Technical Bulletin CR1

TECHNICAL BULLETIN CR1
CONCRETE REPAIR GUIDE
SUMMARY OF FEATURES
solvent free products, safer to handle and apply by using an epoxy primer the risk of bond separation and cracking-out of the repair is totally eliminated surface finish ideal for coating and decoration waterproof, providing fillets and joints that may be used in conjunction with most membranes and coatings fast application, no waiting time between priming and filling can be applied to damp surfaces
Rotafix Ltd. Rotafix House, Abercraf Swansea, SA9 1UR U.K. Tel: +44 (0)1639 730481 Fax: +44 (0)1639 730858 website: www.rotafix.co.uk e-mail: sales@rotafix.co.uk
ROTAFIX is a registered trade mark
When considering concrete repair work the following points are important:
1.
Establish the cause of the problem before considering the method of repair. Repairs required special tools, mixers and techniques to facilitate the total operation.
2.
Seek advice from ROTAFIX before commencing the programme. We have more than 20 years experience of concrete repair techniques.
CONCRETE REPAIRS
CARBONATION
The most common cause for the loss of alkalinity in concrete is through a process known as carbonation. Carbon dioxide by way of carbonic acid reacts with the lime and other alkaline materials in the cement and converts them to carbonates. When this process takes place the pH of the concrete, which is normally 11-11.5 falls. The alkaline passivation which is given to any reinforcing steel is lost corrosion can take place. Carbonation involves reaction with carbon dioxide in moist air, it therefore proceeds from the outer surface towards the inside of the concrete. Rate of penetration depends on a number of factors. These include: 1. Atmospheric humidity. 2. Concrete permeability. Rate of penetration slows down naturally as it proceeds more deeply into the concrete. Surface blemishes such as blow holes, honey-combing or cracking will enable carbonation to proceed at a greater rate than on smooth concrete. Carbonation occurs most rapidly at an optimum humidity level of 50-75%. Below 50% moist films do not form and therefore no acid. Above 70% there is too much water. This prevents penetration of the carbon dioxide - it would be difficult to have carbonation in fully immersed concrete. It has been found that the depth of carbonation is very approximately proportional to the square root of the time. (DEPTH = K x TIME) (Where K is a constant)
CARBONATION TESTING
Use of a chemical indicator to check carbonation is quite straightforward. The most commonly used indicator is a solution of phenolphthalein in alcohol and/or water. Phenolphthalein solution applied to fresh strongly alkaline concrete will turn pink. If the alkalinity has been lost the concrete will not turn pink. In practice it is essential that the phenolphthalein solution is applied to freshly exposed concrete. This can be carried out in 2 ways, either: 1. Break a piece of concrete from the main area and spray the underlying surface immediately. Or 2. Drill a hole into the concrete either at a given depth or in small increments. Immediately after drilling the hole flush out the drillings with de-ionised water to avoid contamination. Follow this immediately with a spray of phenolphthalein. There should be a clear mark indicating the difference between pink and concrete colour. The degree of carbonation can then be measured in millimetres.
VARIATIONS
Depth of carbonation will be found to vary on different parts of one concrete structure. Normally it will be less on areas exposed to heavy rain than on external but sheltered faces. It is essential to test all elevations and situations on a concrete building surface in order to correlate a range of results and thereafter take the appropriate action.
CONCRETE REPAIR GUIDE
1. Mark out all suspect areas indicated by cracking to the concrete and/or corrosion stains.
2. Hammer test all concrete suspected of being included in 1 above.
3. Limit the area of individual repairs by cutting regular shapes at the perimeter of the repair using a small diamond bladed cutter. To avoid feather edging the minimum depth of cut should be 10mm into sound concrete.
4. Break out all loose and friable material, only use mechanical tools where absolutely necessary. In the case of narrow sections such as posts and columns it is essential that mechanical tools are not used as these may cause damage to hitherto sound concrete.
2009 Rotafix (Northern) Limited
Page 1 of 6
5. After all loose material has been broken out inspect, in detail, both the underlying surface of the concrete and the exposed steel that is revealed.
6. In areas where extensive rusting has occurred then it may be necessary to continue breaking out existing concrete around the remainder of the diameter of the steel in order to expose any areas containing active rust. Any removal of concrete should be carried out using hand tools.
7. In areas where extra cutting has been carried out reform the edge of the repair using the diamond disc technique identified in 3 above.
8. In the event that corroded tie wires may be revealed, these may be cut out completely. In the event that extensive corrosion and loss of section has occurred in the reinforcing steel, cut out the damaged steel.
9. Make provision for replacing the cut out steel by drilling the concrete and reinstating new sections of steel with ZEROSET ANCHOR GROUT. Where low cover is anticipated it may be advisable to carry out the replacement with stainless steel.
Page 2 of 6
10. Clean the whole of the repair area, particularly that steel which remains and has surface rust. The ideal method is grit blasting, alternatively a needle gun may be used. Grinding of the steel and mechanical wire brushing are not ideal.
11. Prime the exposed steel with 1 good coat of HR Slurry Primer, allowing 1 hour to dry. Ensure that the steel protective coating is applied to the steel only and not to the concrete.
12. Mix P12 2 part epoxy primer and apply to the total repair area, including the previously coated steel. Application of P12 should be consistent with the minimum quantity required conducive with overall wetting of the entire surface within the repair area.
13. Mix RENDACRETE LW with the correct amount of water as per the data sheet. Alternatively if RM20 epoxy mortar is being used, mix the 3 components as per the data sheet. In both cases the data sheets are provided with the packs of material.
2009 Rotafix (Northern) Limited Page 3 of 6
14. Apply the RENDACRETE LW using a combination of trowels and floats, do not over trowel. Finish with a wood float DO NOT spray or brush on extra water. When RM20 epoxy mortar is being used, use either S200 PC Solvent or detergent and water to clean the trowel prior to finishing. Use a steel float, do not apply solvent or water to the RM20 surface.
15. In the event that there is reinforcing steel within the repair area it may be necessary to use a gloved hand to compact the RM20 or the RENDACRETE LW around the full circumference of any steel. This is then followed by the trowel technique described above.
16. Due to position, i.e. overhead or complexity of shape it may be necessary to use shuttering to support the RENDACRETE LW or RM20 during its cure period. Ensure that the shuttering is treated with a suitable release agent such as ROTAFIX RELEASE WAX.
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17. Ensure that any shuttering is firmly fixed to the sound concrete surround in order that the profile is accurately maintained and that the RENDACRETE LW/RM20 may be firmly compacted between the shuttering and the concrete.
18. If there is any doubt about supporting the repair in one application, I.e. if slump is likely to occur during the application process or the cure time, then the repair mortar should be installed in 2 or more operations.
19. All mortars should be applied whilst the primer is still tacky.
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20. In the event that the primer cures before the application of the RENDACRETE LW or RM20, or the primed surface has been left overnight, then a further application of P12 PRIMER must be made prior to application of the mortar.
21. If the RENDACRETE LW or the RM20 is applied in 2 or more layers, (see 18 above), then an interim primer coat of P12 must be applied, it must be tacky when the new layer of mortar is applied.
22. The completed repair is now part of the total concrete structure and is now ready for a protective treatment of either VINACHEM or AQUACHEM anti carbonation coating.
Page 6 of 6
CLEANING SOLVENT
PRODUCT CODE: 3617 - 2 litre
DESCRIPTION:
METHYL ETHYL KETONE supplied in liquid form. It is a clear highly flammable liquid.
PACKAGING:
METHYL ETHYL KETONE is supplied in 2 litre screw capped containers non returnable.
PHYSICAL AND CHEMICAL PROPERTIES:
Physical state: Colour: Odour: Boiling point: Density: Vapour density: Vapour pressure: Solubility: pH Flash point: Autoignition temperature: Lower explosion limit: Viscosity:
Liquid Colourless Characteristic 79 to 80.5 804-806 at 20C Heavier than air 9500 at 20C (measured as N/m) Complete soluble Not available -4 515 1.8 to 11.5 0.42 at 20C (mm/s)
SPECIFIC USES:
METHYL ETHYL KETONE is used for the cleaning of containers and tools which have been used with and/or for the mixing of epoxy resins and their associated curing agents.
HEALTH AND SAFETY:
When handling or using METHYL ETHYL KETONE chemical goggles (eye protection) should be worn to prevent accidental splashing of the eyes. Do not wear contact lenses. Should eye contact occur, wash thoroughly with water for at least 15 minutes and obtain medical attention. Hazardous in case of eye contact (irritant). Low order of acute toxicity. Oral LD50 (rat) is greater than 2000mg/kg Ingestion should be avoided.
TRANSPORT INFORMATION:
UN number 1193 Class 3 Packing group II ADR/RID: Class 3
The information in this document is based on practical tests, but given without guarantee insomuch as methods of use by others is beyond our control. Due to continuing development and improvements, it may be necessary to change without notice the material specification. All goods are sold subject to our Standard Conditions of Sale.
ROTAFIX, ROTAFIX HOUSE, ABERCRAF, SWANSEA SA9 1UR. U.K. TEL: +44 (0)1639 730481 FAX: +44 (0)1639 730858 e.mail: sales@rotafix.co.uk Website: www.rotafix.co.uk SOUTHERN AREA CONTACT: TEL: +44 (0)1442 243169 FAX: +44 (0)1442 234901
PD3617/9
AQUACHEM
PRODUCT CODE:
3001 - Red BS 04 D 45 3008 - Grey BS 00 A 05 3006 Blue BS 18 E 50 3042 Grey BS 00 A 05 (l Litre) 3017 - Blue BS 18 E 51 3018 - Green BS 14 E 53 3019 - Magnolia BS08B15 3020 White 3021 Black BS 00 E 53 3040 Primer
DESCRIPTION:
AQUACHEM is a series of water miscible, 2-pack, epoxy coating systems. AQUACHEM systems contain no solvents and therefore the Health and Fire hazards are minimised. AQUACHEM is independently tested to BS 6920. It is therefore suitable for coating any containers holding potable water. Cured AQUACHEM is non toxic to aquatic life and is suitable for fish farming equipment and tanks. 1. 2. 3. 4. Surface membranes. Skid resistant surface for bridges and ramps. Decorative Floor Coating Hygienic coating for Food/Dairy/Factories/Warehouses and Workshop areas.
SPECIFIC USES:
PACKAGING:
A standard AQUACHEM pack consists of 2 containers, the contents of which when mixed together will give 5 litres of coloured usable product. In the case of the primer/sealer the two containers will yield 4.5 litres of usable product. All surfaces should be sound and free from grease, oil and contaminants. Steel should be clean and free from loose rust and millscale. Concrete must be sound and free from laitance and oil. AQUACHEM Primer contains an inhibitor to prevent flash rusting. For further explicit information/individual substrate preparation, consult our Technical Bulletin CR2 Aquachem for Tanking (ref TBCR2/4). If in any doubt refer to our Technical Department. The contents of the AQUACHEM Base container should be added to the contents of the AQUACHEM Hardener container and mixed thoroughly. Mechanical mixing is recommended. If AQUACHEM is diluted the water must be mixed with the hardener before the addition of the base. DO NOT MAKE PART MIXES. The mixed product should be applied by roller, or in the case of large surface areas by spray. The Primer coat may be over-coated when the initial milky appearance has cleared. In the case of tanking, second and third coats should be applied at 90 to previous coats. Please note: The coating must be rolled/painted out evenly. Thick or heavy coats are not advisable. To obtain specific dry film thickness, multicoats are preferred. In the case of AQUACHEM PRIMER/SEALER being used as a clear finishing coat it is essential that the coating is applied at no more than WFT: 75-100 microns, conducive with overall wetting of the surface. The 2 mixed components of Aquachem must be used within the pot life of between 1 and 3 hours depending on temperature, volume of mixed material and humidity.
PREPARATION:
MIXING AND APPLICATION:
COVERAGE:
Coverage will depend upon the type and nature of the substrate. As a guide, 3-4m/litre on concrete. 4-5m/litre on steel. 4-5m/litre on timber depending on porosity. Practical film thickness/coat AQUACHEM PRIMER 3040-4.5 litre pack - WFT: 75 - 100 microns. DFT: 65 - 85 microns. AQUACHEM Coloured 3001-3022-5 litre pack - WFT: 100 - 125 microns. DFT: 80 - 100 microns. *Wet film thickness (WFT) Dry film thickness (DFT) AQUACHEM should not be used at temperatures below +5C. The cure is considerably increased when RH is above 70%. Overcoating of the primer is between 1 and 5 hours after primer application. Any external work must be protected against rain for 12 - 15 hours dependent upon relative humidity and temperature: Trafficking of complete system is possible 24 - 72 hours after the final application. AQUACHEM conforms to the Water Research Council test requirements of BS 6920 for use in potable water situations. Uncured AQUACHEM may readily be removed with warm water and soap. Mechanical methods are required to remove cured material.
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CURE SCHEDULE: APPROVAL:

CLEANING OF TOOLS:
The site conditions and equipment required when using individual Rotafix products are specific for each project. Only advice given by Rotafix in writing will be considered as part of our contractual liability.
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Epoxy resins and their associated curing agents can cause irritation to some people. Please take the necessary precautions indicated in the COSHH details available from our offices. Please read our Users Safety Guide on the Handling of Resin and Polymer products.
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AQUACHEM is a Registered Trade Mark of Rotafix (Northern) Ltd ROTAFIX, ROTAFIX HOUSE, ABERCRAF, SWANSEA SA9 1UR. U.K. TEL: +44 (0)1639 730481 FAX: +44 (0)1639 730858 e.mail: sales@rotafix.co.uk web site: www.rotafix.co.uk SOUTHERN AREA CONTACT: TEL: +44 (0)1442 243169 FAX: +44 (0)1442 234901 PD3001-42/ 26
VINACHEM
PRODUCT CODE: DESCRIPTION:
3520 - 5 litre pack 3521 - 25 litre pack VINACHEM is an aqueous polymer solution of fine acrylic particles. The liquid material affords maximum penetration into concrete, masonry and brick and certain types of hard and softwood timber substrates, thereby providing a water-resistant polymer barrier. Uncured N.V. 20%. Viscosity: 90 - 100cps at 20C. pH c 8-9 Particle Size c. 0.1 microns. Supplied in 5 litre and 25 litre plastic bottles. Do not store below 0C. Shelf life minimum 12 months at a storage temperature of between +5oC and +20oC Surfaces should be free from grease, oil and other contaminants. It is essential that all loose and friable material be removed from the substrate that is being treated. The preferred method of preparation is by use of medium pressure water jet. Pre-treatment with a suitable fungicide/biocide solution may be required. Following the preparation, treatment with a suitable fungicide/biocide such as Panacide, may be advantageous. The contents may settle during storage. Check container is securely fastened. Invert 3-4 times to ensure contents are mixed. A small quantity of VINACHEM should always be applied on a test area. This will enable the applicator to check that adequate but not excessive material is being applied. It will also indicate any colour changes which may occur with a particular substrate. VINACHEM may be applied by brush, roller or garden-type spray. VINACHEM should be applied at a rate which is conducive with overall wetting of the surface. Excessive application should be avoided, otherwise a translucent surface film may form. Please protect all glass (windows, car windscreens) from all possible splashing/mist from application of Vinachem. Once cured it would be difficult to remove from these surfaces.
PACKAGING:
PREPARATION:
MIXING: APPLICATION:
COVERAGE:
This will depend on the porosity of the individual substrate and will be between 3m2 and 10m2 per litre. For certain substrates it may be necessary to dilute VINACHEM with clean water. Please consult our Technical Department for further information. VINACHEM is touch dry in 15 - 90 minutes, dependent upon the temperature and relative humidity. M.F.F.T. c. 5 - 8C. Water and alkali resistant. Provides protection against carbonation of concrete and prevents weather erosion of certain types of masonry and stone. VINACHEM is ideal for sealing concrete floors and in some instances helps consolidate loose and friable surfaces. Once cured, it is impervious to water penetration. It is essential that the correct amount of material is applied in one application. Two applications will not offer any further improvement. Ideal for brick, concrete, stone or timber. Uncured VINACHEM may be readily removed from tools and equipment with water. Mechanical methods are required to remove cured material.
Rotafix aqueous based polymer materials do not normally present a hazard. However, standard precautions when handling aqueous polymers include the use of gloves and protection to the face and eyes from splashes. In the event that splashing occurs, apply copious amounts of water. The information in this document is based on practical tests, but given without guarantee insomuch as methods of use by others is beyond our control. Due to continuing development and improvements, it may be necessary to change without notice the material specification. All goods are sold subject to our Standard Conditions of Sale.
CURE SCHEDULE: CURED PROPERTIES: SPECIFIC USES:
CLEANING OF TOOLS:
WITHOUT
WITH
The requirements for a Rotafix product(s) may be specific for an individual project. Advice given by Rotafix can only be considered as part of any contract if it is provided in writing.
ROTAFIX, ROTAFIX HOUSE, ABERCRAF, SWANSEA SA9 1UR. UK TEL: +44 (0)1639 730481 FAX: +44 (0)1639 730858 e.mail: sales@rotafix.co.uk Website: www.rotafix.co.uk SOUTHERN AREA CONTACT: TEL: +44 (0)1442 243169 FAX: +44 (0)1442 234901
PD3520-1/13
HA SLURRY PRIMER
3268 HA SLURRY PRIMER is a pre-mixed, ready to use, acrylic modified powder used to protect steel reinforcing. The system contains a unique blend of fine Portland and microsilica cements, an acrylic co-polymer powder, and a union of compatible admixtures. The powder also contains powerful corrosion inhibitors. The compound, when mixed with water and painted onto steel reinforcing, produces an elastic alkaline coating which will protect the steel against corrosion and chemical attack. 1 Litre Pack (1.25 kg) Primer should only be applied to thoroughly prepared surfaces. All surfaces should be sound, dry and free from grease, oil and any other contaminants. HA SLURRY PRIMER powder is mixed with water using a suitable container, an electric power tool and a 100mm Rotafix Paddle code 3639. Place litre of clean water into a suitable clean container. Slowly add the 1.25 kgs of powder whilst mixing. After the powder has been added continue mixing for a further 30 seconds. Remove all rust, scale and corrosion products on the steel surface by abrasive blasting or by wire brushing. Severely corroded reinforcement should be cut back and replaced. The steel should be free from oil, dust, diesel, loose material or other surface contaminants. Mix and apply one coat of HA Slurry Primer, cover completely and evenly onto the steel or concrete surface to a thickness of not more than mm.
PACKAGING: PREPARATION: MIXING:
APPLICATION:
COVERAGE: CURE SCHEDULE: PROPERTIES:
1.25 kgs when mixed with 500cc of water covers 1.0m2 Ready for over coating 30-60 minutes after application, assuming minimum temperature +8oC R.H. not exceeding 45% Formulated for the protection of steel reinforcement. Use as a primer and protective coating for concrete. Quick and simple to mix and apply. Provides an elastic alkaline protective coating to both steel and concrete. Brush or spray applied onto steel reinforcing to protect steel against chlorides, moisture, oxygen and acid gases. To protect steel against de-icing salts and in marine locations For use on concrete, concrete repairs and in new construction Protective coating to new or freshly prepared steel work An alternative to zinc rich primers or resin coating systems Uncured HA Slurry Primer may be readily removed from tools and equipment with soap and water. Mechanical methods are required to remove cured material.
SPECIFIC USES:
CLEANING OF TOOLS:
The requirements for a Rotafix product(s) may be specific for an individual project. Advice given by Rotafix can only be considered as part of the contract if it is provided in writing. ROTAFIX cementitious based products are midly alkaline. Users should take the necessary precautions indicated in the COSHH details available from our offices. Please read our Users Safety Guide on the Handling of Resin and Polymer products.
ROTAFIX, ROTAFIX HOUSE, ABERCRAF, SWANSEA SA9 1UR. U.K. TEL: (44) 01639 730481 FAX: (44) 01639 730858 e.mail: sales@rotafix.co.uk Website: www.rotafix.co.uk SOUTHERN AREA CONTACT: TEL: (44) 01442 243169 FAX: (44) 01442 234901
PD3265/5
RM20 LW REPAIR MORTAR

PRODUCT CODE: DESCRIPTION: PACKAGING:
3370 - 2.5 litre pack: 3375 - 10 litre pack
Epoxy Resin is a 3-part mix. Lightweight repair mortar.
2.5 litres (3.2 kg) Coverage at 5mm thickness 0.5m 10 litres (12.8kg) Coverage at 5mm thickness 2m Materials supplied in non returnable plastic containers for ease of mixing. Concrete surfaces should be clean and free from Laitance. Reinforcing steel should be clean and free from loose rust. Rotafix RM20 LW REPAIR MORTAR is compatible with most steel primers. All surfaces should be coated with Rotafix P12 PRIMER prior to the application of RM20 LW REPAIR MORTAR. The contents of the RM20 LW REPAIR MORTAR Hardener (curing agent) must be added to the contents of the resin container and mixed thoroughly. The total liquid is then added to the filler and mixed thoroughly. The 10 litre pack requires to be mechanically mixed using a slow speed drill and a Rotafix paddle. The fully mixed material should be placed immediately onto the wet/tacky primer. If the primer dries prior to application of the RM20 LW REPAIR MORTAR the area must be re-primed. RM20 LW REPAIR MORTAR should be applied to the vertical or overhead surface by use of a steel trowel and hawk using a plastering type technique. The contents of the pack should be mixed, placed and trowel finished in not more than 40 minutes at +18C. The thickness obtainable will be dependent on a number of factors:a) whether the position is vertical or overhead (b) the type of primer used c) the ambient temperature (d) the individual skill of the operator e) the amount of compaction required around reinforcing steel A thickness of 50-60mm minimum should be obtainable in one application. In the event that a further application is required the RM20 LW REPAIR MORTAR should be re-primed. 1 litre covers 1m at 1mm thickness. Initial cure 4-12 hours at +20C. Suitable for grinding or drilling 24-48 hours at +20C. Final cure 5-7 days. Minimum application temperature +5C. Shelf life of unmixed components minimum 12 months providing extremes of temperatures are avoided. Unaffected by rain or moisture within 3 hours of application at +18C. Compressive strength 25 N/mm. Tensile strength 15 N/mm (provisional). Flexural strength 17 N/mm (provisional). Specific gravity 1.27 at +20C. Standard colours Beige/Grey (Colour matching service available for stonework). Chemically resistant - unaffected by a wide range of industrial and domestic chemicals. For specific applications please consult our Technical Department. Suitable for structural repairs of reinforced concrete in horizontal and overhead situations. 50mm in one application is possible.
PREPARATION:
MIXING:
APPLICATION:
COVERAGE: CURE SCHEDULE: CURED PROPERTIES:
SPECIFIC USES: APPROVAL: CLEANING OF TOOLS:
conforms to the Water Research Council Test Requirements of BS 6920 for use in potable water situations.
Uncured RM20 LW REPAIR MORTAR may be readily removed from tools and equipment with Rotafix S200 PC Solvent Cleaner. Mechanical methods are required to remove cured material.
Epoxy resins and their associated curing agents can cause irritation to some people. Please take the necessary precautions indicated in the COSHH details available from our offices. Please read our Users Safety Guide on the Handling of Resin and Polymer products. The information in this document is based on practical tests, but given without guarantee insomuch as methods of use by others is beyond our control. Due to continuing development and improvements, it may be necessary to change without notice the material specification. All goods are sold subject to our Standard Conditions of Sale.
PD3370-5/9
P12 PRIMER
3319 - 250cc.
P12 PRIMER
3320 - 0.5 litre pack.
3325 - 1 litre pack.
3330 - 5 litre pack.
is a solvent free 2-part unfilled epoxy primer usually used in conjunction with epoxy mortars and screeds. Special versions are available for use with potable water and timber substrates.
PACKAGING:
0.5 litre - 250-350 gms/m on average concrete 1 litre - Proportional to the above 5 litres - Proportional to the above Primer should only be applied to thoroughly prepared surfaces. General: All surfaces should be sound, dry and free from grease, oil and any other contaminants. Concrete: Concrete must be fully cured. All laitance must be removed by either grinding, acid etching, scarifying, scabbling, bush hammering, shot blasting, wet grit and sand blasting or flame cleaning. Metal Substrates: Any steel intended for treatment must be free of blue millscale. Firm adherent light rust may be tolerated. Heavy scale and loose rust must be removed. All machine oil and grease must be removed. The ideal treatment for steel is grit or shot blasting to commercial standard SA2. Other metals such as aluminium, copper and stainless should be grease free and lightly abraded with 320 grade carborundum paper. Timber should be clean, dry and free from contamination and timber preservative. The contents of the hardener (curing agent) are added to the contents of the base resin container and mixed thoroughly. Pot life 30 - 50 minutes dependent on ambient temperature. Rotafix P12 PRIMER can be applied by brush, roller, squeegee or steel trowel dependent, upon type of substrate. Rotafix P12 PRIMER may be used with most products in the Rotafix range. Before use, reference must be made to the technical information on the relevant product. 1 litre covers approximately 3m2 on stone, or 5m2 on steel. Maximum chemical bond between primer and mortar application is achieved whilst the Primer is still in the tacky state. In the event that the P12 PRIMER is fully cured, it will be necessary to overcoat before application of the mortar. Base resin, low viscosity 100% reactive. Viscosity 12,000 mPa.s. at + 25C. Density 1.12. Shelf life 12 months, providing extremes of temperature are avoided. Pot life 20-30 minutes/100gms mass at + 20C. Touch dry - 3 hours at +20C at 15 microns. Full cure - 7 days at +20C Compressive strength: >50N/mm. Tensile strength: 25N/mm Flexural strength: 35N/mm.
P12 PRIMER may
PREPARATION:
MIXING: APPLICATION:
COVERAGE: CURE SCHEDULE:
CURED PROPERTIES:
SPECIFIC USES: APPROVAL: CLEANING OF TOOLS:
be used for bonding new concrete to old.
P12 PRIMER conforms to the Water Research Council test requirements of BS 6920 for use in potable water situations.
Uncured P12 PRIMER may be readily removed from tools and equipment with Rotafix S200 PC Solvent Cleaner. Mechanical methods are required to remove cured material.
Epoxy resins and their associated curing agents can cause irritation to some people. Please take the necessary precautions indicated in the COSHH details available from our offices. Please read our Users Safety Guide on the Handling of Resin and Polymer products.
PD3319-30/12
RENDACRETE LW
PRODUCT CODE: DESCRIPTION: SPECIFIC USES:
3400
RENDACRETE LW
is a prepacked, preweighed powder mix containing graded cements, fibres, aggregates, accelerators and polymers. The material does not contain calcium chloride.
is specifically formulated for use as a concrete repair material in vertical and overhead situations. In many cases the 'high build' nature of the material enables work to be carried out without shuttering.
RENDACRETE LW
PACKAGING: PREPARATION OF SUBSTRATE: MIXING:
Packaged in 25kg durable sacks. YIELD: 25kg of powder yields 19.5 litres of Lightweight Mortar. 1m of Lightweight Mortar requires 1500 kgs of powder. All concrete surfaces should be clean and free from laitance. Steel surfaces should be free from loose rust, grease and millscale. Rendacrete Lightweight powder is mixed with water in a 25 litre container. The mortar should be mixed slowly, using 200mm Rotafix mixing paddle (Ref: 3640) for 2-3 minutes. Alternatively for larger amounts of Rendacrete LW use a forced action pan mixer such as a Creteangle Add 4 to 4.5 litres of water to the container or mixer. Pour 25kg of powder onto the water while mixing slowly, Max 200 rpm. After all the powder has been added, mix for 30 seconds. The mortar is now ready for use. If small amounts of the material are to be used, suitable measuring equipment must be available in order to weigh accurately the powder in relation to the volume of water, e.g. 25 kgs of Rendacrete LW would require 4 to 4.5 litres of water. The material must be placed within 30mins of mixing. Prior to mixing the Rendacrete LW, treat any exposed reinforcing steel with Rotafix HA Slurry Primer. Allow to cure, approximately 30mins. Apply P12 Primer (PD3319-30/11) to all concrete surfaces to be treated with mortar including all reinforcing steel. Apply RLW onto wet P12 Primer. Further water should not be added to in an attempt to reconstitute the mixed RENDACRETE LW. The general rules with regard to cementitius materials in terms of temperature, humidity and the curing regime should always be observed. Once the material is in place and has placed, apply Vinachem at a rate conducive with overall wetting of the surface. 1 bag covers 1m at 19mm thickness. TYPICAL DATA at 18% water/powder ratio at 20C CONSISTENCY: stiff mortar WORKING LIFE: 15 minutes (dependent on temperature and humidity) DENSITY: 1500kg/m 7 MINIMUM COMPRESSIVE STRENGTH: 10 28 32 MPa 14 28 Days
APPLICATION AND EQUIPMENT:
CURE SCHEDULE:
MATERIAL USAGE/ COVERAGE:
CURED PROPERTIES:
CLEANING OF TOOLS:
Uncured RENDACRETE LW may be readily removed from tools and equipment with clean water.
The site conditions and equipment required when using individual Rotafix products are specific for each project. Only advice given by Rotafix in writing will be considered as part of our contractual liability.
ROTAFIX cementitious
based products are mildly alkaline. Users should take the necessary precautions indicated in the COSHH details available from our offices. Please read our Users Safety Guide on the Handling of Resin and Polymer products. RENDACRETE is a Registered Trade Mark of Rotafix (Northern) Ltd.
ROTAFIX, ROTAFIX HOUSE, ABERCRAF, SWANSEA SA9 1UR. U.K. TEL: +44 (0)1639 730481 FAX: +44 (0)1639 730858 e-mail: sales@rotafix.co.uk Website: www.rotafix.co.uk SOUTHERN AREA CONTACT: TEL: +44 (0)1442 243169 FAX: +44 (0)1442 234901
PD3401/18
RF1: ANCHORAGE STRENGTHS FOR ROTAFIX ZEROSET ANCHOR GROUT
Bolts installed in holes drilled with rotary percussive drills on air or water flush Recommended curves indicate ULTIMATE values for design and calculation of permanent anchorages. SWL to be based on these values and recommended not to exceed 50% of them.
UNAXIAL LOAD IN TONNES

For Further information, please contact our Technical Department. This information in this document is based on practical tests, but given without guarantee Inasmuch as methods of use by others is beyond our control. Rotafix Ltd., Rotafix House, Abercraf, Swansea, UK SA9 1UR Tel: +44 (0)1639 730481 Fax: +44 (0)1639 730858 e-mail: sales@rotafix.co.uk, Web: www.rotafix.co.uk Southern area contact: Tel: +44 (0)1442243169 Fax: +44 (0)1442 234901
RF2 MATERIAL REQUIREMENTS FOR ADHESIVE ANCHORS

In most civil engineering applications, the adhesive anchor systems comprise of deformed rebar incorporating thread, nut and washer as the hardware. The adhesive system may consist of a capsule (cartridge) or a mix and pour (pumped) adhesive. ROTAFIX market a mix and pour grout, namely ROTAFIX ZEROSET ANCHOR GROUT. Experience indicates that the anchorages are to be installed into holes drilled by a rotary percussive air flush method and we recommend the use of hand held drills as giving the optimum power to weight ratio The following table indicates the volumes of adhesive required per anchorage:
REBAR BOLT MM 8 12 16 16 20 25 25 32 32 40 PREFERRED HOLE MM 12 16 20 24 26 32 36 38 40 50 MINIMUM ANCHORAGE LENGTH MM 100 100 100 100 100 100 100 300 300 300 THEORETICAL VOLUME OF ADHESIVE CC 6 10 11 25 22 31 53 100 140 212
Double the anchorage length double the volume i.e. 25mm bolt in 32mm hole 200mm deep 62cc adhesive required.
In practice, add 10% minimum to allow for wastage. To reduce wastage: 1. 2. 3. 4. Drill minimum hole required. Do not drill hole to excess depth Do not overfill hole Do not mix more material than can be handled in one continuous grouting operation.
RF3 TYPICAL STRENGTHS OF REBAR AND TOR-BAR BS 4449

Nominal Bar Cross Sectional Area of Shank Ultimate Tensile Strength 70% of Ultimate Shear Strength mm mm in kN in kN tonf kN tonf 12 113.1 0.175 47 4.7 33 3.3 26 2.6 16 201.1 0.312 84 8.4 59 5.9 47 4.7 20 314.2 0.487 130 13 91 9.1 73 7.3 25 490.9 0.762 204 20.4 143 14.3 114 11.4 32 804.2 1.248 334 33.4 234 23.4 187 18.7 40 1256.6 10.950 522 52.2 365 36.5 292 29.2
Type of Cut Thread Cross Sectional Area of Mean of B.S.W. Cut Thread Ultimate Tensile Strength 70% of Ultimate Shear Strength
B.S.W.
/8
mm in
101.3 0.157
162.6 0.252
238.7 0.37
429 0.665
683.9 1.06
983.9 1.525
kN tonf kN tonf kN tonf
42 4.2 29 2.9 23 2.3
67 6.7 47 4.7 38 3.8
99 9.9 69 6.9 55 5.5
178 17.8 125 12.5 100 10
284 28.4 199 19.9 159 15.9
408 40.8 286 28.6 229 22.9
The above figures to be used in calculating diameter of anchor required for specific loading requirements. Rotafix will supply other grades of bolts to suit individual requirements, including stainless steel systems for critical environments.

Technical Bulletin CR1

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TECHNICAL BULLETIN CR1

CONCRETE REPAIR GUIDE

ROTAFIX is a registered trade mark

CONCRETE REPAIR GUIDE

2. Hammer test all concrete suspected of being included in 1 above.

2009 Rotafix (Northern) Limited

2009 Rotafix (Northern) Limited

2009 Rotafix (Northern) Limited

2009 Rotafix (Northern) Limited

2009 Rotafix (Northern) Limited

PHYSICAL AND CHEMICAL PROPERTIES:

HEALTH AND SAFETY:

UN number 1193 Class 3 Packing group II ADR/RID: Class 3

MIXING AND APPLICATION:

CURE SCHEDULE: APPROVAL:

CURE SCHEDULE: CURED PROPERTIES: SPECIFIC USES:

PACKAGING: PREPARATION: MIXING:

COVERAGE: CURE SCHEDULE: PROPERTIES:

RM20 LW REPAIR MORTAR

Epoxy Resin is a 3-part mix. Lightweight repair mortar.

COVERAGE: CURE SCHEDULE: CURED PROPERTIES:

SPECIFIC USES: APPROVAL: CLEANING OF TOOLS:

3320 - 0.5 litre pack.

3325 - 1 litre pack.

3330 - 5 litre pack.

COVERAGE: CURE SCHEDULE:

SPECIFIC USES: APPROVAL: CLEANING OF TOOLS:

be used for bonding new concrete to old.

PACKAGING: PREPARATION OF SUBSTRATE: MIXING:

APPLICATION AND EQUIPMENT:

RF1: ANCHORAGE STRENGTHS FOR ROTAFIX ZEROSET ANCHOR GROUT

UNAXIAL LOAD IN TONNES

RF2 MATERIAL REQUIREMENTS FOR ADHESIVE ANCHORS

RF3 TYPICAL STRENGTHS OF REBAR AND TOR-BAR BS 4449

kN tonf kN tonf kN tonf

42 4.2 29 2.9 23 2.3

67 6.7 47 4.7 38 3.8

99 9.9 69 6.9 55 5.5

178 17.8 125 12.5 100 10

284 28.4 199 19.9 159 15.9

408 40.8 286 28.6 229 22.9

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