Spalling Repairs to Concrete Building Structures

Surface Preparation for Spalling Repairs: 

How to spalling repairs to concrete cancer – requires that surfaces should be clean and free of dirt, grease and loose particles.
Remove all damaged and unsound concrete to expose a structurally sound substrate.

Preparation of corroded and rusty Reinforcement steel

Expose all reinforcements affected by rust and corrosion making spalling repairs necessary.
Clean and remove concrete, and rust from around the reo bars by wire brush, needle gun, sandblasting or water blasting. Then wash with clean water to remove any loose contaminants such as dust, oil and grease.

Apply Maxrest® Passive, without dilution or addition of other materials. Use a brush, spray gun or by immersion of the reo elements for full protection.
Apply two coats, the second one when the first coat is dry to touch (between 2 – 3 hours at 20ºC).
Avoid painting the surrounding concrete around the reinforcement. Apply successive layers as required.

Apply Maxrest or Maxrite®700 for the Structural Concrete Repairs: usually consumes 
For an optimum bond, prepare a slurry mixing 5 parts Maxrest or Maxrite®700 with 1 part water, mixing well until achieving a homogeneous consistency without any lumps.
Apply the slurry using a Maxbrush onto the concrete cancer surface to be repaired and the reinforcement bars. While the slurry is still damp start placing Maxrest or Maxrite®700 with its consistency of repair mortar to fill all voids and pores, allowing 5 to 8 minutes before continuing the repair.
Keep repair areas damp and apply in successive layers between 2.5 and 3 cm, scratching the surface with the trowel to make sure the next layer adheres firmly.
Between layers, wait 10 to 15 minutes depending on temperature.

If the different layers become warm, wet the surface with cold water.

Mixing:
A 25 kg bag of Maxrest  – mix only in clean with clean water. 25 kg usually consumes 3.5 – 4.5 litres of clean water. (not recommended to use a 25 Kg bag at a time). Depending on the ambient conditions and the consistency required, either manually or mechanically by low speed drill (400 – 600 r.p.m). Maxrest takes fifteen to twenty minutes to set, depending on the temperature.

Maxrite®700 – mix only with clean water. Water is to be free from contaminants, either manually or mechanically by low speed drill (400 – 600 rpm). One 25 kg. bag or drum of MAXRITE 700 requires about 3,75 to 4,25 litres of water to achieve proper consistency of a repair mortar (16% ± 1%).
For applications using a pump or spray the mixing water can be increased up to 4,5 litres per bag. In any case, these quantities are only indicative and should be checked depending on the desired consistency and the existing ambient conditions.

Mix only the amount of Maxrest or Maxrite®700 that you can apply within eight to ten minutes.

Drizoro Recommends:- waterproof your finished repairs using Drizoro Maxseal. 

IMPORTANT CAUTIONS

If the slurry primer dries. The previous layer is completely set. Apply a new slurry coat to continue the job.

 Do not use

  • any Maxrest or Maxrite 700 leftovers to prepare a new batch.
  • mixing methods that cause violent mix and do not mix for prolonged periods. Spraying Texture Finished
  • curing compounds on the repair.
  • exceed the thickness per layer in the application.
  •  Do not exceed the amount of mixing water recommended.
  • Quick set mortars – avoid storing in direct sunlight or hot places. Higher temperatures reduce setting time and lower temperatures delay setting time.

The normal. Setting times are measured at 20 ºC. 

Application Conditions:

Do not apply Maxrest at temperatures below 5 ºC.

  • lower temperatures are expected. Within the following 24 hours after application. Do not apply to frozen or frosted surfaces.

Best curing practice. The job is completed. Cover the repair with a wet cloth. This protects the repair from high temperatures or direct hot sun.

Cleaning:

Clean all tools and equipment immediately with water after use. Remove the hardened Maxrest or Maxrite®700 by mechanical means (i.e. hammer and chisel)

Consumption: 

The estimated consumption of:-

  1. Maxrest is approximately 1,67 kg/m2 per 1 mm thickness. One kilogram of Maxrest will fill approximately 0.6 litres.
  2. Maxrite®700 is approximately 1.85 kg/m2 per mm. thickness. One 25 kg. sack of Maxrite®700 fills approximately 13.75 litres (0.54 l/ kg of product).

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The different Benefits of Maxrest and  Maxrite 700

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