Technology

Current technical recommendations were developed on the basis of the saved up practical experience of performed tasks for repairing and restoration of reinforced concrete constructions, and creation of the water impermeability of various constructions.

It is recommended that crystalline concrete waterproofing KALMATRON to be applied to the surface of reinforced concrete construction with the layer of 1,5-2,0 mm thickness to create a hydro insulation of reinforced concrete designs. The KALMATRON materials were designed as both protective coating and active admixtures to concrete and mortar mixes raising their operational properties and providing strong merging of “old” concrete with “new”.

The following sequence of tasks when creating hydro insulation of concrete and reinforced concrete constructions must be considered.

Surface preparation:

Clean the surface of the protected structure from plaster, easy removable debris of concrete and cement film with jackhammers, perforators or manual tools up to “healthy” concrete. An exposed reinforcement must be cut by 1,5-2,0 cm from the surface of the concrete.

Clean polluted or smooth concrete surface with sand blasting equipment or metal brushes, scrapers, etc. For automatic cleaning of large areas the high pressure hydro-monitors (150-200 atmospheres) are recommended. If the needed effect is not yet achieved, use other ways of cleaning including chemical by means of acid or alkaline solutions. The prepared concrete surface should have the open capillary structure, without traces of concrete peeling, oil contamination, a cement film, efflorescence, etc.

Wet concrete surfaces with water till complete soaking on a depth of no less than 1 cm.

External surfaces exposed on to the heat of the sun and the air temperature over 22°C should be covered with dampened fabric (a sacking, a non-woven synthetic material, etc) to prevent extensive drying of the protective structure.

The minimal temperature of concrete surfaces and air for conducting repair work should be not less than +5°C.

Sealing the seams and cracks

Cut total length of cold seams in concrete structure regardless of their width using jackhammers or punchers. Depth of cutting should be 25-30 mm, considering that width of seams is 20 mm and more. For seams of smaller width, depth of cutting should be 10-20 mm.

Remove dust from the open seams by washing or blowing it off the surface, preferably by means of high pressure hydro-monitor. Directly before filling in seams, they should be wet till complete soaking of the concrete.

Cracks in concrete with the width of disclosure more than 3 mm should be cut on depth not less than its width. Cracks with the width of disclosure less than 3 mm should be cleaned by the high pressure hydro-monitor. In case of impossibility to remove products of lixiviation from cracks, perform mechanized or manual means on depth up to 5 mm.

Seal the seams and cracks with solution KALMATRON-ECONOMY. Cracks with the width of disclosure less than 3 mm should be sealed with solution KALMATRON.

Apply solution KALMATRON (1 part of solution KALMATRON to 3-5 parts of water) using brush to the wet concrete surface 15-20 minutes prior to sealing the seams.

Restoration of structures

The following decisions are recommended for repairing works of various difficulties:

Layer with thickness up to 2 cm (locally up to 3 cm) of solution KALMATRON-ECONOMY applied without a grid.

Layer with thickness of 2-3 cm of solution KALMATRON-ECONOMY applied on a flat plaster grid.

Layer with thickness of 3-5 cm of solution KALMATRON-ECONOMY applied on to the metal gauze (from which it is necessary to wash off oil prior to work).

Layer with thickness more than 5 cm of concrete mixed with fine filler with the additive of solution KALMATRON.

Start timbering after gaining 50% of strength (after 3 days at the surrounding temperature of 20C). If settling cracks start to appear on the protective layer after 2-3 days, it is necessary to grind those places with solution KALMATRON.

Before repairing works start (15-20 minutes prior), wet concrete surfaces should be brushed or sprayed on from spray-gun with KALMATRON solution (1 part of KALMATRON solution to 3-5 parts of water). The amount of composition KALMATRON is 0,8-1,0 kg/m2.

Preparation of solution

Materials based on composition KALMATRON are applied in the form of solutions.

The quantity of prepared for application solution should match up to the volume of manufacture within no more than 30-40 minutes.

Add KALMATRON composition to repairing mixture during its preparation at a stage of dry hashing of components up to mixing them with water.

Use industrial or potable water for the preparation of solution. Mixing with water should be followed after careful hashing of dry components. The quantity of the water used for preparation of solution is specified depending on the chosen technology of application of repairing composition.

Solutions can be prepared manually as well as mechanically by mixing components thoroughly to obtain homogeneity.

In a case of stiffness, keep mixing normally. No additional water to the prepared solution is allowed!

The concrete mix with the additive of KALMATRON solution prepares by entering of 16 kg (industrially) or 25 kg (on a building site) of KALMATRON composition to 1m3 of a standard mix for preparation of concrete of class B22.5 (M300) with use of rubble of size up to 8 mm.

Application of protective composition KALMATRON

Continuous hydro insulation is created by applying protective layer prepared with solution KALMATRON of 1,5-2,0 mm thickness (when applied by spray-gun) and 2,0-3,0 mm(when applied manually by palette knife).

Solution KALMATRON is applied manually by palette knife in one go, or mechanically by spray-gun in one-two goes.

The amount of KALMATRON composition required for layer of 1 mm thickness is 1,6 kg/ì².

Care for the restored structure/ Curing of protective coating

Plentiful watering during first 3 days, 2-3 times a day is necessary.

For surfaces with protective coating exposed on to the heat of the sun, wind and hot weather, it is recommended to cover them up with damp fabric (sacking, non-woven synthetic material, roof paper, etc) to prevent extensive drying of the protective structure. This operation should continue on regular basis and round the clock.

Quality check of protective coating

Protective coating KALMATRON should be continuous.

The roughness of waterproofing coating is acceptable.

Presence of beads of KALMATRON is acceptable no more than 3 mm deep in hydro insulation coating.

Durability of a superficial layer on 28th day after application should not be below 20 MPa. An estimation of durability and adhesion of the protective layer of solution "KALMATRON" should be performed not earlier than in 7 days after application.

Safety requirements

Protective coating KALMATRON is non-toxic, non-flammable and non-explosive and doesn’t require additional safety precautions in comparison with plaster works.

When performing hydro insulation works, it is required to follow normative safety precautions regulations.

Workers should be provided by the following means of protection: coveralls made of dense fabric, rubber boots (boots on a rubber sole), rubber gloves, mittens, goggles, cotton helmets, respirators, gauze bandages for protection of a face skin.

In case of contact of protective solution with bare skin, it is necessary to wash contaminated area with water within 5-10 minutes from the moment of contamination.

Prior to the beginning of mechanized application of solution by means of atomizers (spray-guns), it is necessary to check the equipment: hoses, tank, compressor installation and an atomizer. Air hoses in places of connections should be strongly fixed by collars.

Packing, transportation and storage

The KALMATRON composition is available in 25 kg pressure-tight closed multi-layered paper and plastic bags. Other packages are available upon request, but no more than 40 kg.

The KALMATRON composition can be transported by all types of covered vehicles which protect materials from moisture and pollution, according to rules of transportation of cargoes, operating for the given type of transport.

The KALMATRON composition should be stored in heated indoor warehouses in sealed /not broken packaging from manufacturer.

The warranty period of KALMATRON composition stored in accordance with the above conditions is 6 months from the date of manufacturing.

 

Usage recommendations...

 

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