Mapei Planitop HPC Floor

Mapei Mapegrout HPC Floor is a pre-blended powder mortar composed of high strength cement, selected graded aggregates, special additives and rigid steel fibres. Class R4.

Best Uses

When Planitop HPC Floor is mixed with water, it forms a fluid mortar suitable also for casting into formwork without segregating in layers from 1 to 4 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 must be cured in a damp environment. To allow expansion in the open air, Planitop HPC Floor can also be admixed with 0.25% of 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, 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 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

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. Particularly recommended for
reinforcement from the top of floor slabs.
Some application examples
▪ 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 to 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;

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 Mapei Planitop HPC Floor 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 mortar
Pour Planitop HPC Floor into the mixer and add 3.0 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 (2.9-3.1 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 mortar on floor slabs
Pour Planitop HPC Floor on the surface: if necessary, use a rake to spread the product.

Application of the mortar into a formwork
Pour Planitop HPC Floor 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. 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.