FUTURA-15 - Horizontal Repair Mortar

32 01 29.61

No. 398

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FUTURA®-15

VERY RAPID-HARDENING HORIZONTAL REPAIR MORTAR

DESCRIPTION
FUTURA-15 is a one component, cementitious, very rapid-hardening structural repair mortar designed for horizontal applications. FUTURA-15 is composed of selected cements, graded sands and chemical additives. This proprietary blend produces a very rapid-setting structural repair mortar even in cold weather conditions without the aid of chloride or gypsum based accelerators.

USES
FUTURA-15 is ideal for structural patching of concrete pavements, bridges, parking decks, airport runways and taxiways. FUTURA-15 is also designed for repair of industrial floors, expansion joint nosings, sidewalks and general commercial applications, along with grouting keyways.

FEATURES AND BENEFITS

• Temperature usage range from 20 to 85º F (-7 to 29º C)/ Can be used for a wide range of applications
• May be top-coated in as little as four hours
• Rapid strength gain/ Repairs can be opened to traffic in as little as an hour
• Shrinkage compensated/ Minimizes cracking and de-bonding
• Contains no chlorides/ WIll not promote reinforcing steel corrosion
• Contains no added gypsum/ Excellent resistance to freeze/thaw and wet environments
• Low permeability/ Protects reinforcing steel from future corrosion
• Economical/ Can be extended up to 50% by weight with aggregate
• One component/ Easy mixing, saves labor
• Self-compacting/ Easy to apply

SPECIFICATIONS
Conforms to ASTM C 928-99a "Packaged, Dry, Rapid Hardening Cementitious Materials for Concrete Repair," Classification R3, Very Rapid Hardening.

SHELF LIFE
12 months when stored on pallets in a dry, cool area.

YIELD

• 50 lb. (22.7 kg) bag yields 0.43 ft.³ (12.16 L)
• Extend with 12.5 lb. (5.68 kg) of aggregate - yields 0.51 ft.³ (14.49 L)
• Extend with 25 lb. (11 kg) of aggregate - yields 0.60 ft.³ (17.06 L)

Yields listed above are based on 5.25 pints (2.48 L) of water per 50-lb. bag and will vary based on substrate profile, mix ratios, aggregate type and waste. Field trials should be performed to determine yields based on aggregate type.

TECHNICAL DATA*
The following physical properties were determined using the maximum water to powder ratio of 5.25 pints (2.48 L) per 50 lb. (22.7 kg) of FUTURA-15 at 75ºF (23.5ºC)

FOR BEST PERFORMANCE

• FUTURA-15 is recommended for concrete repairs only
• Not intended to be used as a self-leveling underlayment or topping; FUTURA-15 is designed as a trowel down repair mortar.
• Protect from freezing for a minimum of 24 hours.
• Do not bridge moving cracks. Extend existing control and expansion joints through FUTURA-15.
• For large areas with no control, expansion or construction joints, refer to ACI Guidelines.
• Do not exceed a length-to-width ratio of 2 to 1 for the repair area.
• Do not add any admixtures.
• Exceeding liquid requirements shall result in reduced physical properties.
• Realize that set time will decrease as the product, air, substrate and mixing liquid temperature increases and will increase as the temperature decreases.
• Repair areas should be saw cut and slightly undercut to a minimum depth of a 1/2" (12.5 mm). Do not featheredge.
• Protect from conditions that may cause early water loss; high winds, low humidity, high temperature and direct sunlight. Early water loss is exasperated in thin applications.
• Realize that the use of extender aggregate will alter physical properties.
• Do not use evaporation retardants, such as EVAPRE with this product.
• Failure to follow industry standard practices may result in decreased material performance.
• Proper application is the responsibility of the user. Field visits by W. R. MEADOWS personnel are for the purpose of making technical recommendations only, and are not to supervise or provide quality control on the job-site.

SURFACE PREPARATION
Perform surface preparation in accordance with ICRI Technical Guidelines No. 03730, "Guide for Surface Preparation for the Repair of Deteriorated Concrete Resulting from Reinforcing Steel Corrosion." Mechanically abrade existing substrate to remove all unsound concrete, but do not use excessive force, which may cause micro-fracturing. Substrate must be structurally sound and free of any contaminants that will adversely affect the bond. Prepared substrate surface must have a sufficient profile of ¼" to ensure adequate mechanical lock. Saw cut perimeter of repair zone to a depth of ½" to avoid feather edging.

Completely expose all reinforcing steel, ensuring a minimum clearance of ¾" behind reinforcing steel. Abrade entire circumference of steel to a white metal finish. Perform reinforcing steel preparation in accordance with ICRI Technical Guidelines No. 03730. Pre-dampen concrete substrate to a saturated surface dry (SSD) condition. Remove all standing water and puddles.

MIXING
Mix only complete bags. Using a suitable sized mortar type mixer, add 4.75-5.25 pints (2.24-2.48L) of clean water to the mixer per 50 lbs. (22.7 kg) bag of FUTURA-15. If extension is required, add appropriate amount of aggregate to mixer prior to the addition of FUTURA-15. Mix for 3-5 minutes until homogenous and lump-free. Do not mix more product than can be mixed, placed and finished in 15 minutes at 70°F (21°C). Do not over-mix.

AGGREGATE EXTENSION
For repairs greater than 2" (51mm) in depth; extend FUTURA-15 with 12.5 lbs. (5.68 kg) of aggregate. For repairs greater than 4" (102 mm) in depth extend FUTURA-15 with 25 lbs. (11.36 kg) of aggregate. The aggregate must be a minimum of 3/8" (9mm) size, saturated but surface dry condition, clean pea gravel. Always add the aggregate to the mixing water prior to the addition of FUTURA-15. For configurations requiring greater than 50% extension or larger areas, contact your local W. R. MEADOWS representative. Proper stress relief must be given for large patch areas.

PLACEMENT
Apply FUTURA-15 by trowel or screed. Compact FUTURA-15 well against the prepared substrate prior to bulk placement. Ensure complete encapsulation of reinforcing steel. Finish surface by screeding FUTURA-15 to a level surface. For a rough finish, a broom or burlap bag is suitable. Do not re-temper or overwork.

Application Range: 20 to 85°F (-7 to 29°C)
Follow ACI 305-R89 "Standard on Hot Weather Concreting" or ACI 306-R88 "Standard on Cold Weather Concreting," when applicable.

May be top-coated with an epoxy-based overlay after 4 hours. For most systems, wait a minimum of 24 hours prior to topcoating. Consult appropriate installation guide for the product to be overlaid.

CURING
Cure FUTURA-15 immediately following application using a suitable curing compound from W. R. MEADOWS, or in accordance with ACI 308. W. R. MEADOWS recommends 2250-WHITE or 1130-CLEAR for curing. On large patches, cure repair zone as work proceeds. Wet curing for a minimum of one day, followed by a suitable curing compound, helps minimize shrinkage.

SAFETY AND TOXICITY
Avoid inhalation of dust. Avoid direct contact with this product. Utilize gloves and safety glasses to minimize direct contact. If contact occurs, wash affected areas with mild soap and water. Keep product out of reach of children. FOR INDUSTRIAL USE ONLY. Refer to Material Safety Data Sheet for complete health and safety information.

This material last updated July, 2004.