Batimix Concrete 542

Description

BATIMIX Concrete 542 is a pre-packaged ultra-accelerated setting concrete repair material classified as Grade R3 according to ASTM C928. It is made from Portland and alumina cement, carefully-graded fine and coarse aggregates, and set-accelerating, plasticizing, and shrinkage-compensating agents. It is a specialized construction material designed to rapidly restore damaged structures. Engineered with advanced additives and precise aggregate selection, this concrete formulation ensures exceptional early strength development and reduced curing time, allowing for swift repair work. Its Grade R3 classification signifies its capability to achieve rapid setting while maintaining robust structural integrity, providing a reliable solution for urgent repair projects that demand both speed and durability.

Main Purpose

BATIMIX Concrete 542 is a structural material used in partial and full-depth repair and rehabilitation works of concrete structures that have to be ready-for-use within short periods of time. Applications include parking structures, ramps, garages, bridge decks, commercial floors, warehouses, and others.

Features

BATIMIX Concrete 542 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 3 to 4 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 542 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.

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 542 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 542 can be placed under all temperature conditions. However, in warm weather, cold water can be used to cool concrete temperature.

BATIMIX Concrete 542 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 542 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 542 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 542 Results | | --------------------------------------------------- | ---------------------------- | | Water per 50-kg bag, liters | 4 – 5 | | Initial slump (C143), mm | 120 | | Fresh wet density (C138), kg/m³ | 2,320 | | Air content (C231), % | 2 | | Average setting time (C403), hours | 2 – 3 | | Compressive strength after 1 and 28 days (C39), MPa | 3.75 and 48.8 | | Flexural strength after 7 and 28 days (C78), MPa | 5.5 and 7.4 | | 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 542 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