Rehabilitation thixotropic mortar for repair of reinforced concrete structures

Product Characteristics
Single-component dry mortar volume compensated mixture containing PP fibers, re-dispersible polymers and further improving additives. Meets the requirements of class R3 according to EN 1504-3.

  • designed for concrete repair (principle 3, 4 and 7 method 3.1, 3.2, 3.3, 4.4, 7.1 and 7.2 according to EN 1504-3
  • good workability, is thixotropic, applied manually or by spraying
  • compensated in volume
  • perfect adhesion to the concrete base and reinforcement
  • is frost resistant and resistant deicing salts
  • As required by Act No. 258/2000 Coll. and Ministry of Health Decree No. 409/2005 Coll. it is eligible for direct contact with drinking water

MONOCRETE PPE TH is a single-component dry mortar that meets the requirements of class R3 according to EN 1504-3. Polymer-cement mortar MONOCRETE PPE TH is intended especially for repairs of damaged concrete and reinforced concrete vertical surfaces and ceilings principle 3, 4 and 7 method 3.1, 3.2, 3.3, 4.4, 7.1 and 7.2 according to EN 1504-3). It comes in three grain sizes. MONOCRETE PPE TH can be coated either with directly applicable type of secondary protection in dependence on exposure of the repaired structure or can be further surfaced by application of the DENSOFIX spread coating.

Physical and mechanical parameters

Requirements / results according to EN 1504-3 class R3

Testing method R3 Requirements Results
Compressive strength (MPa) EN 12190 >25 R3
Chloride Ion Content EN 1015-7 <0.05% <0.01%
Adhesive Bond (MPa) EN 1542 >1.5 >2.0
Carbonation Resistance EN 13295 dk ≤ control concrete complies
Restrained shrinkage/expansion (MPa) EN 12617-4 Adhesion after test ≥1.5 >1.5
Elastic Modulus (GPa) EN 13412 >1.5 >15

Physical and mechanical parameters

Color Non-standard grey
Bulk density (kg/m3) 1,540 ± 40
Bulk density of fresh mortar (kg/m3) 2,200 ± 50
Grain size (mm) 0 ÷ 1 0 ÷ 4 0 ÷ 8
Tensile bending strength (MPa) 7 days > 40 > 4.5 > 4.8
28 days > 7.0 > 7.5 > 8.5
Compressive strength (MPa) 7 days > 20 > 23 > 25
28 days > 36 > 40 > 44
Dynamic E-module (GPa) < 23 < 26 < 28
Thermal expansion coefficient (K-1) 11.5 ± 0.4×10-6
Frost resistance > T150
De-icing chemicals resistance according to ČSN 73 1326 Method A D1 > 75

Test certificates
Meets the requirements of EN 1504-3, TP ŘSD Sec. 31 and TP SSBK III.
Initial tests types according to EN 1504-3, Protocol No. 1301-CPD-0295 issued by TSÚS
Bratislava. Resistance to CHRL according to ČSN 73 1326, protocol No. 32/2000-B, issued by ŘSD Prague. Supervision of the quality system, EMS and OHSAS is carried out by Notified Body No. 1020

Instruction for preparation and application.
During the processing of dry mortar mixes MONOCRETE PPE TH it is generally necessary to comply with the principles contained in the relevant technological process BETOSAN for repair of reinforced concrete structures (TP n.1/06).

Base. Any incoherent, loose, weatherworn or otherwise visibly damaged concrete shall be completely removed from the surface of the repaired base. Corroded reinforcement shall be carefully released and cleaned of any corrosive products before application of repair material, humidification of the base surface shall be properly and continually performed for at least 120 minutes. The properly humidified concrete shall be dully dump, and not covered with dump shining water film. If necessary, it is possible to anchor the material to the base with the adhesive bridge DENSOCRETE 111.

Preparation of repair mortar. The mortar is prepared by simple mixing with water. During stirring it is necessary to use a low-speed mixer with forced circulation. The recommended mixing ratio is specified in the following table:

Indication/type of mortar max size of fillers Recommended mixing ratio Thickness of applied layer in single working area
Dry component (kg) Water (litres) min. (mm) max. (mm)
MONOCRETE PPE TH f fine 1 mm 25 3,70 ÷ 3,95 5 12
MONOCRETE PPE TH r medium 4 mm 25 3,45 ÷ 3,70 10 25
MONOCRETE PPE TH c coarse 8 mm 25 3,40 ÷ 3,65 20 40

Workability of the product is 50 – 60 minutes under 20 °C.
Neither temperature of base nor temperature of ambient air shall be below + 5 °C and above + 30 °C.
Mortar application can be done either manually or by dry or wet spraying. The mortar can be manually applied either by rendering or fining off.
First layer (connecting) needs to be applied in such a way to ensure that no unfilled spaces are created (behind reinforcement, in caverns etc.). After initial application it is recommended to spread the mortar into pores and uneven spaces. This can be done well with flat paint brush with short hair, or by a toothed trowel. Proper adhesion of the material to substrate in application stage is basic condition for good quality adhesion in the final state. In localized repairs it is necessary to pay appropriate attention to edge regions or repaired area, where the edge needs to be properly compacted, without entrapped air pockets or other non-homogeneities. The repair is always done from place of deepest degradation, in such a way that the final layer it to be continuous over entire area, if possible.

Surface finalization. After initial setting of the last layer, smoothing by a dry polyurethane finisher is used for surfacing. Wet surfacing is not allowed. If the surface is to be smoothed with fine spread coating (e.g. DENSOFIX), ruling off by a wooden tamper is sufficient.

Surface treatment. Repaired surfaces shall be properly treated immediately after completion to avoid especially direct exposure to sun, wind effect and other factors accelerating undesirable evaporation of the batch water. Use of the treatment agents DENSOCURE W and DENSOCURE R proved well.

Specific consumption
Specific consumption of dry mortar is 1.7 ÷ 1.8 kg/m2 at 1 mm of layer thickness. In spray application, it is necessary to count with loss of 10 ÷ 12 %.

More info on the product page