SikaEmaco® T 1200 PG

• Environmental Product Declaration (EPD) in accordance with EN 15804. EPD independently verified by Institut für Bauen und Umwelt e.V. (IBU)

• CE marking and declaration of performance based on EN 1504-3:2005 Products and systems for the protection and repair of concrete structures — Structural and non-structural repair

• Concrete Permeability Test ASTM C 1202 & NT BUILD 492, Emaco T 1200 PG, BASF, Test report NO.11/14/RD

Portland cement, hydraulic binders, well-graded sands, selected polyacrylonitryl (PAN) fibres, and special additives

Refer to product packaging.

The Product must be stored in original, unopened and undamaged packaging in dry conditions at temperatures between +5 °C and +35 °C. Always refer to the packaging.

Refer to the current Safety Data Sheet for information on safe handling and storage.

4.0 mm

¹⁾ Curing, water and powder temperature: +20 °C

²⁾ Curing, water and powder temperature: +5 °C

³⁾ Curing at -5°C; water and powder temperature: +20 °C

Pot life depends on temperature

Note: Pot life will be shorter at higher temperatures. Pot life will be longer at lower temperatures.

Note: Times are approximate and will be affected by changing ambient conditions, particularly temperature and relative humidity.

Approx. 2.25 kg/L

Approx. 2000 kg powder is needed to prepare 1 m³ of fresh mortar.

Note: Consumption data is theoretical and does not allow for any additional material due to surface porosity, surface profile, variations in level, wastage or any other variations. Apply the Product to a test area to calculate the exact consumption for the specific substrate conditions and proposed application equipment.

Note: Consumption data is theoretical and does not allow for any additional material due to surface porosity, surface profile, variations in level, wastage or any other variations. Apply the Product to a test area to calculate the exact consumption for the specific substrate conditions and proposed application equipment.

CONCRETE

1. Clean the substrate thoroughly so it is free from dust, loose material, surface contamination and material which reduces adhesion, prevents suction or wetting by the repair materials.
2. Remove delaminated, weak, damaged and deteriorated concrete, and where necessary, sound concrete. Remove using mechanical hand-held tools, high or ultra-high-pressure water blasting equipment.
3. Remove sufficient concrete from around corroded reinforcement to allow cleaning, application of a corrosion protection coating (where required) and compaction of the concrete repair mortar.
4. Prepare repair surface areas in simple square or rectangular layouts to avoid shrinkage stress concentrations and cracking while the repair material cures. This can also avoid structural stress concentrations from thermal movement and loading during the service life.

SURFACE ROUGHENING

1. Roughen the surface using mechanical tools such as a chisel or scarifier, or using grit blasting or high-pressure water blasting equipment.

Aggregate is clearly visible on the surface of the concrete structure after surface preparation.

STEEL REINFORCEMENT

1. Remove rust, scale, mortar, concrete, dust and other loose and deleterious material which reduces bond or contributes to corrosion.
2. Prepare surfaces to bright steel, Sa 2 (ISO 8501-1), using abrasive blast cleaning or high-pressure water blasting equipment.

REPLACEMENT OF STEEL REINFORCEMENT

1. Replace heavily damaged rebar that no longer fulfils safety or structural requirements.
2. Ensure the distance between the rebar and the surface is at least 2 cm.

MANHOLE FORMWORK

1. Set the manhole frame to the required level.
2. Install watertight formwork. Inflatable formwork can be used.
3. Fill the formwork with water to test for tightness.
4. If vacuum extraction equipment is not used to remove pre-wetting water, ensure the formwork contains outlets for the pre-wetting water to drain.
5. Ensure that displaced air can escape from the formwork during repair mortar application.  

PRE-WETTING

Proper pre-wetting prevents the substrate from absorbing water from the mortar.

Preconditions

The water absorbency of the substrate is known and the pre-wetting has been scheduled accordingly.

1. Saturate the substrate with clean, low-pressure water or a wet sponge up to 24 hours before application.
2. Constantly pre-wet the substrate for at least 2 hours before application.
3. Ensure that all pores and pits are thoroughly wet.
4. Just before application, remove excess surface water using a clean sponge or oil-free pressurised air.

The substrate is saturated-surface-dry (SSD): it has a dark matt appearance without standing water or glistening, and surface pores and pits do not contain water.

DEFROSTING

Although the Product can be applied when the ambient air temperature is below 0 °C, the substrate temperature must be above 0 °C. Refer to the Application information section for the precise temperature ranges.

1. Defrost frozen substrates, including metal parts such as steel reinforcement and manhole frames.
2. Keep the temperature uniform during application and hardening.

IMPORTANT

Risk of reduced strength gain and impaired physical properties in cold weather

Take the following measures in cold weather:

1. Store bags in a warm environment.
2. Use warm mixing water.

IMPORTANT

Risk of cracking and impaired physical properties in hot weather

Take the following measures in hot weather:

1. Store bags in a cool environment.
2. Use cold mixing water to assist with controlling the exothermic reaction.

ELECTRIC SINGLE OR DOUBLE-PADDLE MIXER (SMALL TO MEDIUM VOLUMES) OR FORCED-ACTION MIXER (LARGE VOLUMES)

Preconditions

The bags of SikaEmaco® T 1200 PG are full, unopened and undamaged.

1. Mix only as much material as can be used within its pot life.
2. Pour the recommended quantity of clean water for the consistency required into a suitable mixing container.
3. Stir the water slowly (max. 400 rpm).
4. Slowly and continuously add two-thirds of the bag of SikaEmaco® T 1200 PG.
5. Mix for 1 minute.
6. Add the rest of the bag of SikaEmaco® T 1200 PG and mix for a total time of 3–4 minutes.
7. Add more water as required, up to the maximum specified, and mix.

The mixture is lump-free and homogenous.

ADDITION OF AGGREGATE

For applications over 150 mm, add up to 30 % clean, well-graded aggregate. Select aggregates with the following features:

• Non-reactive

• Rounded, clean, well-graded

• 4–8 mm or 8–16 mm depending on the layer thickness

1. Use up to 30 % coarse aggregate by weight of SikaEmaco® T 1200 PG, for example, up to 7.5 kg aggregate for a 25 kg bag of SikaEmaco® T 1200 PG.
2. Add the aggregate to the mixing container after adding the water and powder.

Do not add cement or any other materials which may affect the properties of the Product.

Preconditions

The ambient air temperature is not expected to fall below -5 °C within 24 hours of application.

1. Apply a bonding slurry of undiluted SikaEmaco® T 1200 PG with a brush. Work it into the concrete substrate.
2. Pour the mixed SikaEmaco® T 1200 PG wet-on-wet into the patch repair area, or place it behind the formwork.
3. Smooth the surface with a finishing trowel.
4. Do not add water or fresh mortar to a mortar mix which has already begun to set.

The Product is self-curing. Do not wet-cure.

Protect from wind, rain, frost, and direct sunlight during curing.

When working at sub-zero temperatures, cover the Product with insulation materials or dry cloths until sufficiently hardened, preferably for 24 hours or until the area is to be opened for traffic.

Clean all tools and application equipment with water immediately after use. Hardened material can only be removed mechanically.