Repair and protection method for existing mortar surfaces using polymer cement mortar.
This construction method involves surface protection of slopes using polymer cement mortar and allows for a wide range of processes from mixing, pumping, to spraying with a compact specialized machine optimized for this material. It is expected to improve material quality, construction efficiency, safety, and cost-effectiveness. 1. Reduction of industrial waste (no need for stripping; minimal rebound) 2. Minimal traffic regulation (no need for large temporary protective fences) 3. Narrow construction yard (does not use large spraying plants, etc.) 4. Cost savings on construction (an economical method that is about half the cost of conventional methods) 5. Shortened construction period (significant reduction in construction time) 6. Reduction of environmental costs (smaller machinery leads to reduced CO2 emissions)
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basic information
This is a polymer cement mortar (PCM) that incorporates carefully selected fine aggregates to be suitable for application as a repair method, particularly for vast slopes, using a spraying technique. By adding polymers as an admixture to enhance adhesion with the existing structure, the adhesion properties are significantly improved. Additionally, due to its flexibility and high extensibility, it is expected to prevent the recurrence of cracks. Moreover, by filling voids, it enhances material barrier properties, providing good protective effects for mortar and concrete. Furthermore, short glass fibers are also included, which help to minimize excessive cracking even when the polymer component hardens and flexibility decreases over time, as well as improving resistance to repeated deformation (fatigue) caused by sunlight and temperature changes. Additionally, the incorporation of fine blast furnace slag not only improves the color but also enhances long-term strength due to its latent hydraulic properties, resulting in a "sprayable environmentally friendly fiber-reinforced polymer cement mortar."
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Applications/Examples of results
1. Existing aging mortar and concrete sprayed slopes (Prevention of weathering, peeling, and crack formation) 2. Surface of concrete structures (Prevention of deterioration and cracking) 3. Stone masonry, retaining walls, and sediment control dams (Prevention of weathering, peeling, and crack formation)
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Company information
Materio Repair Co., Ltd. is a company located in Kumamoto City, Kumamoto Prefecture, that specializes in the Basque Method Wide, among other services. The Basque Method Wide utilizes the material properties of "glass short fiber reinforced cement and emulsion resin composite materials (Basque)" without removing the existing aging mortar or concrete spray. It repairs cracks on the surface of the existing mortar spray, fills voids that occur on the back, and further covers the entire surface of the existing mortar spray with Basque, thereby preventing the progression of deterioration such as cracking, peeling, and flaking, and extending the lifespan through repair and protective renewal methods.