Structural R4-class, rapid setting, shrinkagecompensated, thixotropic, fibre-reinforced, cementitious mortar, applied in a single layer from 3 to 40 mm thick, for repairing and smoothing concrete
Structural R4-class, rapid setting, shrinkagecompensated, thixotropic, fibre-reinforced, cementitious mortar, applied in a single layer from 3 to 40 mm thick, for repairing and smoothing concrete
Structural repairs and smoothing over internal and external horizontal and vertical concrete surfaces; suitable for repairing structures exposed to the open air and in permanent contact with water.
Structural repairs and smoothing over internal and external horizontal and vertical concrete surfaces; suitable for repairing structures exposed to the open air and in permanent contact with water.
Planitop Smooth & Repair R4 is a one-component, thixotropic mortar with very low emission of volatile organic compounds (EMICODE EC1 Plus) made from special, highly reactive hydraulic binders, fine selected aggregates, synthetic polyacrylonitrile fibres, synthetic polymers and special admixtures according to a formula developed in the MAPEI Research Laboratories. After mixing, the product forms a 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 R4 hardens without shrinkage and is characterised by its excellent adhesion to concrete substrates. Once hardened, Planitop Smooth & Repair R4 has the following characteristics:
Planitop Smooth & Repair R4 complies with the principles defined in 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 structural R4-class mortars and the requirements of EN 1504-2 coating (C) according to principles MC and IR (“Concrete surface protection systems”)
| Consistency: | Powder |
| Colour: | grey |
| Packaging: | 20 kg & 5 kg bags |
| Consistency of mix: | thixotropic–trowellable |
| Application data of product (at +20°C–50% R.H.) | |
| Colour of mix: | grey |
| Mixing ratio: | 100 parts of Planitop Smooth & Repair R4 with 16.5– 17.5parts of water (approximately 3.3–3.5 litres of water per 20 kg bag) (* |
| Consistency of mix: | thixotropic–trowellable |
| Density of mix (kg/m³): | 2000 |
| pH of mix: | 12 |
| Application temperature range: | from +5°C to +35°C |
| Pot life of mix: | approximately 15 mins. (**) |
| Waiting time before finishing with float: | approximately 20 mins |
| Time to completely set: | approximately 25 mins |
Pour approximately 3.2 litres of clean water into a container and slowly add a 20 kg bag of Planitop Smooth & Repair R4 while mixing.
Carefully mix the blend for several minutes then remove any powder lodged on the sides and bottom of the container. Add more water to obtain the consistency required without exceeding the recommended amount (approximately 3.2–3.5 litres). Mix again for several minutes to form a well-blended, plastic, lump-free mix. To make it easier to form a smooth, even mix, use an immersion mixer or a drill at low speed with a spiral mixing attachment to avoid entraining air into the mix. Mixing by hand is not recommended as 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 R4 remains workable for approx. 15 minutes at a temperature of +10°C to +25°C
If the workability time of Planitop Smooth & Repair R4 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 admixture, which may be added at a rate up to 200 ml for every 20 kg of Planitop Smooth & Repair R4, allows the already excellent workability time of the mortar to be extended by a further 15–20 minutes.
Due to its plasticising effect, adding Mapetard ES to Planitop Smooth & Repair R4 allows the amount of mixing water to be reduced by 0.2–0.3 litres. In this case, pour approximately 3 litres of clean water and 200ml of Mapetard ES into a container and slowly add a 20 kg bag of Planitop Smooth & Repair R4 while mixing. Carefully mix the blend for several minutes then remove any powder which has lodged to the sides and bottom of the container. Add more water to obtain the consistency required without exceeding the recommended maximum amount of 3.3 litres.
For the 5 kg bag, pour 850 ml of clean water into a container and slowly add Planitop Smooth & Repair R4 while mixing. As an option to increase workability time, replace 50 ml water with 50 ml of Mapetard ES.
Apply the mortar with a smooth trowel in a single layer from 3 to 40 mm thick without using formwork.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 range or an acrylic product from the Colorite range. 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 structure to be repaired is 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 Guard or Mapelastic Smart before applying the coloured finish. In such cases, Elastocolor Paint must be used for the coloured finishing coat.
Wash the mortar from tools before it hardens using water. Once hardened, cleaning is much more difficult, and it must be removed mechanically.
