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WHERE TO USERepair of damaged concrete structures on vertical orhorizontal surfaces or on ceilings.

Some application examples Repairing deteriorated areas of concrete damaged by

the oxidation of reinforcing rods. Reconstruction of reinforcing rod covers in reinforced

concrete structures. Repairing surfaces subjected to heavy abrasion and

impact (canals, industrial floors, ramps, etc.). Levelling diaphragm and tunnel walls. Repairing viaducts for highways, roads and railways. Repairing spillways. Repairing sewarage systems.

TECHNICAL CHARACTERISTICSMapegrout FMRis a ready-mixed powder composedof high-strength cements, selected aggregates, specialadmixtures and flexible metal fibres manufactured to aformula developed in the MAPEI research laboratories.The fibres are manufactured with corrosion resistantamorphous metal alloy of iron-chrome having thefollowing properties: length/diameter ratio: 125 length: 30 mm tensile strength: > 1,900 MPaThe metal fibres improve the mortars flexural performanceand considerably increase its resistance to impact.Mapegrout FMRmixed with water becomes an easilyworkable highly thixotropic mortar, easy to apply onvertical and horizontal surfaces or on ceilings, even inthick layers without needing formwork.When Mapegrout FMRis prepared by adding only

water, it must be cured in a damp environment in orderto develop and fully exploit its expansive propertiescorrectly. These conditions are difficult to obtain on site.Therefore, to guarantee its expansive properties,0.25% of Mapecure SRAmay be added to theMapegrout FMRmix, in order to reduce the amountof plastic and hydraulic shrinkage.Mapecure SRAplays a very important role byguaranteeing improved curing of the mortar. Whenmixed with Mapegrout FMR, it may also be considereda technologically advanced system, since the admixturehas the capacity of reducing quick evaporation of thewater in the blend and helps develop the hydration.Mapecure SRAacts as an internal curing agent.With its interaction with some of the main componentsof cement, final shrinkage is reduced by 20-50%

compared with the normal shrinkage of the productwithout admix. This reduces the potential formation ofcracks.Once hardened, Mapegrout FMRhas the followingproperties: Very high flexural and compressive strength. Coefficient of thermal expansion and permeability to

water vapour similar to those of high quality concrete. Waterproof. Excellent adhesion to old concrete, provided that it

has been saturated with water beforehand, and alsoto reinforcing rods, especially when they have beentreated with Mapefer or Mapefer 1K.

Mapegrout FMRmeets the requirements defined byEN 1504-9 (Products and systems for the protectionand repair of concrete structures - Definitions,requirements, quality control and evaluation ofconformity - General principles for the use of products

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REN 1504-3

Shrinkage compensated

sulphate-resistant

thixotropic mortar,

fibre-reinforced with

flexible metal alloy fibres,

particularly suitable for

the repair of concrete

structures where more

workability is required

IN COMPLIANCE WITH

EUROPEAN STANDARD

REPAIR MORTAR

R4

EN 1504-3

Polve

re+Fibre

Powder

+Fibers


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grease, oils and previously applied paints,by sand-blasting.

After cleaning, treat the reinforcing rods withMapefer or Mapefer 1K, corrosion-inhibitingcement mortars, following the applicationprocedure described in the relevant technicaldata sheets. When Mapefer or Mapefer 1Khas dried completely then soak the substratewith water.

Wait for the excess water to evaporatebefore applying Mapegrout FMR. Tofacilitate the elimination of free water,use compressed air.

Preparing the mortar Pour into the mixer the amount of water

needed to obtain the consistency requiredfor the application (17-18% of the amountof powder).

Start the mixer and slowly addMapegrout FMRto the water in acontinuous flow.

If curing of the mortar needs to beimproved, add 0.25% by weight of

Mapecure SRA(0.25 kg per 100 kg ofMapegrout FMR).

Mix for 1 to 2 minutes, then check to makesure the mix is well blended. Scrape anyunmixed powder from the bottom and sidesof the mixer. Mix again for another 2 to3 minutes.

Depending on the amount needed, amortar mixer or a drill fitted with an agitatorattachment may also be used. Mix at lowspeed to avoid air entrainment.

Avoid mixing manually unless absolutelynecessary. If so, mix small amounts ata time for at least 5 to 6 minutes until a

completely homogenous paste is obtained.Mixing by hand requires a larger amount ofwater. This adversely affects several of themortars properties, including mechanicalstrength, shrinkage, watertightness, etc.Mapegrout FMRremains workable forapproximately 60 minutes at +20C.

Applying the mortarThe grout can be applied with a trowel orsprayed using a piston sprayer e.g. Turbosolor Putzmeister (except continuous-mixingtype rendering pumps) without formworkeven on vertical surfaces or soffits. Themaximum thickness per coat must not

be more than 50 mm. If a second coatof Mapegrout FMRis required, it mustbe applied before the previous one hascompletely set. If it has to be applied ona layer which has already hardened, werecommend that the surface of the firstlayer is left rough and that the substrate isdampened with water.The mortar can be finished with a woodenor plastic tamper once it has hardened. If afurther protective finish is required, removeany fibres that cover the surface with a flattrowel and clean with high pressure water

jets before finishing.

PRECAUTIONS TO BE TAKEN DURINGAND AFTER APPLICATION When preparing the mix, only use bags of

Mapegrout FMRthat have been storedclosed on original pallets.

and systems) and the minimum requirementsclaimed by EN 1504-3 (Structural and nonstructural repair) for structural mortars ofclass R4.

The expansion of Mapegrout FMR, as thatof all the products of the Mapegroutline,has been calculated to compensate forhygrometric shrinkage. To be effective, thesubstrate needs to be well abraded. This is

a necessary condition because, due to highbonding properties and content of fibres,an internal constraint will be generated inthe mortar which will be like that found inconcrete by pre-compression.Because of this effect, Mapegrout FMRcanbe used without using a reinforcing metalmesh (which is necessary when using normalrepair mortars) even if the thickness of theconcrete that needs repair is high.

RECOMMENDATIONS Do not use Mapegrout FMRon smooth

concrete surfaces: abrade them well. Do not add water to a mix that has already

began to set. Do not use Mapegrout FMRat

temperatures below +5C. Do not use Mapegrout FMRif the

packaging has been damaged or has beenopened beforehand.

Do not add cement or admixtures toMapegrout FMR.

Do not use Mapegrout FMRto repairstructures by pouring into formwork(use Mapegrout Hi-Flow).

Do not use Mapegrout FMRfor anchoring(use Mapefill).

APPLICATION PROCEDUREPreparing the substrateRemove deteriorated and loose concrete untilthe substrate is sound, strong and roughedby at least 5 mm. Any previous repairs thatare not fully bonded to the substrate shouldbe removed.Clean the concrete and reinforcing rodsuntil free of dust, rust, cement, laitance,

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A detail of a concretesurface during repair


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TECHNICAL DATA (typical values)

PRODUCT IDENTITY

Class according to EN 1504-3: R4

Type: CC

Consistency: powder

Colour: grey

Bulk density (kg/m): 1,350

Maximum aggregate size (mm): 2.5

Dry solids content (%): 100

Chloride ions content: minimum requirements 0.05% - according to

EN 1015-17 (%): 0.05

PRODUCT APPLICATION DATA (at +20C - 50% R.H.)

Colour of mix: grey

Mixing ratio: 100 parts of Mapegrout FMRwith 17-18 parts water(approx. 4.25-4.5 l per 25 kg bag)

Consistency of mix: plastic-thixotropic

Density of mix (kg/m): 2,200

pH of mix: > 12.5

Application temperature range: from +5C to +35C

Pot life of mix: approx. 1 hour

Waiting time between one layer and the next: max 1-2 hours

FINAL PERFORMANCE (with 17% mixing water)

Performance characteristicTest

method

Requirements accordingto EN 1504-3 Standards for

R4 class mortar

Performance

of product

Compressive strength (MPa): EN 12190 45 (after 28 days)> 20 (after 1 day)> 50 (after 7 days)> 64 (after 28 days)

Flexural strength (MPa): EN 196/1 not required 8 (after 1 day)9 (after 7 days)

11 (after 28 days)

Modulus of elasticity in compression (GPa): EN 13412 20 (after 28 days) 27 (after 28 days)

Bond strength to concrete (MC 0.40 -type substrate water/cement ratio = 0.40)according to EN 1766 (MPa):

EN 1542 2 (after 28 days) > 2 (after 28 days)

Impeded expansion (m/m):UNI 8147

A methodnot required 400 after 1 day

Crack resistance: O Ring Test not required no cracksafter 180 days

Resistance to accelerated carbonation: EN 13295

depth of carbonation referenceconcrete (MC 0.45 type withwater/cement ratio = 0.45)

according to UNI 1766

test passed

Impermeability to water penetration depth - (mm):

EN 12390/8 not required < 5

Capillary absorption (kg/mh0.5): EN 13057 0.5 < 0.08

Slip resistance of steel rods - bonding stress -(MPa):

RILEM-CEB-FIPRC6-78

not required > 25

Bond strength measured according toEN 1542 (MPa): freeze-thaw cycles with deicing salt immersion: storm cycling:

dry cycling:

EN 13687/1EN 13687/2

EN 13687/4

2 (after 50 cycles) 2 (after 30 cycles)

2 (after 30 cycles)

> 2> 2

> 2

Reaction to fire: EN 13501-1 Euroclass A1

Note:due to the presence of metallic fibres within the mix it is important to pay particular attention when preparing the samples forflexural strength determination in order to ensure that these fibres are evenly and homogenously distributed throughout the matrix to

achieve reliable and consistent results.


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During hot weather, store the product in acool place and only use cold water whenpreparing the mix.

During cold weather, protect the productfrom frost at a temperature of +20C anduse lukewarm water when preparing themix.

After applying Mapegrout FMR, werecommend that it is cured carefully toavoid rapid evaporation of the mixing watercausing surface cracks due to plasticshrinkage, especially in hot, windy weather.Spray water on the surface 8-12 hours afterapplying the mortar and repeat this processevery 3-4 hours for at least the first 48hours. As an alternative, after tamping themortar, apply a coat of either Mapecure Eanti-evaporation agent with a low pressurepump, Mapecure Ssolvent-based curingfilm for mortar and concrete orElastocolor Primersolvent-based, highpenetration sealing base for absorbentsubstrates and curing agent for repairmortar. As with all top quality products in

this category, Mapecure Eand Mapecure Simpedes bonding of successive layers.Therefore, if a smoothing compound orpaint is to be applied later, they mustbe completely removed beforehand bysandblasting. If Elastocolor Primerisused to reduce evaporation, a finalprotective layer of Elastocolor PaintorElastocolor Rasantemay be applieddirectly on the treated surface withoutremoving it.

CleaningMortar that has not hardened can beremoved from tools with water. After setting,

cleaning is very difficult and can only becarried out mechanically.

CONSUMPTION19 kg/m per cm of thickness.

PACKAGINGMapegrout FMRis available in 25 bags.

STORAGEMapegrout FMRmay be stored for up to12 months in its original packaging.The product is available in special 25 kgvacuum-packed polyethylene bags which

may be stored outside for the entireconstruction phase of the site. Rain hasno effect on its characteristics.The product complies with the conditions of

Annex XVII to Regulation (EC) N 1907/2006(REACH), item 47.

SAFETY INSTRUCTIONS FORPREPARATION AND APPLICATIONMapegrout FMRcontains cement that when

in contact with sweat or other body fluidscauses irritant alkaline reaction and allergicreactions to those predisposed.It can cause damage to eyes.In case of contact with eyes or skin washimmediately with plenty of water and seekmedical attention.It is recommended to wear protectivegloves and goggles and to take the visualprecautions when handling chemicalproducts.For further and complete information aboutthe safe use of our product please refer tothe latest version of our Material Safety DataSheet.

PRODUCT FOR PROFESSIONAL USE.

WARNINGAlthough the technical details andrecommendations contained in this productdata sheet correspond to the best of ourknowledge and experience, all the aboveinformation must, in every case, be taken asmerely indicative and subject to confirmationafter long-term practical application; forthis reason, anyone who intends to use theproduct must ensure beforehand that it issuitable for the envisaged application. Inevery case, the user alone is fully responsiblefor any consequences deriving from the useof the product.

Please refer to the current version of theTechnical Data Sheet, available from ourwebsite www.mapei.com

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Anyreproductionofte

xts,photosandillustrationspublished

hereisprohibitedandsubjecttoprosecution

(GB)A.G.

BETA

BUILDING THE FUTURE

All relevant referencesfor the product are available

upon request and fromwww.mapei.com

1052-5-2014(GB)

1052 mapegroutfmr gb

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