Mapegrout T60 is a one-component pre-blended thixotropic cement-based mortar composed of sulphate-resistant hydraulic binders, synthetic polyacrylonitrile fibres, organic corrosion inhibitors, select aggregates and special water-retaining admixtures.

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• Features & Benefits
• Technical Characteristics
• Recommendations
• Application Procedure
• Precautions To Be Taken During And After Application
• Cleaning
• Consumption
• Technical Data

Technical Characteristics

• If Mapegrout T60 is prepared by only adding water, it must be cured under damp conditions in order to guarantee that the product’s expansive properties develop completely and correctly. However, there is no guarantee that these conditions can be created on site.
• Therefore, to guarantee that the expansive properties of Mapegrout T60 take place when drying in the open air, 0.25% of Mapecure SRA, a special admixture which has the property of reducing both plastic and hydraulic shrinkage, may be used to great advantage when added to the mix.
• Mapecure SRA has a very important role to play in guaranteeing better curing of mortar. Also, when mixed with Mapegrout T60, it may be considered a technologically advanced system, in that the admixture has the capacity of slowing down evaporation of the water and of promoting the development of hydration reactions.
• Mapecure SRA behaves like an internal curing agent and, thanks to its interaction with some of the main components which make up the cement, it helps to reduce shrinkage by between 20% and 50% compared with the standard values of the product without the admixture. This will obviously lead to a reduced risk of cracking phenomena.
• Mapegrout T60 may be used also without adding Mapecure SRA, when the environmental conditions permit optimal curing.
• Mapegrout T60 meets the requirements defined by EN 1504-9 (“Products and systems for the protection and repair of concrete structures - Definitions, requirements, quality control and evaluation of conformity - General principles for use of products and systems”) and the minimum requirements claimed by EN 1504-3 ("Structural and non-structural repair”) for structural mortars of class R4. Mapegrout T60 complies with Highways England specifications for the repairs to highway structures.

Recommendations

• Do not use Mapegrout T60 on smooth surfaces: roughen the surface thoroughly and add rebars if necessary
• Do not add cement or admixtures to Mapegrout T60
• Do not pour Mapegrout T60 into forms for repairing works (use Mapegrout Hi-Flow)
• Do not use Mapegrout T60 for anchoring (use Mapefill)

Application Procedure

Preparation of the substrate

• Remove deteriorated and loose concrete down to the solid, strong and roughened part of the substrate. Any previous repair work that is no longer thoroughly bonded must also be removed
• Once prepared, the concrete surface to be repaired must have an uneven texture with at least 5 mm peak roughness
• Sandblast the concrete and the reinforcing bars until they are free of dirt, rust, cement laitance, grease, oil, varnish or old paint
• Saturate the substrate with water
• Before repairing with Mapegrout T60, wait until the excess water has evaporated. To facilitate the elimination of free water, use compressed air if needed

Preparation of the mortar

• Pour into the mixer the amount of water needed to obtain the consistency required for the application

Application per 25KG Bag:

• Trowel: from 4.1L to 4.3L
• Spray: from 4.2L to 4.4L

• Start the mixer and slowly add the Mapegrout T60 to the water in a continuous flow
• If improved open-air curing of the mortar is required, add Mapecure SRA at the end of the mixing phase at a dosage of 0.25% in weight of the mortar (0.25 kg every 100 kg of Mapegrout T60)
• Mix for 1 to 2 minutes, then make sure the mix is well blended. Scrape any unblended powder from the bottom and the sides of the mixer. Mix again for another 2 to 3 minutes
• Depending on the amount needed, a mortar mixer or a drill with an agitator attachment may also be used. Mix at low speed to avoid entraining air
• Avoid mixing manually unless absolutely necessary. If so, mix small amounts at a time for at least 5 to 6 minutes until a completely homogeneous paste is obtained

Remember that mixing by hand requires a larger amount of water. This adversely affects several of the mortar’s properties, including mechanical strength, shrinkage, watertightness, etc.

Mapegrout T60 remains workable for approx. 1 hour at 20°C.

The expansion of Mapegrout T60 is calculated to compensate for hygrometric shrinkage. For it to be effective, the expansion needs to be restrained by rebars or restraints inserted into the substrate.

Buildups of Mapegrout T60 without restraints in thicknesses of more than 3 cm should be done only after inserting rebars and roughening the surface of the concrete, taking care to cover the reinforcement with a layer at least 2 cm thick.

Lesser thicknesses can be applied without rebars as long as the substrate has been thoroughly roughened to counter the expansion. The expansion phase ends during the first days of hardening.

Application of the mortar

Mapegrout T60 may be applied with a spatula or trowel on vertical surfaces in layers up to 10 cm thick per coat, or on ceilings in layers up to 2 cm thick per coat, without the use of form-work.

It may also be applied using a suitable piston or worm-screw type rendering machine, such as a Turbosol or Putzmeister.

Do not use a continuous mixing type rendering machine.

For repairing concrete faces (e.g. balconies, columns, beams, etc.) we recommend treating the rebars with Mapefer or Mapefer 1K after sanding them.

When further coats of Mapegrout T60 are needed, leave the previous hardened coat rough and wet the surface with water.

Precautions To Be Taken During And After Application

• Only use bags of Mapegrout T60 which have been stored on their original pallets
• In warm weather store the material in a cool place. Use cold water to prepare the mix
• In cold weather, store the product in a place which is protected from frost at a temperature of 20°C, and use tepid water to blend the mortar

• After applying Mapegrout T60, it is recommended that it is cured carefully, especially in hot or windy weather, to avoid the water evaporating too quickly and causing the formation of surface cracks due to plastic shrinkage. Spray water on the surface 8-12 hours after applying the mortar, and repeat the operation (every 3-4 hours) for at least the first 48 hours. As an alternative, after tamping the mortar, spread on a layer of either Mapecure E anti-evaporation treatment in watery emulsion with a low-pressure pump, Mapecure S solvent-based curing film for mortar and concrete or Elastocolor Primer solvent-based, high-penetration primer for absorbent substrates and curing agent for repair mortar.

  Mapecure E and Mapecure S, as with all the best quality products in the same category which are currently available on the market, impede bonding of successive coating layers. Therefore, if a smoothing layer or paint is to be applied later, they must be completely removed by sandblasting. If Elastocolor Primer is used as an anti-evaporation treatment, on the other hand, a final protective layer of Elastocolor Pittura or Elastocolor Rasante may be applied directly on the treated surface without having to remove it.

Cleaning

Mortar that has not yet hardened can be removed from tools with water.

After setting, cleaning is very difficult and can only be done mechanically.

Consumption

18.5 kg/m² per cm of thickness if used pure and 14.5 kg/m² if used mixed with 30% of 3 to 6-8 mm aggregate.

Technical Data