Planitop Smooth & Repair R2 is a one-component, thixotropic mortar with very low emission of volatile organic compounds (EMICODE EC1 R Plus) made from special hydraulic binders, fine selected aggregates, synthetic polyacrylonitrile fibres, synthetic polymers and special admixtures.

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

Features & Benefits

• After mixing, the product forms mortar with good workability and with setting and hardening times that can be modulated by adding Mapetard ES
• It is applied by trowel in a single layer from 3 to 40 mm thick to repair and smooth over concrete
• Planitop Smooth & Repair R2 hardens without shrinking and is characterised by its excellent adhesion to concrete substrates
• After hardening, Planitop Smooth & Repair R2 has the following characteristics:
• Excellent bond strength to both old concrete (≥ 1.5 MPa) if wetted beforehand with water, and steel reinforcement, especially when treated with Mapefer or Mapefer 1K anti-corrosion and re-alkalising cementitious mortars, certified EN 1504-7 “Corrosion protection of reinforcement”
• High dimensional stability and, therefore, low risk of cracking during the plastic phase and when hardened
• Thermal compatibility to freeze/thaw cycles, measured as adhesion according to EN 1542
• Low permeability to water

Planitop Smooth & Repair R2 meets the 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 of products and systems”) and the minimum requirements of EN 1504-3 (“Structural and non-structural repairs”) for non-structural R2-class mortars and the requirements of EN 1504-2 coating (C) according to principles MC and IR (“Concrete surface protection systems”).

Recommendations

• Do not apply Planitop Smooth & Repair R2 on smooth substrates: roughen surfaces beforehand
• Do not apply Planitop Smooth & Repair R2 on dry substrates
• Do not add cement or admixtures, except Mapetard ES
• Do not add water to the mix to make it more workable once it starts to set
• Do not leave bags of Planitop Smooth & Repair R2 exposed to the sun before use
• Do not use Planitop Smooth & Repair R2 if the temperature is lower than 5°C
• Do not use Planitop Smooth & Repair R2 if the bag is damaged or if it has been opened previously
• Do not use Planitop Smooth & Repair R2 for fixing elements accurately in place (use Mapefill or Mapefill R)

Application Procedure

Preparation of the substrate

• Remove all deteriorated and loose concrete to form a solid, rough and strong substrate. Any areas previously repaired and which are not perfectly bonded must also be removed
• Remove all dust, rust, cement laitance, grease, oil and paint from the concrete and reinforcement rods by sandblasting or hydro-sandblasting
• Treat reinforcement rods with Mapefer or Mapefer 1K, according to the procedure illustrated in the relative Technical Data Sheet for each product
• Wait until Mapefer or Mapefer 1K has dried
• Saturate the substrate with water
• Before carrying out repairs with Planitop Smooth & Repair R2, wait until excess water has evaporated off. If necessary, use compressed air to help remove excess water. The substrate must be saturated with water but with a dry surface

Preparation of the mortar

Pour approximately 4.2 litres of clean water into a container and slowly add a 25 kg bag of Planitop Smooth & Repair R2 while mixing.

Carefully mix the blend for several minutes then remove any powder which has stuck to the sides and bottom of the container. Add more water to obtain the consistency required without exceeding the recommended amount (approximately 4.3-4.8 litres). Mix again for several minutes to form a well-blended, plastic consistency, lump-free mix.

To make it easier to form a smooth, even paste, use an immersion mixer or a low- speed drill with a spiral mixing attachment to avoid dragging air into the mix. Mixing by hand is not recommended, more than the recommended amount of water would be required. If manual mixing is unavoidable, use a trowel and press the mortar against the sides of the container to break down all the lumps.

Planitop Smooth & Repair R2 remains workable for around 15 minutes at +10°C to +25°C. If the workability time of Planitop Smooth & Repair R2 needs to be increased due to specific site requirements or if the weather is particularly hot, the set- retarding admixture Mapetard ES for rapid- setting cementitious mortar may be added to the product.

This special additive, which may be added at a rate of up to one 0.25 kg canister every 25 kg bag of Planitop Smooth & Repair R2, allows the already excellent workability time of the mortar to be extended by a further 15-20 minutes.

Thanks to its slight plasticising effect, adding Mapetard ES to Planitop Smooth & Repair R2 allows the amount of mixing water to be reduced by 0.2-0.3 litres. In this case, pour approximately 4 litres of clean water and a canister of Mapetard ES into a container and slowly add a 25 kg bag of Planitop Smooth & Repair R2 while mixing. Carefully mix the blend for several minutes then remove any powder which has stuck to the sides and bottom of the container.

Add more water to obtain the consistency required without exceeding the recommended maximum amount of approximately 4.5 litres.

Application of the mortar

Apply a layer of mortar from 3 to 40 m thick with a trowel or putty knife; no formwork is required.

As soon as the mortar starts to set, tamp the surface with a sponge float. The waiting time required before carrying out this operation depends on surrounding weather conditions.

To paint and protect the surface, apply a coat of an elastomeric product from the Elastocolor line or an acrylic product from the Colorite line. The finishes available may be chosen from product’s relative colour chart or from a much wider range of shades available using the ColorMap® automatic colouring system.

If the structures to be repaired are subject to high dynamic stress, it may be advantageous to apply a 2 mm thick layer of flexible smoothing and levelling compound such as Mapelastic, Mapelastic Guard or Mapelastic Smart before applying the coloured finish. In such cases, Elastocolor Paint must be used for the coloured finishing coat.

Precautions To Be Taken During And After Application

• Only use bags of Planitop Smooth & Repair R2 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 at a temperature of +20°C and protect from frost. Use tepid water to prepare the mortar
• After applying and tamping the mortar, particularly in hot or windy weather, we recommend curing Planitop Smooth & Repair R2 carefully to avoid the mixing water evaporating too quickly, otherwise surface cracks may appear due to plastic shrinkage. Spray water on the surface for at least 24 hours after applying the mortar or use a curing agent from the Mapecure range. If a curing agent is applied, make sure that it is removed from the surface by sand-blasting or hydro- blasting before applying any other product, since the curing agent may impede a good bond of successive coating layers

Cleaning

Mortar which has not yet hardened may be washed from tools using water. Once hardened, cleaning is much more difficult, and it must be removed mechanically.

Technical Data