Repairing concrete structures where high thicknesses and special shapes of deterioration require the use of a free-flowing mortar, including at low temperatures.

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

Technical Characteristics

Mapegrout SV Fiber is a pre-blended mortar in powder form, made from special hydraulic binders, high-strength cement, selected graded aggregates, special admixtures, and stiff, hooked fibres in brass-plated steel.

The stiff, hooked fibres in brass-plated steel contained in Mapegrout SV Fiber have the following characteristics:

• Length: 30 mm
• Diameter: 0.38 mm
• Tensile strength: > 2,600 MPa

When Mapegrout SV Fiber is mixed with water, it forms a fluid mortar which is suitable for casting into formwork, without segregation, at a thickness of between 1 and 5 cm.

Once hardened, Mapegrout SV Fiber has the following characteristics:

• High flexural and compressive strength
• Modulus of elasticity, thermal expansion coefficient and permeability coefficient similar to high quality concrete
• Impermeable to water
• Excellent bond strength to old concrete, if dampened with water before application, and to reinforcement rods especially if treated beforehand with Mapefer or Mapefer 1K
• High resistance to wear due to abrasion or impact

Mapegrout SV Fiber meets the main requirements of EN 1504-9 (“Products and systems for protecting and repairing concrete structures: definitions, requirements, quality control and conformity assessment. General principles for the use and application of systems”), and the minimum requirements for EN 1504-3 (“Structural and non-structural repairs”) for R4-class structural mortars.

Mapegrout SV Fiber is recommended for thicknesses of up to 5 cm. If a thicker layer is required, we recommend the addition of 30 to 50% in weight of a suitable size aggregate; refer to our Technical Department for further details on 0113 2455450 (option 2) or send a message to [email protected].

Thanks to its rapid hardening properties, Mapegrout SV Fiber may be walked on and opened to rubber-wheeled traffic after only 2 hours from application at a temperature of +23°C.

Recommendations

• Do not apply Mapegrout SV Fiber on smooth surfaces. Roughen the surface of the substrate (ridges of at least 5 mm) and, if necessary, add reinforcement rods
• Do not apply Mapegrout SV Fiber on surfaces treated with asphalt or bitumen
• Do not add cement or admixtures to Mapegrout SV Fiber
• Do not add water once the mix has started to set
• Do not use Mapegrout SV Fiber for fixing elements accurately in place (use Mapefill)
• Do not use Mapegrout SV Fiber if the temperature is lower than -5°C or higher than 35°C. If the product has to be applied at a different temperature than the recommended application range, please contact the Technical Services Department
• Mapegrout SV Fiber hardens very quickly. Therefore we recommend preparing quantities of the product which will be applied within 20 minutes of mixing
• Do not use Mapegrout SV Fiber if the packaging is damaged

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
• Remove all dust, rust, cement laitance, grease, oil and old paint from the concrete and reinforcement rods by sandblasting
• Saturate the substrate with water
• Before casting, wait until excess surface water has evaporated off. Use compressed air to accelerate this process if required

Preparation of the mortar

Pour 3.4-3.6 litres of water into the cement mixer, slowly add Mapegrout SV Fiber.

Mix for 2-3 minutes, remove all powder which has stuck to the walls of the mixer and mix again for 2-3 minutes to form a fluid, lump-free mix.

A mortar mixer or drill with a mixer fitting may also be used, according to the quantity of mortar required. Avoid excessive air entrainment while mixing.

Mapegrout SV Fiber remains workable for approximately 20 minutes at 20°C.

If there is insufficient boundary support, filling layers of Mapegrout SV Fiber thicker than 5 cm must only be applied after inserting reinforcing rods. A layer of at least 2 cm thick must be applied over the rods.

Application of the mortar

Pour Mapegrout SV Fiber in a continuous flow from one side only of the area to be filled, making sure that all air is expelled.

Immediately smooth over the surface with a trowel.

After application, Mapegrout SV Fiber does not require vibration.

If applied in formwork, water must not be absorbed from Mapegrout SV Fiber. In this case, we recommend treating the formwork with a form-release agent (for example Form Release Agent DMA 1000).

Precautions To Be Taken During And After Application

• Only use bags of Mapegrout SV Fiber which have been stored unopened on their original 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 application, and particularly in hot or windy weather, we recommend curing Mapegrout SV Fiber carefully, to avoid the mixing water evaporating too quickly, otherwise surface cracks may appear due to plastic shrinkage. Spray water on the surface 2-4 hours after applying the mortar and repeat this operation at regular intervals for at least 48 hours

As an alternative, after tamping the surface of the mortar, apply Mapecure E, anti-evaporation agent in water emulsion with a low pressure pump, Mapecure S, film-forming curing agent for mortar and concrete or Elastocolor Primer, high- penetration solvent fixing agent for absorbent surfaces and curing agent for repair mortar.

As with all the best products in this category available on the market, they impede a good bond of successive layers. Therefore, if a smoothing layer or paint is to be applied after, they must be completely removed by sandblasting. If Elastocolor Primer is used to block evaporation, the final protective layer of Elastocolor Paint or Elastocolor Rasante may be applied directly on the surface without removing it.

Cleaning

Fresh mortar may be removed from tools used to prepare and apply the mortar with running water.

Once hardened, cleaning is much more difficult, and the mortar must be removed mechanically.

Consumption

Approximately 20 kg/m² per cm of thickness.

Technical Data