Batimix Concrete 540

Description

BATIMIX Concrete 540 is a pre-packaged fast-setting high strength concrete repair material. It is made of Portland cement, carefully-graded fine and coarse aggregates, and selected additives such as set-accelerating, plasticizing, and shrinkage-compensating agents. It is a specialized concrete blend optimized to swiftly attain robust strength and setting attributes, making it an ideal choice for efficient and timely repair undertakings. By employing high-quality materials and additives, including accelerators, this concrete type fosters accelerated hydration and setting reactions, allowing rapid progress in repair projects such as infrastructure maintenance and construction. It ensures not only quick restoration but also sustained durability, although proper mixing, placing, and curing practices remain imperative for optimal long-term performance of the repaired structures.

Main Purpose

BATIMIX Concrete 540 is a structural repair material for partial and full-depth repair and rehabilitation works of concrete structures that have to be ready-for-use within short periods of time. Typical applications include parking structures, ramps, garages, bridge decks, commercial floors, and warehouses.

Features

BATIMIX Concrete 540 has the following characteristics:

• Easy to use, suitable for both interior and exterior works
• Rapid setting for quick repairs (open for light foot traffic in 5 to 7 hours)
• High early compressive strength without added chlorides
• Reduced bleeding and segregation
• High degree of adhesion/bond to the repaired structure
• Low water absorption, yet increased water vapor transmission

Properties

• Appearance/color: powder/grey
• Bulk density: around 1.82
• Chloride content: nil
• Grain size: 0 to 10 mm (upon request, this product can be made with smaller or bigger maximum aggregate size)
• Yield: approx. 0.023 m³ per bag of 50 kg

Health and Safety

BATIMIX Concrete 540 contains cement. It is irritating for the eyes and skin. In case of contact, rinse immediately with plenty of water. Wear suitable gloves. For further information, kindly refer to Material Safety Data Sheet.

Specifications / Compliance with Standards

BATIMIX Concrete 540 meets the requirements of ASTM C 928 Grade R1 for Packaged, Dry, Rapid-Hardening Cementitious Materials for Concrete Repairs.

Directions for Use

1 – Concrete removal Exposed surfaces to be repaired should be visually inspected and sounded for weakness and delamination. All deteriorated concrete should be removed to a near uniform depth of a minimum 25 mm by suitable means.

2 – Substrate preparation Prior to preparation of substrate surfaces, exposed reinforcing bars should be inspected to ensure the following:

• Appropriate exposure, with a minimum clearance of 20 mm
• Loose reinforcing bars replaced in their original design location
• Proper cross-sectional area, with a maximum reduction of 25%

For optimum bonding, sandblast the concrete and reinforcing bar surfaces and then remove all dust and debris by air blasting, low pressure water blasting, or brooming. If the damage was the result of corrosion, an epoxy coating should be considered. Prior to concreting, the substrate should be saturated but free of standing water (SSD condition).

3 – Formwork If repairs are to be made to vertical or overhead surfaces, formwork will be required. Prior to installing forms, the concrete surface must be inspected for any surface contours that could result in trapped air during concrete placement. Formworks should be designed to withstand the developed concrete lateral pressure; refer to ACI 347 “Formwork for Concrete”.

4 – Product preparation A 50-kg bag of BATIMIX Concrete 540 should be mixed with 4 to 5 liters of clean water, depending on the desired slump consistency. The mixing should be done with a medium-speed mechanical mixer until obtaining a consistent homogenous material. The mixing time should not exceed 2 minutes, as concrete may loose its workability very rapidly.

5 – Concrete placement Because of its fast setting characteristics, BATIMIX Concrete 540 can be placed under all temperature conditions. However, in warm weather, cold water can be used to cool concrete temperature.

BATIMIX Concrete 540 should be discharged from the mixer and placed immediately using buckets, without any delay. Pumping is to be avoided because of the fast setting characteristics. It must be thoroughly worked and vibrated in the forms so that they are entirely filled and the reinforcing bars adequately and tightly surrounded. All placement, compaction, and finishing operations should be completed within 10 minutes at 23 ºC from the time of contact of the powder concrete with water.

6 – Curing Freshly deposited BATIMIX Concrete 540 must be protected from excessively hot or cold temperatures and maintained with minimum moisture loss; refer to ACI 308 “Practice for Curing Concrete”. Curing should begin immediately after the finishing operations and continue for a minimum of 7 days.

Curing of BATIMIX Concrete 540 can be done using absorptive mats which are kept continuously wet. Alternatively, appropriate sheet materials or curing compounds conforming to ASTM C 171 / C 309 can be used.

Physical Properties

| ASTM Test Method | BATIMIX Concrete 540 Results | | --------------------------------------------------- | ---------------------------- | | Water per 50-kg bag, liters | 4 – 5 | | Initial slump (C143), mm | 150 | | Fresh wet density (C138), kg/m³ | 2,320 | | Air content (C231), % | 2.1 | | Average setting time (C403), hours | 3 – 4 | | Compressive strength after 1 and 28 days (C39), MPa | 16.4 and 34.5 | | Flexural strength after 7 and 28 days (C78), MPa | 5.2 and 6 | | Adhesion to substrate (D4541), MPa | > 3 |

The following data are averages of several tests under laboratory conditions of 23 °C and 50% R.H.; they may significantly vary in the field.

To adapt mixture composition to specific applications and climatic conditions, supplementary admixtures such as air entrainer and synthetic fibers may be added to the original mix design.

Storage

BATIMIX Concrete 540 should be stored in a closed and dry place. Avoid freezing and excessive temperatures. Unopened bags have a shelf life of six months when stored as recommended.

Packages

• 1 t big bag
• 50 kg paper bag