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Copsatec 500 

High resistant mortar for structural concrete repair

Description

COPSATEC 500 is a one-component product based on inorganic binders, fibers, selected aggregates, admixtures and polymer. It involves the latest technological developments in the chemistry of hydraulic nature mortars.

Its high mechanical resistance, resistance to sulphates and carbonation, high module and compensated shrinkage make it suitable for high-scale structural industrial rehabilitation, construction and civil works.

Technical Data

• Type: Enhanced cement mortar.
• Aspect: Powder.
• Colour: Grey.
• pH: 12.
• Density fresh: ~2.05 kg/dm³.
• Grain size max: 2 mm.
• Water/product relation: 17%
• Application temperature: 5 - 30 ºC.
• Workability time (20 ºC): 30 min.
• Mechanical strength (EN 12190):
  • Compressive str. at 24h: > 18 N/mm².
  • Compressive str. at 7d: > 40 N/mm².
  • Compressive str. at 28d: > 60 N/mm².
  • Flexural strength at 28 d: > 50 N/mm².
• Bond strength to concrete (EN 1542):
  • At 28 d: > 2 N/mm2.
• Bond str. to concrete after frost-defrost cycle with immersion (EN 13687-1): > 2 N/mm².
• Bond strength to concrete after thermal shock (EN 13687-2): > 2 N/mm².
• Bond str. to concrete after dry thermal cycles (EN 13687-4): > 2 N/mm².
• Capillary absorption (EN 13057): <0.5 kg m^-2 h^-0,5.
• Thickness of application: 5 - 50 mm.

Features

• Applicable both to outdoor and indoor surfaces.
  
• Chloride free.
• Very high resistencies.
• High adhesion to most of the conventional substrates.
• Excellent workability.
• Sulfates resistant.
• High thixotropy.
• Fiber reinforced.
• Highly waterproof.
• Meets the requirements of UNE-EN 1504, part 3, class R4.
• Can be pumped and projected.

Application procedure

Substrate preparation: The substrate must be water saturated, clean and free from friable material, paint, varnish, framework residuals or curing liquid.

Deteriorated material must be cleaned either by hand or mechanically, to obtain a rough, clean and solid substrate.

Oxides, which could exist in fittings and reinforcements, must be eliminated and rebars must be covered with PREREPAR S 100. In case of water leakages, these should be plugged prior to the application by any grout of the PRERESEAL range.

If no binding adhesive is used, the surface must be saturated with water and will have a dark appearance, free from puddles or visible water.

If a higher adherence is required or substrates are complicated because of their low absorption or possible movement, PREPOXY ADHERENTE should be applied to enhance adhesion.

Product preparation: Pour 4 to 4.5 liters of water in a clean container, according to the desired consistency. Add slowly the content of the bag, mixing by a mechanical mixer to obtain a homogeneous, lump free mixture.

Leave the mixture to rest for 1-2 minutes for the concrete to moisture and mix a little again.

Do not add more water and do not mix if the material loses its consistency.

Product application: The ambient and the substrate temperature should be between +5 ºC and +30 º C, taking care to maintain it throughout 12 hours following the application.

If a binding adhesive has been used, this will be still superficially sticky. If not, a new coat has to be applied before the mortar placement.

If the mortar is placed straight over concrete, the substrate has to be wet, with no water residuals.

COPSATEC 500 can be injected mechanically or by hand, using a trowel. The thickness of the material applied should be uniform. An initial levelling coat is recommended in case of highly uneven substrates.

Afterwards, a final coat could be applied by a trowel or a sponge as soon as the mortar setting has started.

COPSATEC 500 does not need a special curing when applied over low-porous concrete and mortar. If the surface is highly porous, it is recommended to protect COPSATEC 500 by a plastic or a wet burlap to avoid fast water evaporation. Curing is also highly necessary in singular conditions, such as dry ambient, strong wind, etc. This is carried out by COPSA products of the PRECURING range.

Tools cleaning: Tools and application equipments are washed immediately after use. If the product hardens, it can be removed by mechanical means only.

Recommended for

• Structural repair of civil, industrial and construction works.
• Marine structures.
• Buried structures, canals, sewers, tunnels under aggressive conditions.
• Repair and profiling of concrete walls.
  

Special precautions

This product contains cement. Avoid its contact with the eyes and the skin. Avoid inhaling the product.Use rubber gloves and goggles. Keep out of children‘s reach. Do not apply the product at temperatures lower than 5 ºC.

Empty packaging must be disposed of according to the local legal environmental regulations.

Consumption

COPSATEC 500 yields 1.80 kg/m²/mm thickness. This can vary according to the substrate texture.

Packaging

The product is supplied in 25 kg bags.

Storage

COPSATEC 500 must be stored in a dry place, protected from frost and direct sunlight, in its original, unopened packaging.

Its shelf life is 12 month from the date of production, provided it is well kept.

Activities where this product appears:

• 03. Repair and Rehabilitation Systems

The information and technical data in this «Product Guide» are indicative and are subject to change without notice. Are based on ourexperience and knowledge and customary uses and applications of the product. The specified values may suffer some variationsdepending on: conditions of entry into work, manufacturing tolerances, testing, etc. For this reason, our warranty is limited to thequality delivered.For further expansion or consult our Technical Department.
This information supersedes all previously issued.