Services
CONCRETE REPAIRS
GRANDPLUG 1Rapid setting mortar for plugging leak on running water
SCOPE
This section covers the standard requirements for concrete repair system using GRANDPLUG 1.
GRANDPLUG 1 is supplied as a dry powder which needs only the addition of water to produce an ultra rapid set plugging mortar. It is designed to seal leaks in running water where conventional mortars would be washed away. It is ideal to seal leaks prior to applying waterproof renderings in basement. Upon setting, the product develops excellent structural strength and water tightness.
GRANDPLUG 1 is supplied as a dry powder which needs only the addition of water to produce an ultra rapid set plugging mortar. It is designed to seal leaks in running water where conventional mortars would be washed away. It is ideal to seal leaks prior to applying waterproof renderings in basement. Upon setting, the product develops excellent structural strength and water tightness.
1) Surface Preparation Works
1.1 All surfaces must be clean and sound and free from all surface laitance, oil and grease and any bond inhibiting material.
1.2 Areas to be patched should be cut back/undercut to a depth of 20mm with an inverted cone section to give a good mechanical key. Feather edges must not be allowed.
1.3 Preparation should include enlarging small cracks and holes and avoiding V-shaped cuts.
2) Mixing
2.1 Mixing proportion: 1 part water to 3 parts GRANDPLUG 1 by volume.
2.2 Due to rapid setting, use only the quantity which can be placed within the prescribed time of not more than 1 minute.
3) Application
3.1 Wear protective clothing, gloves and mask should be worn at all times when working with this product.
3.2 Apply the mixed GRANDPLUG 1 in place, ensuring maximum contact with the substrate before the material sets.
3.3 If being used to plug a running water leak, the mixed GRANDPLUG 1 should be held in place until it reaches initial set.
3.4 Push the putty into the hole, the material expands as it sets instantly stopping running water, and hold in place while the material sets. This step can either be done by hand or with a trowel.
3.5 Normal setting time is 45 to 90 seconds at 30 ℃. Time may vary according to ambient conditions.
3.6 For repair of cracks, start applying GRANDPLUG 1 at the top of the crack making your way down. Press firmly the paste into place, maintaining the same amount of pressure until the cement begins to harden and the leak is stopped.
3.7 Finish the surface by grinding the excess GRANDPLUG 1 up to the desired profile after 24 hours.
GRANDPATCH 203Cementitious rapid setting repair mortar for pavement and floor
SCOPE
This section covers the standard requirements for concrete repair system using GRANDPATCH 203.
GRANDPATCH 203 is a cementitious pre-packed repair mortar with shrinkage compensation properties. It is supplied as a single component powder which only needs mixing with a specific quantity of water to produce a non-shrink, free flowing, fast setting and high strength mortar. It is a blend of inorganic cement, special fillers and chemical additives to control the rate of strength gain.
GRANDPATCH 203 is ideal for use in heavily trafficked areas where a rapid return to service in 2 – 3 hours is critical.
Assessment of existing floor
The first step in the installation of GRANDPATCH 203 products is to carry out a detailed survey of the existing floor and an assessment of the service conditions, which will determine the performance characteristics required of the new floor. Any signs of damage, contamination or other defects should be noted and corrected.
Floor strength
A weak substrate can lead to floor topping failure usually due to impact damage or abrasion or delamination.
Floor strength should be at least 3,000 psi (210 N/mm2).
New concrete floors must normally be at least 14 days old prior to application of GRANDPATCH 203 flooring systems.
Floor strength should be at least 3,000 psi (210 N/mm2).
New concrete floors must normally be at least 14 days old prior to application of GRANDPATCH 203 flooring systems.
1) Surface Preparation Works
1.1 The substrate must be clean, sound and free from dust, oil, grease or surface contaminants. Pressure washer is ideal to ensure the cleanliness and saturation of the substrate.
1.2 Removed any cement laitance, formwork traces and loosely bonded particles.
1.3 For cracks on concrete pavement, sectional repair by squaring procedure is ideal and should use concrete cutter to obtain required depth and avoid concrete edge feathering during application. After cutting, use jack hammer or chipping hammer to remove the concrete.
1.4 Clean the surface afterwards using pressure washer. It is important that the surface must be flooded for few hours thus making the substrate saturated. Remove excess and ponded water using foam.
2) Priming
A. Using GRAND EPOBOND STD (a solvent free epoxy resin formulation used for bonding new cementitious materials to existing cementitious surfaces )
As the excess and ponded water is removed, the primer Grand Epobond STD can be applied on the damp surface using brush or roller. A gallon kit of this product covers and area of about 5 to 6 sq.m. Do not wait the bonding agent to dry. The mortar must be applied when the adhesive is still fresh or tacky.
Tack free time of GRAND EPOBOND STD is between 65-70 minutes at 25℃.
At higher temperature, tack free time will be shorten.
At higher temperature, tack free time will be shorten.
Primer Application
2A.1 Pour the entire contents of the hardener into the resin and mixed the two materials thoroughly until homogenous.
2A.2 Do not apply thickly or allow to puddle.
If any area appears to absorb the primer rapidly, re-prime those areas immediately to ensure the adhesion between the substrate and the concrete repair material.
If any area appears to absorb the primer rapidly, re-prime those areas immediately to ensure the adhesion between the substrate and the concrete repair material.
B. Using GRANDCRETE ACR (Acrylic Emulsion Cement Modifier and Concrete Bonding Agent )
As the excess and ponded water is removed, the primer GRANDCRETE ACR can be applied on the damp surface using brush or roller. Approximately one liter will cover 6-8 sqm depending on the surface profile. Do not wait the bonding agent to dry. The mortar must be applied when the adhesive is still fresh or tacky.
Primer Application
2B.1 Pour the entire contents of the hardener into the resin and mixed the two materials thoroughly until homogenous.
2B.2 Do not apply thickly or allow to puddle.
If any area appears to absorb the primer rapidly, re-prime those areas immediately to ensure the adhesion between the substrate and the concrete repair material.
3) Mixing
Measure 4.0 to 4.5 liters of drinking water and pour three- quarter into the mixer. While mixer is in operation, add one full 25 kg bag of GRANDPATCH 203 and mix for one minute before adding the rest of the water. Mix it further 3 to 4 minutes until a smooth and even consistency is obtained.
3.1 Two types of mixers can used with the GRANDPATCH 203 range of products depending on the size of the job:
3.1.1 A slow speed drill fitted with an spiral paddle. This technique is suitable for single bag of GRAND PATCH 203, but is not ideally suited to 2 – bag mixing or bulk application techniques
3.1.2 A mortar/bagger mixer or paddle mixer (blades revolve, pan stationary) is suitable for large volume pours.
3.1.2 A mortar/bagger mixer or paddle mixer (blades revolve, pan stationary) is suitable for large volume pours.
4) Application
GRANDPATCH 203 should be placed within 10 minutes in order to gain the full benefit of fluidity. The repairs may be surfaced finished using trowel or wood float but should not be overworked. GRANDPATCH 203 can be applied up to 100 mm thickness in single application.
For repair section deeper than 100 mm, it will be necessary to add suitable and properly graded aggregates to GRANDPATCH 203 in order to minimize temperature rise. Add 3/8 “ size aggregates 12% to 15% of 25 kg bag of Grandpatch 203. If necessary, adjust water ratio not less than 4 liters per bag depending the moisture content of the aggregates.
Since this product sets in just 10 minutes, proper number of manpower and work designation before preparation is very important to avoid the setting time of the product. Do not overworked the application to attain good finishes.
The minimum applied thickness of GRANDPATCH 203 is 20 mm.
NOTE: A 25 kg bag of GRANDPATCH 203 mixed with 4.5 liters of water yields 12.5 liters (0.0125m3).
For repair section deeper than 100 mm, it will be necessary to add suitable and properly graded aggregates to GRANDPATCH 203 in order to minimize temperature rise. Add 3/8 “ size aggregates 12% to 15% of 25 kg bag of Grandpatch 203. If necessary, adjust water ratio not less than 4 liters per bag depending the moisture content of the aggregates.
Since this product sets in just 10 minutes, proper number of manpower and work designation before preparation is very important to avoid the setting time of the product. Do not overworked the application to attain good finishes.
The minimum applied thickness of GRANDPATCH 203 is 20 mm.
NOTE: A 25 kg bag of GRANDPATCH 203 mixed with 4.5 liters of water yields 12.5 liters (0.0125m3).
5) Curing
Rapid moisture loss from the exposed surface may result in plastic cracking as well as dusting in later days. GRANDPATCH 203 requires curing in accordance with good concrete practice. As soon as trowelling has been completed apply GRANDCRETE ACR or GRANDCURE PME15 to the finished surface by spray or soft brush.
GRAND EPOGROUT IJEpoxy Injection Resin
SCOPE
This section covers the standard requirements and application for epoxy injection works using GRAND EPOGROUT IJ ( Epoxy Injection Resin).
1) Surface Preparation Works
a. Identify and mark all cracks subject for repair.
b. Clean the crack and the surface surrounding it to allow the epoxy to bond to sound concrete. At a minimum, the surface to receive paste-over should be brushed with a wire brush. Oil, grease or other surface contaminates must be removed in order to allow the putty-over to bond properly. Take care not to impact any debris into the crack during cleaning. Using clean, oil free compressed air, blow out the crack to remove any dust, debris or standing water. Best results will be obtained if the crack is dry at the time of injection.
b. Clean the crack and the surface surrounding it to allow the epoxy to bond to sound concrete. At a minimum, the surface to receive paste-over should be brushed with a wire brush. Oil, grease or other surface contaminates must be removed in order to allow the putty-over to bond properly. Take care not to impact any debris into the crack during cleaning. Using clean, oil free compressed air, blow out the crack to remove any dust, debris or standing water. Best results will be obtained if the crack is dry at the time of injection.
c. If water is continually seeping from the crack, the flow must be stopped in order for epoxy injection to yield a suitable repair. Other materials such as GRANDPLUG 1(fast setting repair mortar for active leaks) may be required to repair an actively leaking crack.
d. If a coating, sealant or paint has been applied to the concrete it must be removed before placing the putty-over epoxy (Epobond Putty). Under the pressure of injection these materials may lift and cause a leak. If the surface coating is covering the crack, it may be necessary to route out the opening of the crack in a "V" shape using a grinder in order to get past the surface contamination.
d. If a coating, sealant or paint has been applied to the concrete it must be removed before placing the putty-over epoxy (Epobond Putty). Under the pressure of injection these materials may lift and cause a leak. If the surface coating is covering the crack, it may be necessary to route out the opening of the crack in a "V" shape using a grinder in order to get past the surface contamination.
2) Tools, Equipment and Materials
a. Pressurized injection Machine
b. Aluminium or copper tube ¼” thickness and fittings
c. Flaring tools
d. Aluminium tube cutter
e. Adjustable wrench
f. Hand drill
g. Grand Epogrout IJ/UW set
h. Set of pliers
c. Flaring tools
d. Aluminium tube cutter
e. Adjustable wrench
f. Hand drill
g. Grand Epogrout IJ/UW set
h. Set of pliers
3) Sealing of cracks and Installation of Injection port
a. To adhere the port to the concrete, apply a small amount of epoxy around the bottom of the port base. Place the port at one end of the crack and repeat until the entire crack is ported.
As a rule of thumb, injection ports should be at least spaced the thickness of the concrete member being repaired.
(Do not allow epoxy to block the port or the crack under it, this is where epoxy must enter the crack.)
As a rule of thumb, injection ports should be at least spaced the thickness of the concrete member being repaired.
(Do not allow epoxy to block the port or the crack under it, this is where epoxy must enter the crack.)
b. Using a putty knife or other paste-over tool, generously work epoxy along the entire length of the crack. Take care to mound the epoxy around the base of the port to approximately 1/4" thick extending 1" out from the base of the port
and to work out any holes in the material. It is recommended that the paste-over should be a minimum of 3/16" thick and 1" wide along the crack. Insufficient paste-over will result in leaks under the pressure of injection.
c. Allow the paste-over to harden before beginning injection. Spreading paste-over into a thin film (approximately 1/8") on the mixing surface will slow curing by allowing the heat from reaction to dissipate.
and to work out any holes in the material. It is recommended that the paste-over should be a minimum of 3/16" thick and 1" wide along the crack. Insufficient paste-over will result in leaks under the pressure of injection.
c. Allow the paste-over to harden before beginning injection. Spreading paste-over into a thin film (approximately 1/8") on the mixing surface will slow curing by allowing the heat from reaction to dissipate.
4) Injection Procedures
a. Attach the injection fittings to the first port until it tightly secures into place. Make sure that the heads of all the ports are pushed in to the open position. In vertical applications, begin injection at the lowest port and work your way up. In a horizontal application start at one end of the crack and work your way to the other end. The injection is done using suitable nozzles connected to air compressors or by hand operated modified grease guns. Pressure of 3.5 to 7 kg /cm2 is normally used.
b. Inject epoxy into the first port until it will no longer flow into the crack. If epoxy shows at the next port and the first port still accepts material, close the second port and continue to inject into the first port until it accepts no more epoxy. Continue closing ports where epoxy appears until the first port refuses epoxy. When the first port reaches the point of refusal, brace the base of the port and pull out gently on the head of the port to close it. Pulling too hard may dislodge the port from the surface of the concrete, causing a leak.
c. Go to the last port where epoxy appeared while injecting the first port, open it, and continue injection at this port. If the epoxy has set up and the port is bonded closed, move to the next clean port and repeat the process until every portion of the crack has refused.
d. Cure the injected epoxy and left undisturbed for at least 24 hours.
e. After the injected epoxy has cured, the surface seal and ports should be removed by grinding or any applicable means.
c. Go to the last port where epoxy appeared while injecting the first port, open it, and continue injection at this port. If the epoxy has set up and the port is bonded closed, move to the next clean port and repeat the process until every portion of the crack has refused.
d. Cure the injected epoxy and left undisturbed for at least 24 hours.
e. After the injected epoxy has cured, the surface seal and ports should be removed by grinding or any applicable means.