaired into a square with a minimum depth of W' (13 mm). a.Referto current ICRI Guideline no.310.2R for surface prep requirements to permit proper bond. REINFORCING Sin t.Remove all oxidation and scale from the exposed reinforcing steel in accordance with ICRITechnical Guideline No. 310.111. a.For additional protection from future corrosion, coat the prepared reinforcing steel with Masterlarotect P 8100 AP. MASTER° »BUILDERS SOLUTIONS TechNcal Data Guide MasterEmaca-SMO Technical Data Test Data Composition, t"... ,. "P'ta._� p80P.E(gY{ 'Ss '^°"t,rL 1,ES,1LT$.. r-�`t...'i:. MasterEmaco S 440 is a proprietary blend of cement, graded aggregate, shrinkage- Fresh wet density, Wife (kg/mi 142(2,275) ASTM C 138 compensating agents, and additives. slump Flaw`, In (cm) 25 (63.5) ASTM C1611 Visual Stability Index Offghly Stable No Bleeding) J-Ring Slump Flow*, In (cm) 24.5 (62.5) ASTM C1621 Passing Ability, in (cm) 0.5 0) No visible blocking Compressive strength, psi (MPai ASTM C 109 2" (51 mm) cubes 1 day 2,500 (17.2) , 7 days 5,000 (34.5) 28 days 6,000 (41.4) Compressive strength, psi (MPai 5,000 (34.5) ASTM C 39 3 by 6" (76 by 152 mm) cylinders, at 28 days Flexural strength, psi (MPa), 1,150 (7.9) ASTM C 348 at 28 days - Slant shear bond strength, 3,000 (20.7) ASTM C 882. (modified') psi (MPa), at 28 days Splitting tensile strength, 500 (3.4) ASTM C 496 psi (MPa), at 28 days Drying shrinkage, pstraln, 350 ASTM C 157. (unmodified) at 28 days Drying shrinkage, pstrain, 611 ASTM C 157. (modified) at 21 days Freeze/thaw resistance, % RDM' 100 ASTM C 666 Coefficient of thermal expansion, 5.5 x 10' (9.9 x 1 O-a) CRD C 39 IIKie F (mVcrN" C) 'No handing agent 'ROM = Relative Dynamic Modulus '2.75 Gus water/ 55 to bag (Minimum water Sieben) Results were obtained with a water per powder ra to of 27 die per 55 to (2.6 L per 25 kg) bag. All application and pedmmance values are typlied for the maiedal, but may vary with test methods, cart itiore, and configurations. j � jj }.iv9 p_iL1 S Mata Builtlem Sdations by BASF wtw+masts-builtlers-solulisas.basf.us MIXING 7.Ensure that MasterEmaco S 440 is thoroughly mixed; a forced -action mixer is essential. Mbdng. in a suitably sized container using an appropriate paddle with a slow -speed (400-500 rpm) heavy- duty drill is acceptable. Do not use free -fall mixers. 2.Measure 2.7 quarts (2.6 L) of potable water and pour 2 quarts into the mixer. With the machine in operation, add 1 full 55 to (25 kg) bag of MasterEmaco S 440 and mix for 1 minute before adding the rest of the water. Always add powder into the water. The quantities mixed may be scaled up as required. 3.Mix for a further 2-3 minutes to obtain a smooth consistency. 4.When using the drill -and -paddle mixing method, place the complete 2.7 quarts (2.61 j of water in the mixing drum. With the paddle rotating, add 1 full 55 lb (25 kg) bag of MasterEmaco S 440 and min 3 minutes to reach a smooth, even consistency. 5.Depending on the ambient temperatures and the desired consistency, additional water may be added. The total water content should not exceed 2.9 quarts (2.7 L) per 55 lb (25 kg) bag. APPLICATION 1.Build forms in accordance with ACI 347R. Keep the unrestrained surface area of the repair to a minimum. 2.Saturate the prepared concrete substrate by filling the prepared formwork with clean water 24 hours before placement a.lmmediately before the placement of MasterEmaco S 440, completely drain this water and seal the drainage outlets, leaving the substrate saturated surface -dry (SSD) with no ponded water remaining. 4.In jobsite circumstances where the formwork cannot be filled with water to achieve an SSD surface, the prepared concrete substrates must be thoroughly hosed down with clean water to achieve an equal level of saturation. Apply the repair material with sufficient pressure to ensure intimate contact with the substrate. &A long open -time bonding agent such as MasterEmaco P 124 may be used in place of a saturated substrate. In such a case, place the MasterEmaco S 440 before the bonding agent becomes tack free. B.Immediately after mixing, pump or pour the MasterEmaco S 440 into the formed area. The material does not require vibrating. 7.The recommended application range of MasterEmaco S 440 is from 40 to 85' F (4 to 29° Q. Follow ACI 305 and 306 for hot or cold weather guidelines. CURING 1.1-eave the formwork in place until the compressive strength reaches 2,500 psi (17.2 MPa)'or a strength specified by the engineer. 2.Cure with an approved curing compound compliant with ASTM C 309 or preferably ASTM C 1315. If the repair area will receive a coating, wet curing Is recommended. CLEAN UP Clean tools and equipment with clean water immediately after use. Cured material must be removed mechanically. FOR BEST PERFORMANCE • Minimum ambient, surface, and material temperature is 40° F (40 C) and rising. • Do not mix longer than 5 minutes. • Minimum application thickness is 1.5" (38 mm). When the depth is less than 1.5, use MasterEmaco S 440 MC. • Do not mix partial bags. • Do not use to make overlay repairs where the surface of fresh, wet MasterEmaco S 440 will remain unrestrained during cure. • Do not vibrate • Do not add plasticizers, accelerators, retarders, or other additives. • For professional use only; not for sale to or use by the general public. • Make certain the most current versions of product data sheet and SDS are being used; visit www.master-builders-solutions.BASF.us to verify the most current versions. • Proper application is the responsibility of the user. Field visits by BASF personnel are for the purpose of making technical recommendations only and not for supervising or providing quality control on,the jobsite. F'So""I lam r� J Technical Data Guide MasterEmaeo•s4 () HEALTH, SAFETY AND ENVIRONMENTAL Read, understand and follow all Safety Data Sheets and product label information for this product prior to use. The SIDS can be obtained by visiting www.master-builders-solutions.basf.us, e-mailing your request to basfbscst®basf.com or calling 1(800)433-9517. Use only as directed. For medical emergencies only, call ChemTre& 1(800) 424-9300. BASF Corporation Construction Systems O a115 d64 faDvetim Far th1 at 8991 m eY15 LIMITED WARRANTY NOTICE - BASF warrants this product to be free from manufacturing defects and to meet the technical properties on the currentTechnical Data Guide, if used as directed within shelf life. Satisfactory results depend not only on quality products but also upon many factors beyond our control. BASF MAKES NO OTHER WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WITH RESPECTTO ITS PRODUCTS. The sole and exclusive remedy of Purchaser for any claim concerning this product, including but not limited tD, claims alleging breach of warranty, negligence, strict liability or otherwise, is the replacement of product or refund of the purchase price, at the sole option of BASF. Any claims concerning this product must be received in writing within one (1) year from the date of shipment and any claims not presented Within that period are waived by Purchaser. BASF WILL NOT BE RESPONSIBLE FOR ANY SPECIAL, INCIDENTAL, CONSEQUENTIAL (INCLUDING LOST PROFITS) OR PUNITIVE DAMAGES OF ANY KIND. Purchaser must determine the suitability of the products for the intended use and assumes all risks and liabilities in connection therewith. This information and all further technical advice are based on BASF's present knowledge and experience. However, BASF assumes no liability for providing such information and advice including the extent to which such information and advice may relate to existing third party Intellectual property rights, especially patent rights, nor shall any legal relationship be created by or arise from the provision of such information and advice. BASF reserves the right to make any changes according to technological progress or further developments. The Purchaser of the Product(s) must test the product(s) for suitability for the intended application and purpose before proceeding with a full application of the product(s). Performance of the product described herein should be verthed by testing and carded out by qualified experts. 889 Valley Park Drive, Shakopee, MN 55379 Customer Service 1(800)433.9517 www.master-builders-solutions.basf.us Technical Service 1(800)243.6739 go The Chemical Company 3 0301 00 Maintenance of Concrete Technical Data Guide MasterEmaco° T 1061. Rapid -setting cement -based concrete repair mortar with extended working time FORMERLY 10-61 RAPID MORFAR DESCRIPTION MasterEmacoT 1061 is a one -component shrinkage -compensated cement -based mortar with an extended working time. It Is designed for repairing horizontal concrete surfaces. PRODUCT HIGHLIGHTS • Extended working time • Extra low permeability helps minimize chloride intrusion • Rapid -setting for quick turn -around repairs • Low residual moisture, can be coated in as little as 6 hours • Excellent resistance to freeze/thaw cycling • Shrinkage compensated, minimizing cracking from drying shrinkage reducing stress atthe bond line • Can be placed neat up to 2" (50 mm) thickness • Can be extended up to 100% by weight providing higher yields • Proprietary cement blend bonds to carbonated and noncarbonated concrete substrates APPLICATIONS • Interior and exterior • Horizontal surfaces • Applications requiring high early -strength gain • Structural concrete repairs • Partial and full -depth repairs SUBSTRATES • Concrete Master Binders Solutions by BMF v master-builders-solu0ons.basfus HOW TO APPLY SURFACE PREPARATION CONCRETE 7.Substrate must be structurally sound and fully cured (28 days). 7 Saw cut the perimeter of the area being repaired into a square with a minimum depth of W (13 mm). 3.The surface to be repaired must be clean, saturated surface -dry (SSD), strong, and roughened to a CSP of 8-9 following ICRI Guideline no. 310.2 to permit proper bond. REINFORCING STEEL 7.Remove all oxidation and scale from the exposed reinforcing steel in accordance with ICRI Technical Guideline No. 310.1 R. zFor additional protection from future corrosion, coat the prepared reinforcing steel with MasterProtect P 8100 AP. MASTER° »BUILDERS SOLUTIONS Technical Data Gulde MasterEmac0-TIO61 Technical Data Test Data Composition The following results were obtained with a water I powder ratio of 5.5 pints (2.6 Q of water to 50 fast (22.7 kill MasterEmacoT 1061 is a projerjecary, blend of of MasterEmaras T 1051 at 73' F (23' C). cement, graded aggregate, shrinkage -compensating ' :' " -:,, rf V E agents, and set -control additives. Fresh wet density, lb/ft' Wm7) 130(2,082) ASTM C138 Compliances Set time, min, at 72' F (22° q Ts- C 1 �91 ASTM G 928 Initial 50 Final 80 Working time, min 25 Length change, % (indralfl) ASTM C928 Drying shrinkage —0.05 (-500) Watling expansion +0.03 (+300) Coefficient of theme[ expansion, 6.8 x 1 V (12.6 x 10-') CRD C $9 inrinl* F (cmkm/' Q Modulus of elasticity, psi (GPa) 4.6 x 101 (32) ASTM C 469 Rapid chloride permeability, <300 ASTM C1202 coulombs Freeze/thaw resistance, % ROM, 100 ASTM C 666, (Procedure A) at 300 cycles Scaling resistance, at 25 cycles 0 rating; no scaling ASTM C 672 Slant shear bond strength, psi (MPa) ASTM C 882, modified' 1 day 2.30006) 28 days 2,60008) Splitting tensile strength, psi (MPa) ASTM C 496 1 day 400(3) 28 days 450(3) Flexural strength, psi (MPa) ASTM C348 1 day 700(5) 28 days 850(6) Compressive strength, psi (MPa), ASTM C109 2" cubes 3 hr 3.000(21) 1 day 4,000(28) 28 days 8,000(55) Compressive strength, psi (MPa), 7,400(61) ASTM C 39 3 by 6" cylinders, at 28 days wo burning agent used; mortar scrubbed Into substrate. Ail application and performance values we typical for the natural, but may vary with test methods, comillans, and configurations. Ok Master Builders Solutions by BASF w .master-builders-solutions.basf.us MIXING APPLICATION CLEAN OP i.Precondition matedal to 7Oo F±5• (21° C t3°) i.After removing all standing water, thoroughly Clean tools and equipment with clean water before mixing. scrub a thin layer of bond coat into the Immediately after use. Cured material must be z.Add 5Yz pints (2.6 Q of potable water to the mixing saturated surface with a stiff-brist ed broom or removed mechanically. containerfor each bag of MasterEmacoT 1061. brush. Do not dilute the bond coat with water. If required, add the correct amount of aggregate Do not apply more of this bond coat than can be to the mixer. Add the powder to the water while covered with mortar before the bond coat dries. FOR BEST PERFORMANCE continuously mixing with a slow -speed drill and Do not retemper the bond coat. Minimum ambient, surface, and material paddle, mortar mixer, or other forced action mixer. 2.Immediately place the repair mortar from one temperature is 500 F (100 C) and rising. 3.Mix for a minimum of 3 minutes until side of the prepared area to the other. Work • Do not mite longer than 5 minutes. fully homogeneous. the material firmly Into the bottom and sides • Minimum application thickness Is W (13 mm). of the patch to ensure good bond. Level the • Consult coating supplier for overcoating SIO AGGREGATE FXfEN51ON Mesta rEmacoT 1061 and screed it to the requirements. depth, t.For repair areas (51-102 rum) in depth, n elevation of the existing concrete. Apply the • Do not mix partial bags. recommendedadditiont the minimum recommended addition minim appropriate finish. • Do not add plastic¢ers, accelerators, retarders, Ihs 1.4 kg) (10 rum of W (10absorption, 3.Fnish the completed repair, as required, taking or other additives. graded, rounded, high- care not to overwork the surface. • For professional use only; not for sale to or use 1b (22.6 kg) hag. density aggregate per 50 lb 4.The recommended application range of by the general public. z.For areas greater than 4" 2 rum) in depth, MasterEmaco T 1061 is from 40 to 850 F (4 • Make certain the most current versions of the minimum recommended addition is 25-50 the minimumr to 290 Q. Follow ACI 305 and 306 for hot or product data sheet and SDS are being used; kg) of 3en (10 rum) washed, cold weather. visit www.master-builders-solutions.BASF.us to graded, rounded, SSD, low -absorption, high- 5.A maximum of 25 minutes should be allowed to verify the most current versions. density aggregate per 50 lb bag. mix, place, and finish MasterEmaco T 1061 at • Proper application is the responsibility of the 3.The maximum aggregate extension Is 50lbs 70, F (21, C) user. Field visits by.BASF personnel are for the (22.6 kg) of pea gravel per bag. purpose of making technical recommendations 4.Aggregate must comply with the requirements CURING only and not for supervising or providing quality of ASTM C 33. Cure with an approved curing compound compliant control on the jobsite. with ASTM C 309 or preferably ASTM C 1315 0 TecMiwl Wa Gulee MasterErnaco8T1061 HEALTH, SAFETY AND ENVIRONMENTAL Read, understand and follow all Safety Data Sheets and product label information for this product prior to use. The SDS can be obtained by visiting www.master-builders-solutans.basf.us. e-mailing your request to basfbscst®basf.com or calling 1(800)433-9517. Use only as directed. For medical emergencies only, call ChemTrec®1(800)424-9300. LIMITED WARRANTY NOTICE BASF warrants this product to be free from manufacturing defects and to meet the technical properties on the curentTechnical Data Guide, if used as directed within shelf fife. Satisfactory results depend not only on quality products but also upon many factors beyond our control. BASF MAKES NO OTHER WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILRY OR FITNESS FOR A PARTICULAR PURPOSE WITH RESPECTTO ITS. PRODUCTS. The sole and exclusive remedy of - Purchaserfor any claim conceming this product; - including but not limited to, claims alleging - breach of warranty, negligence, strict liability or otherwise, is the replacement of product or refund of the purchase price, at the sole option of BASF. Any claims concerning this product must be received in writing within one (1) year from the date of shipment and any claims not presented _within that period are waived by Purchaser. BASF WILL NOT BE RESPONSIBLE FOR ANY SPECIAL, INCIDENTAL, CONSEQUENTIAL (INCLUDING LOST PROFITS) OR PUNITIVE DAMAGES OF ANY KIND. Purchaser must determine the suitability of the products for the intended use and assumes allrisks and liabilities in connection therewith. - This information and all further technical advice are based on BASF's present knowledge and experience. However, BASF assumes no liability for providing such information and advice including the extent to which such information and advice may relate to existing third party Intellectual property rights, especially patent rights, nor shall any legal relationship be created by or arise from the provision of such information and advice. BASF reserves the right to make any changes according to technological progress or further developments. The Purchaser of the Product(s) must test the product(s) for suitability for the intended application and purpose before proceeding with a full application of the product(s). Performance of the product described herein should be verified by testing and canted out by qualified experts. BASF Corporation 889 Valley Park Drive, Shakopee, MN 55379 Construction Systems www.master-builders-olutiens.basf.us a M,WWpm r Nn101M MO 4 , 51. .1 � •'61 iJ d RtuAer � Customer Service 1(800)433.9517 Technical Service 1(800)243.6739 The Chemical Company 3 03 01 00 Maintenance of Concrete Technical Data Guide h!'iasterEmaco T.1.060 Very rapid -setting cement -based concrete repair mortar FORMERLY 10-60 RAPID MORTAR DESCRIPTION MasterEmacoT 1060 is a onecomponentshdnkage-compensated very rapid-seting cement -based mortar. It is designed for repairing horizontal concrete surfaces where high early strength gain is required. PRODUCT HIGHLIGHTS HOW TO APPLY Extra low permeability helps minimize SURFACE PREPARATION chloride intrusion • Very rapid -setting so that structures can be opened to vehicular traffic in 1 hour • Low residual moisture, can be coated in as little as 4 hours • Excellent resistance to freezeltlaw cycling • Shrinkage compensated, minimizing cracking from drying shrinkage reducing stress at the bond line • Can be extended up to 100% by weight providing higher yields • Propdetary cement blend bands to carbonated and noncarbonated concrete substrates APPLICATIONS •Interior and exterior • Horizontal surfaces • Applications requiring high early -strength gain • Structural concrete repairs • Partial and full -depth repairs SUBSTRATES • Concrete Master DwIders Sclurona by BASF wwwmaster-bunders-salunonsAastus CONCRETE 1.Concrete must be structurally sound and fully cured (2B days). 2.Saw cut the perimeter of the area being repaired Into a square with a minimum depth of A" (13 mm). a.The surface to be repaired must be clean, saturated surface -dry (SSD), strong, and roughened to a CSP of 8-9 following ICRI Guideline no. 310.2 to permit proper band.. REINFORCING STEEL 1.Remove all oxidation and scale from the exposed reinforcing steel in accordance with ICRI Technical Guideline No. 310.1 R. 2.For additional protection from future corrosion, coat the prepared reinforcing steel with MasterProtect P 8100 AP. MASTER° BUILDERS SOLUTIONS Technical Data Guide MasuarFinaw• T 1060 Technical Data Test Data Composition The following results were obtained with a water / powder ratio of 5.5 pints (2.6 L) of water to 50 Its (22.7 kg) MasterFinacc T 1060 Is a blend of cement graded of Master6mactsT 1060 at 73' F (23- Q. aggregate, shdnkage-compensating agents, and „; QAQ :. ' Tr..y: ` �} set -control additives. . , Compliances Fresh wet density, Wits ftlms) 130 (2,082) ASTM C 138 • ASTM C 928 Set time, min, at 720 F (22o C) ASTM C 191 Initial 16 Final .28 Working time, min - 8 . Length change, % (pstraln) ASrM C 928 Drying shrinkage _ —0.05 (-500) Wetting expansion +0.03 (+300) 'Coefficient of thermal expansion, 7.0 x 104 02.6 x 1 D4) CPD C 39 IMN° F (cm/cm/° C) Modulus of elasticity, psi (CPa) 4.4 x 106 (19.5) ASTM C 469 Rapid chloride permeability, <300 ASTM C 1202 coulombs Freeze/thaw resistance, % RDM, 100 ASTM C 666. (Procedure A) at 300 cycles Scaling resistance, at 25 cycles 0 rating; no scaling ASTM C 672 Slant shear bond strength, psi (MPa) 'ASTM C 882, modified' 1 day 2,300 (16) 28 days 2,600 (18) Splitting tensile strength, psi (MPa) ASTM C 496 1 day 400 (3) ' 28 days 450 (3) Natural strength, psi (MPa) ASTM C 348 1 day 700 (5) 28 days 850 (6) Compressive strength, psi (MPa), ASTM C 109 2° cubes 1 hr 2,000 (14) 1 day 4,000 (28) 28 days 8,000 (55) Compressive strength, psi (MPa), 7,400 (51) ASTM C 39 3 by 6° cylinders, at 28 days 'No banding agent used; mortar scrubbed Into substrate. Ag appgcaden and pedemande values are typical far the material. but mayvary with test megmds, conddons, and configurations. 11INIZ41ES �ri� .�,R Aid v(% 8 r t Master Builders Solutions by BASF wwwmeslervhuil tlers-eol W ans.hasr.us MIXING APPLICATION . CLEAN BP 1.1arecondition material to 70° F±5° (21 ° C±3°) 1.After removing all standing water, thoroughly Clean tools and equipment with clean water before mixing. scrub a thin layer of bond coat into the immediately after use. Cured material must be ?Add 5%k pints (2.6 U of potable waterto the mixing saturated surface With a stiff -bristled broom or . removed mechanically. container for each bag of MasterEmaco T 1060. brush. Do not dilute the bond coat with water. If required, add the correct amount of aggregate Do not apply more of this bond coat than can be to the mixer. Add the powder to the water while - covered with mortar before the bond coat dries. FOR BEST PERFORMANCE continuously mixing with a slow -speed drill and Do not retemper the bond coat . , • Minimum ambient, surface, and material paddle, mortar mixer, or other forced action mixer. ?Immediately place the repair mortar from one temperature is 40° F (4° C) and rising. &MIX for a minimum of 3 minutes until � . -: side of the prepared area to the other. Work- ^ Do not mix longer than 5 minutes. fully homogeneous. the material firmly into the bottom and sides • Minimum application thickness is W (13 mm). of the patch to ensure good bond. Level the • Consult coating supplier for overcoating AGGREGATE EXTENSION MasterEmacoT 1060 and screed it to the requirements. 1.For repair areas 2-4" (51-102 mm) in depth, elevation of the existing concrete. Apply the • Do not mix partial bags. the minimum recommended addition is 15-25 appropriate finish. ^ Do not add plasticizers, accelerators, retarders, Ibs (6.8-11.4 kg) of %" (10 mm) washed, 3.Finish the completed repair, as required, taking or other additives. graded, rounded, SSD, low -absorption, high- - care notto overwork the surface. • For professional use only; not for sale to or use density aggregate per 50 Ib (22.6 kg) bag. 4,The recommended application range of by the general public. ?For areas greater than 4" (102 In ) in depth, MasterEmaco T 1060 is from 40 to 85° F (4 • Make certain the most current versions of the minimum recommended addition is 25-50 to 29° Q. Follow ACI 305 and 306 for hot or product data sheet and SOS are being used; Ibs (11.4-22.6 kg) of W (10 mm) washed, cold weather. visit www.master-builders-solutions.BASF.us to graded, rounded, SSD, low -absorption, high- 5.A maximum of 15 minutes should be allowed to verify the most current versions. density aggregate per 50 Ib bag. mix, place, and finish MasterEmaco T 1050 at • Proper application is the responsibility of the 3.The maximum aggregate extension is 50lbs 70° F (21° C). user. Field visits by BASF personnel are for the (22:6 kg) of pea gravel per bag. purpose of making technical recommendations 4.Aggregate must comply with the requirements CURING only and not for supervising or providing quality of ASTM C 33. Cure with an approved curing compound compliant control on the jobsite. with ASTM C 309 or prefemblyASTM C 1315. ' ■ Technical Oaf Guide Masterrmaco" T 1060 HEALTH, SAFETY AND ENVIRONMENTAL Read, understand and follow all Safety Data Shoals and product label information for this product prior to use. The SIDS can be obtained by visiting www.master-builders-solutions.basf.us, e-mailing your request to basfbscst®bastoom or calling 1(800)433-9517.Use only as directed. For medical emergencies only, call ChemTrecO 1(800)424-93DO. LIMITED WARRANTY NOTICE BASF warrants this product to be free from manufacturing defects and to meet the technical properties on the curentTechnical Data Guide, if used as directed within shelf life. Satisfactory results depend not only on quality products but also upon many factors beyond our control. BASF MAKES NO OTHER WARRANTY OR GUARANTEE; EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHAMABIUTY OR FITNESS FOR A - PARRCUTARPURPOSE WITH RESPECTTOrTS PRODUCTS. The sole and exclusive remedy of Purchaser for any claim concerning this product, including but not limited to, claims alleging breach of warranty, negligence, strict liability, or otherwise, is the replacement of product or refund of the purchase price, at the sole option of BASF. Any claims concerning this product must be received in writing within one (1) year from the date of shipment and any claims not, presented within that period are waived by Purchaser. BASF WILL NOT BE RESPONSIBLE FOR ANY SPECIAL, INCIDENTAL, CONSEQUENTIAL (INCLUDING LOST PROFITS) OR PUNITIVE DAMAGES OF ANY KIND. Purchaser must determine the suitability of the products for the intended use and assumes all risks and liabilities in connection therewith. This information and all further technical advice are based on BASF's present knowledge and experience. However, BASF assumes no liability for providing such information and advice including the extent to which such information and advice may relate to existing third party intellectual property rights, especially patent rights, nor shall any legal relationship be created by or arise from the provision of such information and advice. BASF reserves the right to make any changes according to technological progress or further developments. The Purchaser of the Product(s) must test the products) for suitability for the intended application and purpose before proceeding with a full application of the product(s). Performance of the product described herein should be verified by testing and carried out by qualified experts. BASF Corporation 889 Valley Park Drive, Shakopee, MN 55379 construction systems www.master-builders-selutions.basf.us O t01300.4 fa{a+9mr 'MIOIM73m W13 Customer Service 1(800)433.9517 Technical Service 1(B00)243.6739 The Chemical Company 3 0301 co Maintenance of Concrete Technical Data Guide Master m*' aco° iV 425 Non -sag concrete repair mortar with integral corrosion inhibitor for vertical and overhead applications FDRMERLY GEL PATCH Master Buidem SalLdlom by BASF w .master-bulldtM-WIWans.basf.es DESCRIPTION MasterEmaco N 425 is a trowel -grade, lightweight, polymer -modified, silica fume -enhanced repair mortar with an Integral corrosion Inhibitor. PRODUCT HIGHLIGHTS • Non -sag consistency able to be placed in 2" (51 mm) thick lifts • Readily sculpted, shaved, and finished to match existing substrate • Very low chloride permeability and an integral corrosion inhibitor protects reinforcing steel • Only requires the addition of potable water • Low shrinkage produces stable, durable bond • Lightweight microscopic beads improve vertical and overhead workability • Polymer modification improves adhesion and provides increased freeze/thaw stability APPLICATIONS • Interior and exterior • Vertical and overhead • Above and below grade • Spells or holes in concrete • Deteriorated edges HOW TO APPLY tSubstrate must be structurally sound and fully cured (28 days). 2 Saw cut the perimeter of the area being repaired into a square with a minimum depth Of %" (6 ram). a.The surface to be repaired must be clean, free of laitance and saturated surface -dry (SSD) following ICRI Guideline no. 310.2 to permit proper bond. REINFORCING STEEL 1.Remove all oxidation and scale from the exposed reinforcing steel in accordance with ICRI Technical Guideline No. 310.1 R. 2For additional protection from future corrosion, coat the prepared reinforcing steel with MasterProtect P 8100 AP. SUBSTRATES • Concrete • Masonry [� ^ • Structural Concrete F f IPY MASTER° »BUILDERS SOLUTIONS Technical Data sure - MasterFinaco• N 425 Technical Data Composition Test Data wPFiDPE(3,1.,::��L::.kA' te'�,`-,+;,4,✓ :x ., ''_l m a'fu..,,. ,. MasterFinaco N 425 is composed of crystalline (quadz) silica and Portland cement. Compressive strength, psi (MPa) ASTM C 109, modified' 1 day - 2,150 (14.8) 7 days - 5,600 (38.6) 28 days 6,750 (46.5) Modulus of elasticity, psi (MPa) 5.6 x.10' (3,861) - ASTM C 215 Typical Properties Splitting tensile strength, psi (MPa) _. ASTM C 496, modified' (wet cure) t 310(2.1) Working time, min 20-30 Wo ki 7 days - - 28 days 560 (3.9) 610 (4.2) at F (ti Flexural strength, psi (MPa) ASTM C 348, modified' 1 day 500 (3.4) 7 days 800 (5.5) 28 days 1,110 (7•7) Bond strength, psi (MPa) ASTM C 882, modified* 1 day 900 (6.2) (mortar scrubbed Into substrate) 7 days 1,900 (13.1) 28 days 2,450 06.9) Water absorption, %, 28 days 4 ASTM C 642 Chloride permeability, Very low range AASKrO T-277(According to coulombs ASTM C 1202. table 1) Length change, %, In/m. wet cure ASTM C 157 1 day +0.019 7 days +0.028 28 day +0.034 Length change, °h, inn, dry cunt' ASTM C 157 1 day —0.026 7 days —0.11 28 days —0.15 Linear coefficient of thermal 5.3 x 10' ASTM C 531 expansion, in/iN' F ' Freeze / Thaw Resistance, % RDM 98.8% ASTM C 666 A Scaling Resistance, Ibs/ t° (kg/mz 0.0 (0.0) No Scaling ASTM C 672 50 Cycles 'At 50% relative humidity Test results are averages obtained under laboratory conditions. Reasonable vadacons can be expected. Master aullders solutions by BASF w xra.ter-0utlaers solutiansAasl." MIXING vPrecondition material to 70• F±5" (21 • C+3•) before mixing. 2.Mechanically mix at slow speed with a a/a" drill and mixing paddle. 3.Add approximately 2Y4 quarts (2.6 L) of potable water into a clean mixing container. Gradually sift in powder'h at a time while mixing continuously at slaw speed (high speeds may entrain air). Mix for a minimum of 3 minutes to ensure a uniform, lump -free consistency. Do not exceed a total of 3 quarts (2.8 L) of mixing.. water per 43 lb (19.8 kg) bag. APPLICATION 1.Dampen the surface with potable water; it must be saturated surface -dry (SSD) with no standing water. 2.With a gloved hand, scrub a small quantity of mixed material into the SSD substrate. Thoroughly key in and work the material throughout the cavity to promote bond. Do not apply more of the bond coat than can be covered with mortar before the bond coat dries. 3.Apply material in lifts of t/a-2" (6-51 mm). Avoid featheredging. For optimum mechanical bond on successive lifts, thoroughly score each lift and allow to reach initial set before the next layer is applied. Placement time is 20-30 minutes at 70• F (21 • C) and 50% relative humidity. 4.Trowel, shave or shape material to the desired finish after Initial set. e.The recommended application range of MasterEmaco N 425 is from 40 to 90• F (4 to 320 Q. Follow ACI 305 and 306 for hot or cold weather guidelines. CURING Cure with an approved water based curing compound compliant with ASTM C 309 or preferably ASTM C 1315. If the repair area will receive a coating, wet curing is recommended. CLEAN UP Clean tocls and equipment with clean water immediately after use. Cured material must be removed mechanically. FOR BEST PERFORMANCE • Do not bridge moving cracks orjoints. • Do not overwork material • Do not add plasticizers, accelerators, retarders, or other additives. • Do not extend with aggregate:.: r • Bonding agents are recommended for large areas as well as permanently damp areas. • Protect from freeing for 24 hours after application. • For professional use only; not for sale to or use by the general public. • Make certain the most current versions of product data sheet and SDS are being used; visit www.master-builders-solutions.BASF.us to verify the most current versions. • Proper application is the responsibility of the user. Field visits by BASF personnel are for the purpose of making technical recommendations only and not for supervising or providing quality control on the jobste. HEALTH, SAFETY AND ENVIRONMENTAL Read, understand and follow all Safety Data Sheets and product label information for this product prior to use. The SDS can be obtained by visiting www.master-builders-solutions.basf.us, e-mailing your request to basfbscst®basf.com or calling 1(800)433-9517. Use only as directed. For medical emergencies only, call ChemTrec61(800)424-9300. LIMITED WARRANTY NOTICE BASF warrants this product to be free from manufacturing defects and to meet the technical properties on the cunentTechnical Data Guide, ff used as directed within shelf life. Satisfactory results depend not only on quality products but .also upon many factors beyond our control. BASF MAKES NO OTHER WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FfTNESS FORA PARTICULAR PURPOSE WITH RESPECTTO ITS PRODUCTS. The sole and exclusive remedy of Purchaser for any claim concerning this product, Including but not limited to, claims alleging breach of warranty, negligence, strict liability or otherwise, is the replacement of product or refund of the purchase price, at the sole option of BASF. Any claims concerning this product must be received in writing within one (1) year from the date of shipment and any claims not presented within that period are waived by Purchaser. BASF WILL NOT BE RESPONSIBLE FOR ANY SPECIAL, INCIDENTAL, CONSEQUENTIAL QNCLUDING LOST PROFITS) OR PUNITIVE DAMAGES OFANY KIND. Purchaser must determine the suitability of the products for the intended use and assumes all risks and liabilities in connection therewith. This information and all furthertechnical advice are based on BASF's present knowledge and experience. However, BASF assumes no liability for providing such information and advice including the extent to which such information and advice may relate to existing third party intellectual property rights, especially patent rights, nor shall any legal relationship be created by or arise from the provision of such information and advice. BASF reserves the right to make any changes according to technological progress, or further developments. The Purchaser of the Product(s) must test the products) for suitability for the intended Application and purpose before proceeding with afull application of the, product(s). Performance of the product described herein should be verified by testing and carded out by qualified experts. cot, F(- sr; :. m �' L I f T.crdcal Gata GNtle MastarErnaco• N 425 BASF Corporation Construction Systems 889 Valley Park Drive, Shakopee, MN 55379 w .master-builders-solutions.hast.us O A➢ta &SFt ramWMW mM4 •?tea 3S} A dl' Customer Service 1(600)433.9517 Technical Service 1(800)243.6739 MA The Chemical Company 3 03 01 00 Maintenance of Concrete Distributed by: BEST MATERIALS Ph:800-474-7570, 602-272-8128 Fax:602-272-8014 www.BestMaterials.com Email: Sales@BestMaterials.com Technical Data Guide MasterEmaco P 124 Water -based epoxy-cementitious bonding agent and rebar coating FORMERLY EMACO P24 .. OESCRIPnoN Ma4erEmaco P 124 is a water -based epoxy-cementtous bonding agent. It is also used to coat and protectrebar. • Extended open time • Integral corrosion inhibitor provides additional protection for reinforcing steel • High alkalinity; compatible with cementitious materials • Premeasured units • Blue color facilitates proper coverage APPLICATIONS • Bonding plastic concrete to hardened concrete • Coating steel rebarto protect against corrosion • Areas where short open times prevent the use of traditional epoxies SUBSTRATES • Concrete • Steel Muter Builders GdUtom by BASF w naster-builders-solutlone.bastw HOW TO APPLY SURFACE PREPARATION CONCRETE 1.Concrete must be structurally sound and fully cured (28 days). zThe surface to be repaired must be clean, strong, saturated surface -dry (SSD) and prepared in accordance with ICRI Guideline no. 310.2 to permit proper bond. a.The clean substrate must be alkaline (pH above 9.5 REINFORCING STEEL Remove all oxidation and scale from the exposed reinforcing steel in accordance with ICRITechnical Guideline No. 310.1R. MIXING 1.Precondition all components to 70 F (21 Q. `.. Thoroughly stir each liquid component before mixing. 2.Pour contents of Part A and Part B into a clean mixing bucket and blend the two components for 2 minutes. Slowly add all of Part C. Use a Jiffy paddle and a drill to property mix the product. MASTER" »BUILDERS SOLUTIONS Technkel on Guide Masmrrmaco• P 124 Technical Data Test Data Compositiony ^,,—s.•.,�T. s fs e = r+tt., ' 6iflOh+'„s•?s � �x: fl0 ? — x MasterEmaco P 124 is a water -based >•"' "-_ ^, vx epoxy-cementitious bonding agent. Pot life, mixed 150 g, min, 90 at 72- F (22° C) Working time, min, 30 at 72° F (22° C) Compressive strength, psi (MPa), 8,000 (55.2) ASTM C 109 28 days Flexural strength, psi (MPa), 1,000 (6.9) ASTM C 348 .. 28 days Tensile bond strength, 14 days ACI 503R Open time, hrs Psi (MPa) 2 > 200 (1.4) 9 - > 200 (1.4) 24 > 200 (1.4) Slant shear bond, 14 days ASfM B82 . Open time, hm Psi (MPa) 2 _ > 3,000 (20.7) ' 9 - > 2,500 (17.2) 24 > 2,000 (13.7) Splitting tensile, psi (MPa), 28 days 1,000 (6.9) ASIM C 496 Test results are averages obtained under Laboratory cmdNons. Evect reasonable variations. Tensile Bond Strength According to ACI 503R at 28 days, Topping applied 12 hours after MasterEmaco P 124. P, e: c rq 9 C 0 m, C IS zbu Y 200 150 100' 50 e ,M Competitive MasterEmaco P 124 Systems Master Builders Solutions by BASF wwwmasteo-builders-salulions.basr.us APPLICATION Apply with a stiff -bristled broom or sprayer. With any method, be sure to work the' bonding agent thoroughly into the substrate. Apply at a rate of 20 wet mils (0.5 mm). When applying to rebar, two coats of 10 mils (0.25 mm) will be required. Protect bonding agent from direct sunlight and temperatures above 95' F (35 •C). CLEAN UP Clean up with soap and water. Dried material must be removed mechanically. FOR BEST PERFORMANCE • Substrate and ambient temperature must be from 40 to 95• F (4 to 35• C). • When MasterEmaco P 124 is used as a bonding agent for overlays or toppings, obtain best - results by topping within 6 hours of application. • Do not add solvent, water, or any other material to the product. • Precondition components to approximately 700 F (21 • C) for 24 hours before using. • Protect from direct sunlight, wind, and other conditions that could cause rapid drying of material. • For professional use only; not for sale to or use by the general public. • Make certain the most current versions of product data sheet and SDS are being used;. visit master-builders-solugons.basf.us to verity the most current version. • Proper application is the responsibility of the user. Field visits by BASF personnel are for the purpose of making technical recommendations only and are not for supervising or providing quality control on the jobsite. HEALTH, SAFETY AND EXIIIHONMENTAL Read, understand and follow all Safety Data Sheets and product label information for this product prior to use. The SDS can be obtained by visiting wvnw.master-builders-solufions.basf. us, e-mailing your request to basfbscst®basf.com or calling 1(800)433-9517. Use only as directed. For medical emergencies only, call ChemTrec®1(800)424-9300. LIMITED WARRANTY NOTICE BASF warrants this product to be free from manufacturing defects and to meet the technical properties on the current Technical Data Guide, if used as directed within shelf Iffe. Satisfactory results depend not only on quality products but also upon many factors beyond our control. BASF MAKES NO OTHER WARRANTY OR GUARANTEE, EXPRESS OR IMPUED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FORA PARTICULAR PURPOSE WITH RESPECTTO ITS PRODUCTS. The sole and exclusive remedy of Purchaser for any claim concerning this product, including but not limited to, claims alleging breach of warranty, negligence, strict liability' or otherwise, is the replacement of product or refund of the purchase price, at the sole option of BASF. Any claims concerning this product must be received in writing within one (1) year from the date of shipment and any claims not presented within that period are waived by Purchaser. BASF WILL NOT BE RESPONSIBLE FOR ANY SPECIAL, INCIDENTAL, CONSEQUENTIAL (INCLUDING LOST PROFITS) OR PUNITIVE DAMAGES OFANY KIND. Purchaser must determine the suitability of the products for the intended use and assumes all risks and liabilities in connection therewith. This information and all further technical advice are based on BASF's present knowledge and experience. However, BASF assumes no liability for providing such information and advice including the extent to which such information and advice may relate to existing third party intellectual property rights, especially patent rights, nor shall any legal relationship be created by or arise from the provision of such information and advice. BASF reserves the dght to make any changes according to technological progress or Maher developments. The Purchaser of the Product(s) must test the product(s) for suitability for the intended application and purpose before proceeding with a full application of the product(s). Performance of the product described herein should be verified by testing and carried out by qualified experts. . �� Y '�'-oval • Technical Data Guide MasterPmaw-P124 Distributed by: BEST MATERIALS Ph:800-474-7570, 602-272-8128 Fax:602-272-8014 www.BestMaterials.com Email: Sales@BestMaterials.com BASF Corporation Construction Systems 02014aac�WO19111 mstne 889 Valley Park Drive, Shakopee, MN 55379 Customer Service 1(800)433.9517 U� www.master-builders-solutions.bast.us Technical Service 1(800)243.6739 ,