CONCRETE REPAIRS


GRANDPLUG 1

Rapid 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.
 
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 to a depth of 20mm with an inverted cone section  to give a good mechanical key. Feather edges must not be allowed.
 
2)    Mixing
        2.1     Mixing proportion: 1 part water to 3 parts GRANDPLUG 1 by volume.
        2.2    Due to rapid set use only the quantity which can be placed within the prescribed time. 
 
3)    Application
           3.1    Apply the mixed GRANDPLUG 1 in place, ensuring maximum contact with the substrate before the material sets. 
           3.2    If being used to plug a running water leak, the mixed GRANDPLUG 1 should be held in place until it reaches initial set. 
           3.3     Normal setting time is 45 to 90 seconds at 30 oC. Time may vary according to ambient conditions.
 
4)    Curing
           4.1   Standard concrete curing procedures should be followed to prevent rapid water loss and consequent loss of strength. 

 


GRANDPATCH 203
Cementitious 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.

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
As the excess and ponded water is removed, the primer Grand Epobond STD (a solvent free epoxy resin formulation used for bonding new cementitious materials to existing cementitious surfaces ) 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. Wait for until 15 to 30 minutes before applying GRAND PATCH 203 .
NOTE: Do not wait the bonding agent to dry. The mortar must be applied when the adhesive is still fresh or tacky.
 
Primer Application
         2.1 Pour the entire contents of the hardener into the resin and mixed the two materials thoroughly until homogenous.
         2.2 Do not apply thickly or allow to puddle.
If any area appears to absorb the primer rapidly, re-prime those areas immediately the 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.
 
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).
 
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.
 
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