Mapegrout Gunite FSD is a one-component ready-mixed cementitious mortar composed of hydraulic binders, silica fume, selected aggregate and special additives.

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• Technical Characteristics
• Features & Benefits
• Recommendations
• Application
• Precautions to be taken during and after application
• Cleaning
• Consumption
• Technical Data

Technical Characteristics

When mixed with water, Mapegrout Gunite FSD acquires a thixotropic consistency and can therefore be easily applied on vertical and overhead surfaces in substantial thickness.

The hardening process starts very early after the application, in order to improve:

• Speed of application (several layers in a shorter time)
• Safety during operation: manpower and equipment can move under the same area in shorter time if compared to standard mortars

Features & Benefits

After hardening, Mapegrout Gunite FSD:

• Has high flexural and compressive strength
• Is watertight
• Adheres very strongly to old concrete, provided the concrete is first saturated with water, and to reinforcement bars especially when they are first treated with Mapefer or Mapefer 1K
• Resists sulphates and resists carbonation

Recommendations

Do not apply Mapegrout Gunite FSD on very smooth surfaces. Roughen them first and add reinforcement if necessary, and if the thickness is more than 50 mm.

Do not add cement or additives to Mapegrout Gunite FSD.

Application

Preparation of the substrate (masonry, stone and concrete)

• Surfaces must be free of oils, grease, dirt, and loose material
• Remove the deteriorated concrete back to where the substrate is solid, resistant and rough-textured. Any previous repairs that are not perfectly bonded must be removed
• Remove dirt, rust, cement laitance, grease, oil, varnish or paint from the concrete and rebars with a high pressure cleaner or by sandblasting
• Saturate the substrate with water: This preliminary operation can be carried out by using the hose of the spray machine to spray water on the substrate
• Before beginning repairs with Mapegrout Gunite FSD, wait until the excess water evaporates. If needed, remove free water using compressed air
• If there are clear signs of water seeping in, we recommend applying Lamposilex to seal off the seepage points

Application of the mortar

Mapegrout Gunite FSD can be applied in wet form and manually for local application where the use of a pump is not necessary.

When mixed with water, Mapegrout Gunite FSD acquires a thixotropic consistency and can be easily applied in thicknesses up to approx. 50 mm per coat without form work. For thicknesses bigger than 50 mm, apply in several coats.

To facilitate bonding between coats we recommend leaving the surface of the previous coat rough and then spraying it lightly with water when it has hardened.

After applying the last coat, smooth with a float (after initial setting and before hardening). For a finer-textured finish, use Mapefinish, Monofinish or Planitop T.

Recommended equipment

Continuous mixing unit: Marmotta pump from ITALSWISS, M300 serie from M-TEC.

Rotor pump: OCMER type OCM-030 compact or OCM-045.

Damp application of the mortar

Once the substrate has been prepared (as described in the previous paragraph), damp application of the mortar may be carried out. We recommend adding water at a rate of 13% in weight of the mortar (3.25 l per sack) to give an ideal consistency for laying.

After mixing, apply the mortar by dry spraying, or with a piston or worm screw-type rendering machine, such as a Turbosol or Putzmeister.

If shorter setting times are required, damp application of the mortar may be carried out, but by adding a setting accelerator in the lance nozzle while spraying.

Precautions to be taken during and after application

• Only use bags of Mapegrout Gunite FSD which have been stored on their original, covered pallets
• In hot weather, store the product in a cool area and use cold water to prepare the mix
• In cold weather store the product in a closed area and protect from frost. Use tepid water to prepare the mortar
• After applying and tamping Mapegrout Gunite FSD, and particularly in hot or windy weather, it is recommended to cure the mortar to prevent the mixing water evaporating too quickly, otherwise surface cracks may appear. Curing can be executed by spraying water on top of the mortar, or using a special curing agent from the Mapecure range

Cleaning

The mortar can be removed from tools with water if it has not yet hardened. The nozzle should be cleaned with water.

Consumption

Approx. 25 kg per 13 litres of void to be filled.

Technical Data