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PAGE LINKS Complete Product Listing by Number Waterproof Elastomeric Coatings |
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SYSTEM 44-Series Polymer-Modified Structural Repair Mortars DESCRIPTION: Edison SYSTEM 44-Series patching compounds are one-component, cement-based mortars designed for effective and economical repairs to all types of concrete structures. The series includes a wide range of formulations, each engineered for maximum performance and workability under a particular set of service and application conditions. RECOMMENDED USES:
SYSTEM ADVANTAGES: Economical pre-packaged repair mortars offer more consistent proportioning and performance than field-mixed mortars. Through consistent ingredient selection, proportioning and control, maximum advantage can be taken of the most advanced performance-enhancing admixtures available in the industry. The result is a series of high-strength repair compounds offering exceptional workability, durability and productivity. SYSTEM SELECTION: 1. SET SPEED: Start with an assessment of the desired setting time. Will repair areas have to be back in service minutes after application, or would longer working time be advantageous? With three standard set speeds to choose from, there is an optimum 44-Series system for each situation: System 44: Sufficient working time for fine finishing and facilitates, work in hot weather, when other products may set too quickly. SYSTEM 44-FS: "Fast Setting" formulas downtime and permit work at temperatures. In vertical applications, multiple "lifts" to be installed in one day. SYSTEM 44-FS+: "Fast Set Plus" formulas allow repairs to areas that cannot be closed to traffic for more than a few minutes. FS+ can also be used to achieve durable repairs at subfreezing temperatures, when other compounds are rendered unusable. 2. APPLICATION: Once set speed has been selected, the next decision revolves around where the product will be used and how it will be applied. Repairs mortars for Horizontal surfaces should provide good flow without reducing strength. At the same time, mixes should not tend to separate or settle, allowing the use of pumping equipment for large-scale applications. Mortars for use on Vertical and Overhead
repair areas must be able to build up without sagging or dropping out of the repair cavity.
SYSTEM 44-FS-V/O Vertical/Overhead Patch
Mortars which will be applied by Shotcreting must be able to adhere and gain strength at low water:cement ratios, and should minimize dust and rebound. Select among the various grades of SYSTEM 44: SYSTEM 44-FS and SYSTEM 44-FS+ for a mortar which closely meets the requirements of your repair situation. 3. OPTIONS: In addition to the standard formulations based on speed and application, the 44-Series also includes various options which allow you to further tailor the repair material to the requirements of the situation. NON-POLYMER: While all 44-Series standard formulations are polymer-modified using the highest quality admixtures, some situations - such as continuous underwater exposures and applications to "can't dry" surfaces - are better addressed by unmodified mixes. Still others may suggest a preference for liquid modifiers, such as an FHWA-approved SBR latex for bridge decks (SYSTEM 41 ), or an acrylic modifier for use with mortars which will be pigmented (SYSTEM 42). Where locally available water is of poor quality, liquid admixtures can be used with non-polymer grades of 44-Series mortars to eliminate any need for mixing water. All 44-Series products are offered in non-polymer formulations for just such situations. If no polymer will be used, provisions for wet curing should be anticipated, and alternative adhesion-promoting techniques - such as slurry coating - should be considered. FIBER REINFORCED: Fiber addition to concrete and mortar has become a well-accepted alternative to secondary reinforcement. Fibers also reduce shrinkage and plastic cracking, increase tensile strength and may aid in dispersing impact and vibrations. Fibers available in 44-Series products are alkali-resistant polymers which will not corrode or change volume. The level of addition and length of fibers used have been selected to provide the optimum enhancement without compromising workability. Fiber addition is not an option for 44-FS+ products, which include fibers in the standard formulations. SILICA FUME: The addition of micro silica to Portland cement mixes is credited with providing reduced permeability to moisture and salt, and consequently, improved corrosion protection for steel reinforcement. In shotcreting applications, silica fume reduces rebound and increases build, improving application economy. Micro silica is offered on SYSTEM 44 (Normal Set Speed) products, which have been balanced to accommodate the effects of micro silica on water demand and workability.
TYPICAL SET TIMES (720F):
Product Initial Set Time SYSTEM 44 60 - 65 minutes SYSTEM 44-FS 45 - 50 minutes SYSTEM 44-FS-V/O 60 - 90 minutes SYSTEM 44-FS+ V/O 20 - 30 minutes SYSTEM 44-FS+ 25 - 30 minutes TYPICAL PROPERTIES: SYSTEM 44, 28-Day Dry Cure, 720F
Compressive Strength 6,000 psi Shear Bond Adhesion >350 psi Flexural Modulus (x 106) 1.1 Tensile Strength >500 psi PRODUCT CHARACTERISTICS: Composition: Products are polymer-modified cement-based mortars, free of chlorides, metallic additives, water repellents and other potentially deleterious admixtures. Adhesion: Products adhere to concrete, masonry, steel, wood and polystyrene foam. SYSTEM 44 not recommended on wood. Weathering: 44-Series products are UV-Stable, non-yellowing, resistant to cyclic wet/dry and freeze/thaw exposures and are intended for both outdoor and indoor use. Minimum Use Temperature:
SYSTEM 44: 400F SYSTEM 44-FS: 360F SYSTEM 44-FS+: 250F APPLICATION: 1. Surface Preparation Proper surface preparation is essential to the success of any concrete repair program. The extent to which existing materials must be removed and replaced will be influenced by a variety of existing conditions and anticipated exposure considerations. Except for minor repairs, structural restoration is best performed under the direction of a qualified professional. As a reference resource, we recommend the l.A.C.R.S. publication "Surface Preparation Guidelines for the Repair of Deteriorated Concrete Resulting From Reinforcing Steel Oxidation." As a general guide, surface preparation must result in the removal of all unsound concrete, and any coatings, oil, dirt, paint, curing compounds, corrosive chemicals or any other material which may hinder adhesion or performance of repair mortars. A clean, hard, rough surface should be provided. Shape and depth of the repair should also be considered. Although 44-Series repair compounds are designed to adhere and gain strength even in thin sections, many types of structural repairs are better accomplished when edges are saw cut. Following removal of concrete from the repair area, abrasive blasting or high-pressure water blasting should be used to remove dust, concrete slurry or loose aggregates. Vacuuming does not effectively remove fine dust from surface pores. 2. Priming Patching compounds should not be applied to dry surfaces. As a minimum measure, surfaces should dampened with clean water for at least 20 minutes before patching. Any excess water should be removed before repair compound is placed. Priming with a latex bonding agent such as SYSTEM 42 is preferable to water dampening. The latex should be allowed to dry sufficiently to turn from a milky liquid to a clear film before patching. Primer should not be allowed to set for more than § hours before patch application, however. An alternative for priming is the use of FLEXI-BOND 540 epoxy bonding agent. This material can be used to protect steel reinforcement, consolidate porous substrates and create a waterproof barrier between the slab and repair mortar while providing exceptional adhesion. Patching compound may be placed any time before FLEXI-BOND 540 cures to a tack-free film. Water/neat cement or water/patching mortar slurry coatings are sometimes used for promoting adhesion. These methods are not recommended for use with 44-Series repair mortars except under specific guidance from Edison Coatings, Inc. 3. Application While application procedures can vary as widely as the concrete repair situations being addressed, certain basic guidelines are important to follow in the use of 44-Series repair mortars: a. Keep water addition levels low. Generally, the lower the water:cement ratio, the lower the permeability and the higher the strength of the completed repair. Use the minimum amount of water which will produce a workable, plastic consistency. Horizontal grades 44 and 44-FS should use less than 2/3 gallon water per 50-pound bag. FS+ and Vertical grades are designed for higher water use levels. Shotcreting mortars should be proportioned and applied in accordance with ACI 506 standard practice for shotcreting. b. Do not retemper or overwork. Maximum workability is obtained shortly after mixing. Do not add more water once material starts to set. Finish surfaces as quickly as possible after placement. Dampening of tools or light misting of plastic mortar surfaces is recommended to aid in finishing, when moderation is exercised. Slight surface dampening is also preferable to making "wetter" mixes. c. Avoid rapid drying, but dry cure. Polymer modified cement mixes require a minimum period of moisture in order to gain strength. When working under hot, dry or windy conditions, surfaces may require misting or plastic film protection to avoid too-rapid drying. This is particularly important when large or deep patches are exposed to direct sun. A minimum of 2 hours before drying is required for thin repairs, while sections over 1" deep will benefit from up to 24 hours moist curing. Beyond this relatively short moist curing period, it is essential that the repair compound be allowed to dry out. Continuous moist cure will prevent the latex admixture from forming a proper film, resulting in reduced mechanical strengths and adhesion. After initial set, however, intermittent wet exposures, such as periods of rain or occasional spillage, do not compromise properties. Patches which will be submerged should dry cure for a minimum of 5 - 7 days before submersion. CAUTION!: Dry-curing guidelines do not apply to non-polymer 44-Series products, which will benefit from extended wet curing. SYSTEM 44-NP should be wet cured for up to 7 days. SYSTEM 44-FS-NP reaches full cure in 24 - 48 hours. SYSTEM 44-FS+ NP can be wet cured for 12 - 24 hours. d. Temperature and humidity affect set times and curing. Be aware of weather changes and their effects on pot life, drying time and strength development. Particular attention must be given when working at low temperatures or when rain is threatening. If materials are not allowed sufficient cure time to reach strengths at which they can withstand rain or freezing, damage may result. Polymer-modified patches must be thoroughly dry before freezing. 3. STORAGE & HANDLING: Observe all safety and handling guidelines as detailed in the Material Safety Data Sheets supplied with this product. Keep dry and off the floor or ground. Store at 45 to 850F for longest shelf life. Do not expose bags to rain or high humidity. Avoid skin and eye contact. Cement can cause burns and injury. Wash exposed skin immediately with mild soap and water. In case of eye contact, flush with clean water for at least 15 minutes and consult physician. Avoid breathing dust. Sand contains free silica which may cause occupational lung disease. Wear NIOSH-approved dust filters rated for silica exposure when handling dry materials. |
