High-strength polymer mortar
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Suited for concrete structure repairs in industrial, municipal, bridge, and residential construction
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High-strength polymer mortar
High-strength polymer mortar is a new type of concrete repair mortar that combines the adhesive properties of high polymer materials with the durability of inorganic materials; it boasts high compressive strength, rapid curing, and excellent bonding properties. Excellent water retention and crack resistance, high alkaline resistance, and UV resistance; easy to operate, suitable for construction on damp substrates, and environmentally friendly. Simplifies and streamlines the construction process, offers durability in sync with concrete, shortens project duration, and ensures cost-effectiveness..
I. Application Scope
Suitable for concrete structure repairs in industrial, municipal, bridge, and residential construction.
II. Categories
Polymer-modified materials for concrete structure repair are categorized into single-component and double-component types.
Single-component:Composed of cement, fine aggregate, polymer dry powder, and additives.
Two-component: Composed of powdered materials consisting of cement, fine aggregates, polymer emulsion, and additives.
Three performance indicators
High-strength polymer mortar is divided into three categories.
Structural repair: Suitable forRepair of concrete structures with compressive strength grades below C60.
Steel wire strand for use:Applicable for reinforcing wire mesh with polymer mortar overlay method.
High-speed rail application:Suitable for repair of concrete structures of prestressed beams and track slabs for high-speed railways with strength grades of C50 and above.
Serial Number | Project | Technical Specifications | |||
Structural repair | Steel wire rope | High-Speed Train | |||
1 | Appearance | Powder is uniform and free of lumps. Liquid is well-mixed with no sediment. | |||
2 | Viscosity mm | 50-80 | |||
3 | Setting Time | Initial Set | ≥45 | ≥45 | ≥45 |
Final Solidification | ≤24 | ≤24 | —— | ||
4 | Compressive Strength MPa | 7d | ≥20.0 | ≥30.0 | 8h≥25.0 |
28d | ≥60.0 | ≥60.0 | ≥60.0 | ||
5 | Flexural strength MPa | 7d | ≥8 | ≥6 | 24h≥10 |
28d | ≥12 | ≥10 | —— | ||
6 | Bond Strength MPa | 28d | ≥2.5 | ≥2.5 | ≥2.5 |
7 | Shrinkage rate % | 28d | ≤0.1 | ≤0.1 | ≤0.1 |
*Note 1: For materials requiring rapid setting and early strength, the setting time will be determined separately by both parties based on supply and demand. *Note 2: If the tensile bond strength of the mortar body does not meet the requirements of Table 1-6, it can be used in conjunction with an interface agent. *Note 3: Requirements for durability indicators shall be in accordance with GB/T 50476, Design Code for Durability of Concrete Structures. | |||||
I. Application
The reinforcement method using stainless steel wire mesh is suitable for reinforcing all structures prone to bending. Particularly applicable to the representative bending structures of civil engineering, such as the flat beams on reinforced concrete bridges, it is also suitable for the central parts of bridge piers and the main tower axes, as well as the cracking sections of roads. It maintains the same system as previous reinforced concrete structures. The basic principle of this reinforcement method is that the stainless steel wire mesh is adhered to the original concrete through the permeability of adhesive and bending strength of the polymer mortar, forming an integrated whole. The stainless steel wire mesh enhances rigidity, improves load-bearing capacity while preventing durability reduction caused by the polymer mortar.
2. When concrete exhibits honeycomb, holes, cracks, or defects like damaged protective layer and exposed reinforcement, it can be repaired and reinforced with polymer mortar patches; thickening the protective layer, leveling uneven surfaces, and repairing old concrete surfaces; enhancing the durability of concrete and extending its lifespan; excellent in water resistance, crack resistance, aging resistance, and alkali resistance; and has good adhesion to various materials.
II. Usage
1. Base requirements and treatment: The base surface should be flat, rough, clean, free of oil stains, and without floating dust. There should be no sanding, hollowing, or cracking. Before construction, it should be washed with high-pressure water and kept moist, but without any standing water. Before bonding, a bonding primer can be pre-applied.
Material Preparation: Weigh and mix powder and water in a mass ratio of 100:13. Add 90% of the actual water amount to the powder and mix well. Then, gradually pour the remaining 10% water while stirring to ensure no lumps form. The mixed slurry should be used up within 0.5-1 hour.
3. Application: First, apply an interface treatment agent (ratio of A:B = 3:1) evenly on the moist concrete base surface. The area for a single application of polymer mortar should not be too large; it should be applied in strips and blocks, with each block not exceeding 10 square meters. The interval between the staggered applications should be at least 24 hours. When applying in layers, the joint positions should be staggered from each other.
4. After polymer mortar is spread, it should be immediately pressed and leveled in one go, avoiding repeated pressing. In case of bubbles, they should be pierced and compacted, ensuring a dense surface. When the surface thickness on the vertical or overhead surface exceeds 10mm, construction should be done in layers. The thickness of each layer should be 5-10mm, and the next layer can be applied only after the previous one is touch-dry.
