AT-MORTAR (PR) TYPE IV is a Polyester Resin based mortar ideal for grouting where rapid early strength development is required. It comes in a 2-pack system packing; ready for onsite mixing. The system pack consists of two containers of base resin and two bags of catalysed filler. The mixed grout will harden to give rapid strength gain reaching upto 60 N/mm² in 2 hours allowing for on road vehicular traffic post 2 hours. The placed frames will resist compressive and high impact loads.
Confirms to EN1504 Part 3 Class R3 and meets all strength requirements of Highway Works Specification HA104. Grout has been tested in accordance with appropriate parts of the following standards: BS 6319, IS : 4443:1980
FUNCTION: The polyester resin reacts with cementitious hardener by way of polymerisation process to form a quick setting, non-expansive system having excellent mechanical properties like high compressive, flexural and tensile strength which is abrasion resistant and also chemical resistant.
FEATURES & BENEFITS:
- Excellent bond strength
- Stronger than concrete
- Resistant to Oil, Grease and Chemicals
- Easy application comes in pre-packed system packing ready for onsite mixing.
- No primer required
- Rapid setting – Finish job operation within 2 – 3 hours (approx) depending on site condition and temperature
- Versatile product – Can be poured, trowelled, filled with coarse aggregates. Will cure in dry, wet, damp, and under water conditions. Can be used at down to 00C or upto 600C
- Wide range of product application
- AT-MORTAR (PR) TYPE IV is highly recommended for:
- For small / local repairs
- For extensive repairs
- Filling day work joints and setting expansion strips
- Filling depression in worn-out steps or slabs
- Location and Fixing
- Paving slabs, grano or quarry tiles
- Posts, railings and balustrading in concrete
- Brackets, support bars, dowel plugs, air bricks, ventilator frames, etc.
- Contouring and Profiling
- Forming gullies, run-offs, channels, ramp, edges, etc. for storm-water or foul water
- Bedding, Jointing and Sealing
- Bedding and sealing manhole and drain cover frames, door and window frames and pipe unions
- Bedding and fixing slip bricks, stone slips and facing tiles
- All surfaces should be clean, dry free from oil, grease, chemical contamination and all loose materials.
- Oil and grease should be removed.
- Concrete surfaces should be free from laitance; this should be removed by scarifying or etching.
- Mechanical mixing is recommended.
- Care should be taken to ensure that the mix is fully wetted out with resin.
- Pour all of the resin contained in the two tins within the pack into the mixing pail.
- Slowly add the catalysed filler and continue to mix until powder free and uniform.
- The mixed should be placed immediately after mixing due to quick setting.
- Place the mixed mortar onto the prepared surface and lower the frame or unit onto the mortar and knock down onto the pre-set shims to line and level.
- The bed thickness should be between 10mm to 50mm in thickness.
- Once placed, allow to set slightly before any other required work like haunching is carried out.
- Working Time = 8 – 12 minutes.
- Best cures between 5°C and 35°C.
- Cured ready for trafficking within 45minutes.
After this is done, and post the reaction has ceased, wash the surface thoroughly with water and allow it to dry. On smooth surfaces a stronger bond will result if the substrate is roughened to produce a mechanical key. Pour the required amount of resin into the mixing bucket and add a hardener/ aggregate slowly with continuous mixing until a trowel-able consistency is achieved. Large quantities should be mixed in a suitable forced action or pan type paddle mixer. Care should be taken not to mix more than can be used within the setting time of the material.
- APPLICATION GUIDE
- If formwork is used a suitable silicone or wax based release agent should be used to avoid the sticking of the mortar.
- The mixed Polyester Bedding Mortar should be trowelled firmly into place to ensure good adhesion; on dense substrates the mix should be made more resin rich to ensure good adhesion.
- A smooth surface can be obtained by keeping the float face clean by wiping with a damp cloth.
- It is recommended that the maximum thickness of 40mm per application should not be exceeded.
- In addition where multiple applications are required a rough surface between layers should be made to provide a mechanical key.
- Clean all tools and equipment after use.
TYPICAL PERFORMANCE PROPERTIES
(obtained under laboratory condition)
|YIELD ||11.2 ltr / 20 kg system pack|
|DENSITY ||2240 kg / m3|
|COMPRESSIVE STRENGTH ||100 N / mm2 (EN 12190)|
|FLEXURAL STRENGTH ||23 N / mm2 (BS 6319-3)|
|TENSILE STRENGTH ||12 N / mm2 (BS 6319-7)|
|MODULUS OF ELASTICITY IN COMPRESSION ||15 k N/mm2 (EN 13412)|
|TENSILE BOND STRENGTH TO CONCRETE ||> 2.0 N/mm2 (EN 1542)|
|SHRINKAGE ||Less than 1%|
|WORKING TIME ||~ 10 minutes, at 20oC|
(at 20°C under laboratory condition)
|1 HOUR ||45 N/mm2|
|2 HOURS ||60 N/mm2|
|4 HOURS ||70 N/mm2|
|1 DAY ||80 N/mm2|
|3 DAYS ||90 N/mm2|
|7 DAYS ||95 N/mm2|
PACKAGING & STORAGE:
- AT-MORTAR (PR) TYPE IV is available in
- 20 kg system pack [Component A : Component B = 1 : 1]
- AT-MORTAR (PR) TYPE IV has shelf life of 6 months if stored in the original sealed packaging in dry conditions at a temperature of 5°C to 25°C
- Higher humidity or temperature may affect the shelf life
- Keep bags in sealed condition when not in use and away from moisture
- Storing of bags over palette platforms is recommended
HEALTH & SAFETY:
- Protect hands with rubber gloves and eyes with goggles.
- Accidental splashes to the skin or eyes must be rinsed immediately with clean water.
- Store in well-labeled containers.