Mapei Planitop HPC Floor 46

Mapei Planitop HPC Floor 46 is a cementitious grout with fluid consistency, reinforced with metal fibres, with extremely high strength and high ductility. Class R4.

Best Uses

Mapei Planitop HPC Floor 46 is formulated for the repairing and strengthening reinforced concrete and horizontal structures where the thickness and shape of areas to be repaired require the use of high-strength, high-flow mortar.

Some application examples include:

• Seismic retrofitting of elements subject to high stresses and where high ductility is required
• Structural strengthening by casting a thin layer on the external faces of floor slabs in reinforced concrete, brick-cement wood or mixed brick-steel beam
• Repairs of concrete floors (industrial, roads, airports)
• Rebuilding and levelling off the upper parts of piers caps and bearings on motorway viaducts
• Reparation of floor slabs after removal of damaged areas by scarifying

Planitop HPC Floor 46 is a pre-dosed powder micro cementitious grout composed of high-strength cement, selected graded aggregates, special additives, and rigid steel fibres. When Planitop HPC Floor 46 is mixed with water, it forms a cementitious grout suitable for casting into formwork without segregating in layers from 2 to 8 cm thick, and without the need for electro-welded reinforcing mesh. To allow the product’s expansive properties to develop fully and correctly, Planitop HPC Floor 46 must be cured in a damp environment. To allow expansion in the open air, Planitop HPC Floor 46 can also be admixed with 0.25% Mapecure SRA, a special admixture that reduces plastic and hydraulic shrinkage.

Mapecure SRA carries out an extremely important role and guarantees better curing of the mortar. When mixed with Planitop HPC Floor 46, it can be considered a technologically advanced system, as it is able to reduce the rapid evaporation of water and promote the development of hydration reactions. Mapecure SRA acts basically as an internal curing agent and, thanks to its interaction with some of the main components in the cement, reduces final shrinkage by 20% to 50% compared with the same product without the admixture, which means there is also a lower risk of cracking. The use of Mapecure SRA could slightly reduce mechanical performance characteristics by 5-6%. The product can also be used without adding Mapecure SRA when climatic conditions allow a favourable curing cycle to be carried out.

Once hardened, Planitop HPC Floor 46 has the following characteristics:

• Very high flexural and compressive strength
• High ductility
• High resistance to cyclical loads
• Impermeability to water
• Excellent adhesion to both old concrete (if soaked with water or consolidated with Mapei Primer 3296 before application) and rebars, especially if treated beforehand with Mapefer or Mapefer 1K Zero
  ▪ high resistance to wear due to abrasion or impact.

Application

Preparation of the substrate
Remove all damaged and detached areas of concrete to form a sound, highly rough (roughness of at least 5 mm) and strong substrate. Any areas previously restored which are not perfectly attached must also be removed. Remove all dust, rust, cement laitance, grease, oil and old paint from the concrete and reinforcing bars by sandblasting.
If it is necessary to consolidate the substrate, apply at least 4 hours before the application of Planitop HPC Floor 46 Primer 3296 diluted 1:1 with water. In the case of pouring the mortar into a formwork, proceed with the following steps:

• Soak the substrate with water
• Before pouring, wait until any excess water has evaporated off. If necessary, this operation can be speeded up by using compressed air.

Preparation of the grout
Pour Planitop HPC Floor 46 in the mixer and add 2.5 litres of water per bag of product. The mixing time depends on the efficiency of the mixer. For example, with a forced-action mixer, mixing requires approximately 5 minutes. If a traditional cement mixer is used, mix for approx. 12 minutes. At the end of the mixing process, the mix must be smooth (the fibres must be completely dispersed), fluid, and lump-free. Small variations in the quantity of mixing water (2.4-2.6 l) are allowed depending on the mixing equipment and the climate conditions. It is recommended to apply the product within 30 minutes of mixing.

Application of the cementitious grout on floor slabs
Pour Planitop HPC Floor 46 on the surface: if necessary, use a rake to spread the product.

Application of the cementitious grout in formworks
Pour Planitop HPC Floor 46 into the formwork in a continuous flow from one side only, making sure all the air is expelled. The formwork must not absorb any of the water from Planitop HPC Floor 46. It is recommended to treat the formwork beforehand with a form release agent (such as Mapeform DMA 1000). Make sure that all the members to be strengthened are completely filled. To help the mortar flow into the more difficult areas, use wooden rods, round iron bars, or vibrate lightly.