Pultruded carbon fibre or glass fibre bars for repairing and structural strengthening damaged concrete, wooden and masonry elements. High tensile bars pre-formed with epoxy resin.

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• Features & Benefits
• Technical Characteristics
• Application
• Precautions To Be Taken During Preparation And Application
• Cleaning
• Technical Data

Features & Benefits

• Unlike interventions using traditional methods, thanks to their extremely low weight, products from the Maperod range may be applied extremely quickly without using special handling or lifting equipment, and often without interrupting the use of structures
• Compared with the cladding technique using metal plates (béton plaqué), Maperod does not require temporary supports during application and there is no risk of corrosion of the strengthening materials applied
• Compared with cladding using fabric impregnated directly on site, bars from the Maperod range may be applied very quickly and the quality of the installation is less dependent on the experience and skill of the workers

Technical Characteristics

Maperod C is a range of deformed, pultruded carbon fibre bars in an epoxy matrix with a peel-ply film, characterised by their high tensile strength. Maperod C is a valid alternative to metal bars.

The bars in the Maperod C range are 10 mm in diameter and have a modulus of elasticity of 155 GPa.

Thanks to their composition and production process, which guarantees constant properties throughout the bars, MapeWrap C have the following characteristics:

• High tensile strength
• Lightweight
• Modulus of elasticity compatible with and suitable for the requirements of concrete and other materials used in constructions
• Easy to apply

Recommendations

• Before bonding, make sure the tensile strength of the substrate is sufficient
• Do not apply Maperod on substrates which are not fully cured
• On particularly absorbent substrates or on concrete in areas with a high level of R.H. (underpasses, underground rooms, cellars, etc.), Mapei recommend priming the substrates with a coat of MapeWrap Primer 1 before bonding Maperod (see relative technical data sheet for preparation and application instructions). Application of MapeWrap 11 or MapeWrap 12, or as an alternative Mapefix EP, must be carried out while MapeWrap Primer 1 is still “fresh”

For applications on wooden substrates, Mapei recommend using an epoxy adhesive from the Mapewood range (please refer to the respective technical data sheet).

Application

Application phases:

1. Drilling the holes
2. Preparation of MapeWrap Primer 1
3. Application of MapeWrap Primer 1
4. Preparation of MapeWrap 11, MapeWrap 12 or Mapefix EP
5. Application of MapeWrap 11, MapeWrap 12 or Mapefix EP
6. Inserting the Maperod bars

Drilling the holes

Preparation of masonry

Drill a series of holes or incisions slightly larger than the diameter of the bar in the face of the wall. The depth of the holes or incisions must be calculated by a design engineer.

Preparation of concrete

Drill a series of holes or incisions around 1.5 times the diameter of the bar in the concrete. The depth of the holes or incisions must be calculated by a design engineer.

Preparation of wood

Drill a series of holes or incisions of the appropriate size, which must be calculated by a design engineer, also in view of a possible recoat.

Preparation of MapeWrap Primer 1

The two components which make up MapeWrap Primer 1 must be mixed together. Pour component B into component A and mix with a low-speed drill with a mixing attachment until the resin is completely blended. Mixing ratio: 3 parts by weight of component A with 1 part by weight of component B.

To avoid dosage errors, use the entire contents of the two components.

If only partial quantities are required, use high-precision electronic scales to weigh out the components (this procedure must also be adopted for the other products).

Once prepared, the workability time of MapeWrap Primer 1 is approx. 90 minutes at 23°C.

Application of MapeWrap Primer 1

After drilling and preparing the holes, apply MapeWrap Primer 1 inside the holes using a bottle brush.

If the surface is particularly absorbent, apply a second coat of MapeWrap Primer 1 once the first coat has been completely absorbed. Then apply MapeWrap 11, MapeWrap 12 or Mapefix EP while the product underneath is still “fresh”.

Preparation of MapeWrap 11, MapeWrap 12 or Mapefix EP

MapeWrap 11 or MapeWrap 12

MapeWrap 11 or MapeWrap 12 must be chosen according to the surrounding temperature and workability time (MapeWrap 12 has a higher workability time than MapeWrap 11).

Pour component B into component A and mix with a low-speed drill with a mixing attachment until they form an even, grey paste.

Mixing ratio for both products: 3 parts by weight of component A with 1 part by weight of component B. At 23°C, MapeWrap 11 remains workable for around 35 minutes after mixing, while MapeWrap 12 remains workable for around 50 minutes.

Mapefix EP

Mapefix EP is a two-component product supplied in bi-axial 385ml cartridges and comprises two separate components, A (resin) and B (catalyser). They are mixed together during extrusion from the cartridge through a static mixer supplied with the product. This product may be applied at 5°C to 40°C.

Application of MapeWrap 11, MapeWrap 12 or Mapefix EP

Completely fill the holes previously treated with MapeWrap Primer 1 while it is still “fresh”. Apply MapeWrap 11 or MapeWrap 12 in the holes using an empty sealant cartridge filled with product and an extrusion gun, and Mapefix EP through the static mixer supplied with the product using an extrusion gun.

Inserting the Maperod bars

Maperod C and Maperod G are supplied in lengths of 2 meters and 6 metres respectively, and are cut to length on site using a diamond cutting disk. Insert the Maperod bars while applying a constant pressure along their entire length. Insert the bar down to the bottom of the hole so that it pushes the epoxy anchoring product out from the hole. Remove excess resin with a trowel, taking care not to move the bars.

When applied on curved elements, the bars must be held in position with clamps or stays until the resin has completely hardened (24 hours is usually enough before the clamps or stays can be removed).

Precautions To Be Taken During Preparation And Application

• The temperature during application must be at least 10°C and the structure must be protected from rain and dust carried by the wind
• After completing application, make sure the treated surface is kept at a temperature of at least +10°C until the products are completely cured
• Protect the surface from rain for at least 24 hours if the temperature does not drop below 15°C, or for at least 3 days if the temperature is lower.

Cleaning

MapeWrap 11 and MapeWrap 12 form a strong bond, including on metal. Cleaning tools with solvent (such as ethanol, toluene, etc.) before they harden is recommended.

Technical Data