32 01 29.61

No. 398A

FUTURA®-45

RAPID-HARDENING HORIZONTAL REPAIR MORTAR

DESCRIPTION
FUTURA-45 is a one-component, cementitious, rapid-hardening structural repair mortar designed for horizontal applications.  FUTURA-45 is composed of selected cements, graded sands and chemical additives. This proprietary blend produces a rapid-setting structural repair mortar, even in cold weather conditions, without the aid of chloride- or gypsum-based accelerators.

USES
FUTURA-45 is ideal for structural patching of concrete pavements, bridges, parking decks, airport runways and taxiways.  FUTURA-45 is also designed for repair of industrial floors, expansion joint edges, sidewalks and general commercial applications, along with grouting keyways.

SPECIFICATIONS
Conforms to ASTM C 928-99a “Packaged, Dry, Rapid Hardening Cementitious Materials for Concrete Repair,” Classification R1, R2 & R3, Rapid Hardening.

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

TECHNICAL DATA*
The following physical properties were determined using the maximum water to powder ratio of 5.00 pints (1.89 L) per 50 lb (22.7 kg) of FUTURA-45 at 75˚ F (23.5˚ C).

FOR BEST PERFORMANCE

• FUTURA-45 is recommended for concrete repairs only.
• Not intended to be used as a self-leveling underlayment or topping; FUTURA-45 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-45.
• 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.
• 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 jobsite.

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 1/4” to ensure adequate mechanical lock.  Saw cut perimeter of repair zone to a depth of 1/2” to avoid possible premature cracking due to point loading.

Completely expose all reinforcing steel, ensuring a minimum clearance of 3/4” 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, 5.0 pints (2.36 L) of clean water to the mixer per 50 lbs. (22.7 kg) bag of FUTURA-45.  If extension is required, add appropriate amount of aggregate to mixer prior to the addition of FUTURA-45.  Mix for 3-5 minutes until homogenous and lump-free.  Do not mix more products than can be mixed, placed and finished in 45 minutes at 70° F (21° C). Do not over-mix.

AGGREGATE EXTENSION
For repairs greater than 1.5” (38.25 mm) in depth, extend FUTURA-45 with 12.5 lbs (5.68 kg) of aggregate.  For repairs greater than 4” (102 mm) in depth, extend FUTURA-45 with 25 lbs (11.36 kg) of aggregate.  The aggregate must be a minimum 3/8” (9 mm) size, saturated but surface dry condition, clean pea gravel.  Always add the aggregate to the mixing water prior to the addition of FUTURA-45.  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-45 by trowel or screed.  Compact FUTURA-45 well against the prepared substrate prior to bulk placement.  Ensure complete encapsulation of reinforcing steel.  Finish surface by screeding FUTURA-45 to a level surface.  For a rough finish, a broom or burlap bag is suitable.  Do not re-temper or over-work.
Application Range: 40 to 100˚ F (4.4 to 38˚ C)

Follow ACI 305-R89 “Standard on Hot Weather Concreting” or ACI 306-R88 “Standard on Cold Weather Concreting,” when applicable. 

CURING
Cure FUTURA-45 immediately following application using a suitable curing compound from W. R. MEADOWS (2250-WHITE or 1130-CLEAR) or in accordance with ACI 308.  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 2007.