MAXRITE® 500
QUICK SETTING, POLYMER MODIFIED SINGLE COMPONENT HIGH PERFORMANCE STRUCTURAL REPAIR MORTAR

Description

MAXRITE 500 is a single component restoration mortar, modified with polymers. Its quick setting and thixotropy allow the repair of new and old structural concrete in a simple way, without the need for using any form work.

Uses

• Structural repair of concrete in columns, beams, walls, etc. affected by mechanical or carbonation damage, etc.
• Repair con prefabricated concrete elements.

Advantages

• Quick setting. The repair can be accomplished in a single phase.
• Good thixotropy. Application in successive layers without slump or the need to use form work.
• High adhesion to concrete and to reinforcements. Loads are transmitted onto the repaired structure.
• Single component mortar. Only requires water for preparing the mix.
• Waterproof. Protects reinforcements and resists freeze-thaw cycles.
• High mechanical resistance and good resistance to impacts. Long lasting repairs.

Application Instructions

Preparation of the surface: Remove all damaged and loose concrete in the repair area, clean cut the edges perpendicularly to a minimum depth of 5 mm. Eliminate any concrete affected by carbonation or chloride attack.

Expose all reinforcements affected by corrosion, removing all the concrete until the edges of the bars are not affected by rust. Remove concrete all around the reinforcement for an efficient treatment all around and to be able to surround it with a minimum thickness of at least 1 cm. of MAXRITE 500.

Eliminate rust by mechanical means, such as sand or shot blasting, needle gun, etc. It is not advisable to use metal brushes. Afterwards, an application of the oxide converter and protector MAXREST PASSIVE (Technical Bulletin Nº.: 12) is recommended. Use for this purpose a fine hair brush, avoiding as much as possible staining the concrete. Dampen the exposed surface until saturated, without leaving excess water.

Mix of the product: MAXRITE 500 is mixed exclusively with clean water, free from contaminants, either manually or mechanically. One 25 kg. bag or drum of MAXRITE 500 requires about 3.5 to 4.0 litres of water to achieve proper consistency of a repair mortar (15% ± 1%). Do not exceed 4 litres per bag in order not to reduce mechanical properties.

In hot weather (above 25 °C) it might be necessary to delay the setting time. Mix with cold water for this purpose, but do not add more water above the recommended limit. Consequently, below 10°C it is advisable to use warm water, to speed up the setting of the product.

Mix only the amount of MAXRITE 500 the applicator can place in about 10 minutes, because after this time, the mortar will have started its setting, and will no longer be workable. Allow the mix to rest for three minutes before starting the application.

Application

For an optimum bonding, prepare a slurry, mixing MAXRITE 500 with about 10% more water than recommended for the repair consistency, mixing well until achieving a homogeneous consistency without any lumps. Apply the slurry using a MAXBRUSH type brush on the surface to be repaired and on the reinforcement bars, filling all voids and pores.

While the slurry is still fresh, start placing the MAXRITE 500. Add more powder to the slurry leftover until achieving the consistency of a repair mortar, and apply layer between 5 and 50 mm. thick. Place special attention in pressing with the trowel to prevent any air from being trapped. Mark the surface of each layer with the trowel to improve the adhesion of the following one, which can be placed after about 30 minutes. Shape the last layer as desired before the final hardening occurs.

Once the repair is finished, it is advisable to coat all the structure with MAXSEAL or MAXSEAL FLEX.
This protection assures the waterproofing of the concrete and, consequently longer durability.

Curing

Under extreme conditions of wind or heat, lightly spray water over the repaired areas for at least an hour. It is also convenient to cover them during the first 24 hours if the temperature is above 25 ºC and the relative humidity is below 50%. Under very cold weather, protect the repair with insulation material. Do not apply below 5 °C or if lower substrate or ambient temperatures are expected during the 24 hours following the repair.

Cautions

If the slurry primer dries up, or the previous layer is completely set, apply a new slurry coat to continue the job.
Do not use any MAXRITE 500 leftovers to prepare a new batch.
Do not use mixing methods which cause violent mix and do not mix for prolonged periods as mechanical properties are reduced, as well as the life of the repair.
Do not use curing compounds on the repair.
Do not exceed the thickness or amount of mixing water recommended.
The setting time and hardening will vary depending on the ambient condition.
At temperatures above 25 ºC it may be advisable to use MAXRITE 700 because of its longer setting time.
MAXRITE 500 is non toxic, but is an abrasive compound by its composition.
When mixing and placing do not use bear hands but protect them with rubber gloves.
If the product comes in contact with the eyes, rinse with abundant water but do not rub. If the irritation persists, consult a doctor.

Packaging

25 kg. bags and drums.

Storage

Nine months in bags and twelve months in drums and cans, it their original unopened container, in a dry covered place, protected from frost and humidity.

Colours

Grey.

Technical Data

Apparent density powder (kg/m3) | 1,131 ± 50
Mixing water (% weight w/ prod.) | 15 + 1
Apparent dry density (kg/m3) | 2,150 ± 50
Pot life (minutes, 20 °C) | 10
Setting time (minutes, a 20 °C) Beginning End | 10 25
Flexural strength (MPa) 7 days 28 days | 5.2 8.5
Compression resistance (MPa) 7 days 28 days | 34.0 49.0
Capillarity (C) (g / dm2 min ½) | 0.76
Dynamic modulus of elasticity (MPa) | 27,000

Tests, generally after 28 days
Mixing water: 14%
Test report 16.953 Part 12.1 by I.C.C. Eduardo Torroja

Guarantee

The information contained in this leaflet is based on our experience and technical knowledge, obtained through laboratory testing and from bibliographic material. DRIZORO reserves the right to introduce changes without prior notice. Any use of this data beyond the purposes expressly specified in the leaflet will not be the Company’s responsibility unless authorised by us. We shall not accept responsibility exceeding the value of the purchased product.

© 2003 DRIZORO S.A. All rights reserved.