Mapei Mapefill Zero

Mapei Mapefill Zero is a pre-blended powdered grout composed of high-strength cement, graded aggregates and special admixtures with an expansive agent formulated by MAPEI research laboratories.

Mapefill Zero is a product with very low emission of volatile organic compounds (VOC), which safeguards the health and safety of installers and final users. It is certified as EC1 Plus by the German association GEV.

Best Uses

Thanks to Mapefill Zero's particular formulation the product has excellent fatigue behaviour up to at least 300,000 cycles, which gives repaired structures a high level of resistance to cracking, including when subject to dynamic loads induced during normal service conditions.

Application examples include:

• Anchoring machine tools by casting below the machine base.
• Anchoring structural steel work.
• Filling rigid joints between elements in concrete and precast concrete structures.
• Installations below wall level.

When Mapefill Zero is mixed with water it forms a fluid grout that is able to fill intricate spaces without segregating. Mapefill Zero is a product with positive internal constraint. In confined anchoring conditions, stresses induced by external loads are lower than those generated by the positive constraint within the mortar.

Preparation

The area should be suitably prepped prior to application. Begin by removing all deteriorated, detaching or contaminated concrete until a rough, sound and resistant substrate is obtained. Remove any previous repair work or coating if not perfectly adhering to the substrate using suitable tools (mechanical demolishing, hydroscarifying etc.).

Clean concrete from previous scarifying works and clean reinforcing rods from dust, cement laitance, rust, grease, oil, paint and other contaminants through sandblasting and high-pressure water jets.

After preparation, the concrete surface to be repaired must be rough, with inert fraction exposed to allow correct adhesion of the mortar to the substrate.

Application

Follow the mixing and application instructions on the technical data sheet. A mortar mixer or drill with a mixer fitting may be used, depending on the amount of mortar to be prepared. Avoid entraining too much air while mixing. Mixing by hand is not recommended.

The use of Mapefill Zero for connecting precast concrete elements and the filling of rigid joints is recommended for thicknesses up to 100 mm. It is not necessary to vibrate the grout mechanically; to facilitate the filling of spaces that are particularly difficult, use a wood list or an iron rod.

For filling cavities that have dimensions greater than those indicated, add Gravel 6-10 of a grain size that varies according to the thickness of the pour. If Gravel 6-10 VAGA is used, it is possible to add up to 50% of dry product. Example: 2 25 kg bags of Mapefill Zero + 1 25 kg bags of Gravel 6-10. Because certain characteristics may vary, such as workability and strength, it is advisable to carry out preliminary tests at the work site or to consult our Technical Services Department.