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Application as rehabilitation

This is a concrete repair system, which uses a particularly impervious, mineral, plastic-free shotcrete or sprayed mortar as placing and repairing material, which is adapted optimal to the basic material of which the structure or part to be repaired is made. The requirements of DIN 1045, as well as of DIN 18551, are fully complied with. The shotcrete mixture (grain size 0 - 8 or 0 - 16) and the sprayed mortar mixture (grain size 0 - 2 or 0 - 4) is mixed using a compulsory mixer in which the Aggregates, cement, water and the additives permitted for the production of concrete and mortar are mixed

By means of this mixing procedure, the following points are achieved and safeguarded:

  1. exact compliance with the water-cement ratio (e.g. 0.40) which is the prerequisite for achieving high concrete qualities.
  2. the solubilising of the cement grain through the exactly proportioned addition of the quantity of water required so that the cement grain can form the cement paste, thus ensuring the cohesion and adhesion which is the prerequisite for the placing and adhesion of the shotcrete and sprayed mortar. In addition, the pore volume is considerably reduced during hydration.
  3. the homogenising of the mixture with the various components, such as Aggregate, cement, water and, d necessary, concrete additives.
  4. an optimal encasing of the Aggregates with cement and water and simultaneous integration of any concrete additives possibly used. (Concrete additives 4 such are used.)
  5. no formation of dust during placing or spraying on the sprayed material, as the causes of the formation of dust, such as fine parts in the Aggregate, cement or dry concrete additives are bound by the water. In this manner, the MAK threshold values (MAK = Maximum Workplace Concentration) laid down by the liability insurance agency are complied with.

The placing of concrete or mortar is made using a wet east process in a thin stream with regulated energy ensuring a very high placing compression. This procedure was developed by us, and has been in use singe 1969.

It is used both in lining underground structures and in the reconstruction of buildings. Up to now, some 60 km of tunnels and stretches with cross sections of 22-76m² have been lined and reconstructed, as well as 16.000m² of stairs, 10.000m² of ceilings in residential buildings, and 20.000 M2 of ceilings in industrial buildings.

British Rail has adapted the procedure under licence for reconstruction of its bridges, tunnels and certain structures, as well as for the Construction of new tunnels.

This wet cast process technology forms a concrete placing and repairing system in which, through the high degree of compression, the use of a high quality repair material in concrete technology, as well as taking account of all concrete technology factors, the demands made for concrete reconstruction are met to a high degree. For example, the resistance to carbonation is several times greater by comparison with a B35 quality concrete. The same applies with respect to water penetration depth, adhesive pull strength, compressive and flexural strength, sulphate resistance, chloride penetration depth, weathering and flaking, as well as resistance to frost, thawing salt and changes.

To sum up, it may be stated that here we have a placing and repairing system available with which, through the reduction of the cover of the reinforcement, on account of its high compression and its great resistance to carbonation, as well as the thinner placing coatings on account of the high concrete quality, reconstruction can be carried out for a more reasonable cost. It can be employed wherever severe attacks from water, air or soil are to be expected, which it can face with great resistance on account of its high degree of compression.

A further advantage of the repair system lies in the fact that through the reconstruction of the whole surface (covering), not only are those parts of a structure repaired which made the reconstruction woks necessary, but also those parts of the structure which are not yet perceivably damaged, but which would highly probably become damaged in the near future.