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 adhesion. It exhibits good water retention, crack resistance, high resistance to alkali, and UV resistance. It is easy to handle, can be applied on moist substrates, and is environmentally friendly. It simplifies and streamlines the construction process, ensures durability in sync with concrete, shortens the project timeline, and guarantees cost-effectiveness.
I. Application Scope
Suited for concrete structure repairs in industrial, municipal, bridge engineering, and residential construction.
II. Categories
Polymer-modified materials for concrete structural repairs are categorized into single-component and double-component types.
One-component: "Consists of cement, fine aggregates, polymer dry powder, and additives."
Two-component: Composed of cement, powdered fine aggregate materials, polymer emulsion, and additives.
Three performance indicators
High-strength polymer mortar is divided into three categories.
Structural Repair-Specific: Designed for repairing concrete structures with compressive strength below C60.
Steel Strand Specific: Suitable for wire rope mesh - polymer mortar overlay reinforcement method.
High-speed Rail Specific: Suitable for repairing concrete structures of prestressed beams and track slabs on high-speed railways, especially for strength grades above C50.
Serial Number | Project | Technical Specifications | |||
Structural Repair-Specific | Steel Strand for Special Use | High-Speed Train-Specific | |||
1 | Appearance | Powder is evenly distributed, with no lumps. Liquid is thoroughly mixed, free of any sediment. | |||
2 | Viscosity mm | 50-80 | |||
3 | Setting Time | Initial setting time | ≥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 | Tensile Adhesion 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 shall be determined separately by both parties. *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: Refer to GB/T 50476 - Code for Design for Durability of Concrete Structures for requirements related to durability indicators. | |||||
I. Application
1. Reinforcement methods using stainless steel wire mesh are suitable for reinforcing all structures prone to bending. Particularly applicable to the representative bending structures in civil engineering, such as the flat beams on reinforced concrete bridge decks, as well as the central sections of bridge piers and the main tower axes, and road cracking areas. This reinforcement method maintains the same system as previous reinforced concrete structures. The basic principle is: stainless steel wire mesh is bonded to the original concrete with a permeable mortar that excels in adhesive and bending strength, forming an integrated whole. The stainless steel wire mesh enhances rigidity, improves load-bearing capacity, and prevents durability reduction caused by the mortar.
2. When concrete shows honeycomb, holes, cracks, and defects such as damaged protective layers and exposed steel reinforcement, polymer mortar repair type can be used for reinforcement and repair; thickening the protective layer, leveling uneven surfaces, and repairing old concrete surfaces; enhancing the durability of concrete and extending its service life; possesses excellent water resistance, crack resistance, aging resistance, and alkali resistance; has good adhesion to various materials.
II. Usage
1. Surface Requirements and Treatment: The base surface should be flat, rough, clean, and free of oil stains and floating dust. There should be no sanding, hollowing, or cracking. Prior to construction, it should be flushed with high-pressure water while maintaining a moist condition, but without any standing water. A bonding agent can be pre-applied during interface bonding.
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 stir well. Gradually add the remaining 10% water while stirring to ensure no lumps form. The mixed slurry should be used within 0.5-1 hour after preparation.
3. Application: First, apply an interface treatment agent (ratio A:B = 3:1) evenly on the moist concrete base surface. Do not apply polymer mortar over a large area at once; it should be applied in strips or blocks with staggered intervals. Each block should not exceed 10 square meters, and the interval between staggered applications should be at least 24 hours. When applying in layers, the joint positions should be staggered as well.
4. After polymer mortar is spread, it should be pressed and leveled in one go, avoiding repeated pressing. If bubbles appear, they should be pierced and compacted, ensuring a dense surface. When the layer thickness on the face or ceiling exceeds 10mm, it should be constructed in layers. The thickness of each layer should be 5-10mm, and the next layer can be applied only after the previous one is touched and feels dry.
