Morcemrest^® Repair

Technical Caracteristics

R4 reparation mortar according to EN-1504-3. 

Advantages and Uses

• High bonding strength to concrete and high elastic modulus.
• High thixotropy. With no risk of coming down from the ceiling.
• Water vapour permeable.
• Good resistance to chlorides.
• Resistant to freeze-thaw cycles
• Joints filling in concrete, prefabricated elements and dilatation joints.
• Retraction shrinkage is compensated to minimise risk of cracking.
• High Resistance to carbonation.
• Weather resistant.
• Restoration of structural elements such as: columns, bridges' beams, treatment plants, tunnels, pillars with a great transfer of load.
• Re-generation of concrete.

Durability

Durability: Carbonation rate and chloride diffusion coefficient.

Tests conducted at the Eduardo Torroja Institute for Construction Science according to UNE EN 12390-10 - Determination of resistance to carbonation of concrete under atmospheric levels of carbon dioxide, yielded a carbonation rate (K) of 0.529 mm/year0,5 for Morcemrest Repair. 
This value can be incorporated into models for estimating the service life of reinforced concrete elements due to corrosion and used to calculate the carbonation depth using the equation: P = K * t0,5, where “P” is the carbonation depth in mm, “K” is the carbonation rate in mm/year0,5, and “t” is time in years.
For example, substituting values into the equation, over 50 years, a section of Morcemrest Repair mortar will carbonate 3.74 mm, and 5.29 mm over 100 years.
Similarly, a 25 mm-thick layer of Morcemrest Repair mortar would take 2,233 years to fully carbonate, far exceeding the expected service life of the structure, even without considering the contribution of potential surface protection renders.
Tests conducted at the Eduardo Torroja Institute for Construction Science according to UNE EN 12390-11 - Determination of chloride resistance, unidirectional diffusion, yielded a non-steady-state chloride diffusion coefficient (Dns) = 2.940 * 1012m²/s for Morcemrest Repair, which can be incorporated into models for estimating the service life of reinforced concrete elements due to corrosion.
The chloride diffusion coefficient obtained is significantly lower compared to those provided in the Structural Code, Table A12.3.2.b, Annex 12. Similar coefficients to those obtained for Morcemrest Repair can only be found in concretes designed with Type III/B cement and low water-to-cement ratios.

Suitable Substrates

• Substrate must be in good condition, clean, free of grease, oil and loose parts (minimum traction strength of 1.5 MPa).
• If necessary, prepare substrate mechanically until leave healthy concrete is reached.
• Absorbent substrates are previously dampened to the point of saturation, avoiding water-logging.
• Apply MORCEMREST J when surface has become matt again .
• If there are reinforcing frames, oxide, greases and oils should be cleaned and bad adhered particles should be removed.
• In case of having oxide frames, use a sandblast or a metallic teeth brush.
• Use IMPLAREST C in order to protect it against corrosion.
• In vertical and horizontal parameter unions expand the joint union up to 10.

Application Procedure

Mortar mixing:

• Add 2/3 of total water 4,5-5l  into a clean bucket and gradually add the powder while mixing.
• Then add the remaining water and mix for 2 more minutes.
• The pot life of the mixed mortar does not exceed 30 minutes at a temperature of +20ºC; therefore do not mix more material than required.

Application:

• Apply MORCEMREST REPAIR with a dented trowel or a spray gun.
• In case it is necessary to press it firmly to get good adhesion and compactness .
• MORCEMREST REPAIR can be applied in several layers, being the minimum thickness of 5 mm per layer.
• On vertical surfaces up to 65 mm thickness can be apply without the help of frames. In horizontal surfaces the maximum thickness should be 100 mm.
• In vertical and horizontal parameter unions fill in the complete width of the joint.

Curing:

• Protect from wind, freeze and sun light during the hardening process.
• In order to avoid excessive desiccation it is advisable to cover the surface with humid sackcloth or plastics during the process of curing.
• The curing process is essential 

Recommendations

• Do not add extra water to the mortar other than the recommended amount and do not remix it.
• Do not apply it under 5ºC or above 30ºC.
• Do not add any cement, sand nor other substances that may alter the proprieties of the material .
• The tools used should be clean with water immediately after being used, in order to avoid the hardening of the material, if not mechanical means will be needed to
• The tools used will be clean with water immediately after being used, in order to remove the products remnants. avoid the hardening of the material, which will need to be remove with mechanical means.
• Please consult with the Technical Department for any application that might not be described in this Technical Data Sheet.
• For all the safety information regarding the use, storage and transportation of the product, please consult our uploaded Safety Data Sheet of the product.
• When applying the repair mortar without a bonding bridge, the foundation of concrete must be rough, clean and well moistened before, but the surface must be free of water at the time of application, that is, the foundation must not be waterlogged. The repair mortar must be applied making it penetrate into the foundation previously prepared and must be compacted avoiding the inclusion of air in order to obtain the required strength, and to protect the reinforcement from corrosion.

Packaging and Storage

MORCEMREST REPAIR served suppliedin 25 kg bags. Shelf life: 1 year storage in its original packaging, away from extreme weather
conditions and humidity.

Technical data

CE Mark

Legal Disclaimer

The instructions for use are given according to our tests and knowledge and do not imply any commitment by GRUPO PUMA nor free the consumer from the examination and verification of the products for their correct use. Claims must be accompanied by the original packaging to allow a proper traceability.

GRUPO PUMA is not responsible, in any case, for the application of its products or constructive solutions carried out by the application company or other parties involved in the process and / or execution of the work, limiting the responsibility of GRUPO PUMA exclusively to the damages directly attributable to the supplied products, individually or integrated in systems, due to failures in their manufacturing process.

In any case, the drafter of the work project, the technical management or the person responsible for the work, or collaterally the application company or other parties involved in the process and / or execution of the work, must ensure the suitability of the products addressing the characteristics of them, as well as the conditions, support and possible pathologies of the work in question.

The values obtained by GRUPO PUMAS's products or its constructive solutions that, as the case may be, are determined by the EN standards or any other regulation that applies to it in each case refers exclusively to the conditions specifically stipulated in said regulation and that are referred to, among others, to certain characteristics of the support, humidity and temperature conditions, etc. without being them required in the tests obtained under different conditions, all in accordance with the relevant regulation.