Product Data Sheet
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Rapid-Hardening Horizontal Repair Mortar
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.
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.
- Temperature usage range from 40° – 100˚ F (4.4° – 38˚ C)/Can be used for a wide range of applications.
- Rapid strength gain/Repairs can be opened to traffic in as little as three hours.
- May be top-coated at 24 hours with most standard coating systems.
- 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.
- Flowable/Easy to apply/Saves labor.
Fifty lb. (22.7 kg) bag yields 0.43 ft.3 (12.16 L). Extended with 12.5 lb. (5.68 kg) of aggregate yields 0.51 ft.3 (14.49 L). Extended 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. (22.7 kg) 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.
One year from date of manufacture when stored indoors on pallets in a dry, cool area. Do not store product outside.
- ASTM C 928-99a “Packaged, Dry, Rapid Hardening Cementitious Materials for Concrete Repair,” Classification R1, R2 & R3, Rapid Hardening.
The following physical properties were determined using the maximum water to powder ratio of 5 pints (2.36 L) per 50 lb. (22.7 kg) of FUTURA-45 at 75˚ F (23.5˚ C).
|Set Time per ASTM C191|
|Initial||45 – 60 Minutes|
|Final||70 – 90 Minutes|
|Working Time||45 Minutes|
|Flow per ASTM C928||100% after 15 Minutes|
|Compressive Strength per ASTM C109|
|@ 3 hours||3500 psi (24 MPa)|
|@ 1 day||5200 psi (35 MPa)|
|@ 28 days||8500 psi (58 MPa)|
|Bond Strength per ASTM C8821|
|@ 1 day||1500 psi (10 MPa)|
|@ 28 days||2500 psi (17 MPa)|
|Modulus of Elasticity Per ASTM C469||4.22 x 106 psi (29 GPa)|
|Length Change per ASTM C9282|
|Scaling Resistance Per ASTM C672 @ 25 Cycles|
|Visual Rating||0 Rating – No Scaling|
|Mass Loss||0.00 – No Mass Loss|
All technical data is typical information, but may vary due to testing methods, conditions, and procedures.
1Modified – No bonding agent used. Pre-dampening of properly prepared substrate.
2Cured after three hours at 73+/-3˚ F (23° C) and 50+/-4% RH.
Surface Preparation … Perform surface preparation in accordance with ICRI Technical Guidelines #310.2-1997: Specifying Concrete Surface Preparation for Sealers, Coatings, and Polymer Overlays. Mechanically roughen or high pressure water jet the existing concrete substrate to a minimum concrete surface profile (CSP) of seven or higher, depending on substrate condition. Remove all unsound concrete and provide a profiled, porous surface. The substrate must be structurally sound, dust-free, and free of grease, oil, dirt, curing compounds, release agents, or any other surface or penetrated contaminants that will adversely affect bond. Sanding, grinding, or wire-brushing are not approved surface preparation methods. Saw cut perimeter of repair zone to a depth of 3/4″ (19 mm). Completely expose all reinforcing steel, ensuring a minimum clearance of 1″ (25.4 mm) behind reinforcing steel. Perform reinforcing steel preparation in accordance with ICRI Technical Guidelines #03730. Pre-soak repair zone for a minimum four hours prior to application of FUTURA-45. Substrate must be saturated, surface dry (SSD) and free of standing water.
Mixing … Mix only complete bags. Using a suitable sized mortar-type mixer, add 4.75 – 5.25 pints (2.25 – 2.48 L) of clean water to the mixer per 50 lb. (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 product than can be mixed, placed, and finished in 45 minutes at 70° F (21° C). Do not overmix.
Aggregate Extension … For repairs greater than 1.5″ (38.25 mm) in depth, extend FUTURA-45 with 12.5 lb. (5.68 kg) of aggregate. For repairs greater than 4″ (102 mm) in depth, extend FUTURA-45 with 25 lb. (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. Proper stress relief must be given for large patch applications.
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 overwork.
Application Range: 40° – 100˚ F (4.4° – 38˚ C)
Follow ACI 305-R89 “Standard on Hot Weather Concreting” or ACI 306-R88 “Standard on Cold Weather Concreting” when applicable.
For epoxy-based coating systems, wait a minimum of six hours at 75˚ F (23.5˚ C) prior to coating. Follow application instructions and recommendations of the coating manufacturer. For all other systems, contact the coating manufacturer.
Curing … Cure in accordance with ACI 308. Cure immediately following removal of forms prior to a seven-day cure time using a curing compound such as 1100 or 2200-WHITE from W. R. MEADOWS. Curing compounds may discolor and may require complete removal prior to topcoating, painting, sealing, waterproofing, or similar application.
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, direct sunlight. Early water loss is amplified 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.
HEALTH AND SAFETY
Contains Portland cement and crystalline silica (sand), which are suspected carcinogens. Skin and eye irritant. Dust may cause respiratory tract irritation. Follow OSHA safety regulations when handling. Avoid inhalation of dust. Avoid direct contact with product. Utilize chemical resistant gloves and safety glasses to minimize direct contact. May cause serious delayed lung injury (silicosis). If contact occurs, wash affected areas with mild soap and water. For eye contact, flush with water for a minimum 15 minutes and contact a physician immediately. Keep product out of reach of children. For industrial use only. Not for consumption. Refer to Safety Data Sheet for complete health and safety information.
May help contribute to LEED credits:
- MRc9: Construction and Demolition Waste Management