TROKEN CBL PCC/SPCC repair mortar

Troken CBL is a single-component, R4*-class PCC/SPCC repair mortar containing corrosion inhibitors. This cement-based, polymer-modified material can be applied either manually or by wet spraying (shotcreting). Thanks to the use of carefully selected microsilica and the aforementioned corrosion inhibitors, it is ideal for protecting exposed steel reinforcement, creating an adhesive layer between old and new concrete layers, and between concrete and repair compounds. It is ideal for dynamic concrete and reinforced concrete structures, both indoors and outdoors.

*Class R4, according to the 1504-03 standard for products and systems for the protection and repair of concrete structures, is the highest possible class. Products in this category are characterized by very high adhesion, compressive strength, and a high modulus of elasticity.

Troken CBL – properties:

• Wide range of applications: Troken CBL is ideal for providing anti-corrosion protection to exposed reinforcing bars and for creating an adhesive layer between repair compounds and new concrete in concrete and reinforced concrete structures exposed to dynamic loads and/or prestressed. The product is suitable for both indoor and outdoor use. It is also resistant to water and various chemicals such as de-icing salt, oil, and petroleum products, as well as corrosion, chemical attack, and weather conditions!
• High adhesion and durability: Troken CBL bonds perfectly with concrete and ensures durability in the R4 class!
• Ease of application: thanks to its consistency, the preparation is suitable for both manual and wet spray application (gunning).
• Versatility: Troken CBL, thanks to its high plasticity and workability, can be applied to horizontal and vertical surfaces as well as ceilings.
• Protection: The product's high airtightness, resistance to carbonation, and low shrinkage ensure long-term protection of the protected areas. Troken CBL also has breathable properties thanks to its water vapor permeability.
• Easy to prepare: just mix with water to obtain a ready-made mortar.
• Key documentation: product compliant with the PN-EN 1504-3:2006 standard.

Troken CBL – application:

• Anti-corrosion protection of exposed reinforcement and a layer improving adhesion between repair mortar and concrete: bridges, viaducts, viaducts, tunnels, culverts, retaining walls, reinforced concrete chimneys, cooling towers and fans, silos, pylons, columns, production halls, warehouses, stadiums, sewage treatment plants, quays, reservoirs, dams, locks, weirs, canals.
• Structures: concrete and reinforced concrete, including prestressed and/or dynamically loaded.
• Surfaces: horizontal, vertical and ceilings, in both monolithic and prefabricated structures.
• Carrying out large concrete repairs using the wet spraying method (wet shotcreting).

Substrate preparation

For reinforcing steel, follow these steps:

1. Surface preparation:

• Corroded areas should be exposed by chiseling away the coating until the non-corroded areas are reached.
• If more than half of the rod circumference has corroded, it is necessary to chip away the entire circumference to a depth of approximately 1 cm beyond the rod.
  It is necessary to remove all contaminants that reduce adhesion (dirt, dust, loose particles, etc.). Surface preparation level: Sa2 (recommended level: Sa 2 1/2)

2. Steel protection:

• Two layers Troken CBL mortar should be applied to the cleaned reinforcing steel to ensure proper protection.
• The period between applying layers is from 1 to 6 hours, depending on temperature and humidity (details in the technical data sheet).

For a concrete base, follow these steps:

1. Preparation of concrete:

• The concrete substrate should be dry, rough and have exposed aggregate to a depth of 2 mm.
• It is necessary to thoroughly clean the concrete of all contaminants such as dust, dirt, traces of lime, chemicals, bituminous substances and other elements that cover the concrete substrate and reduce its adhesion.
• Corroded or damaged concrete must be chipped away to a sound, durable substrate.
• A pressure washer can be used to clean the concrete surface. 

2. Concrete substrate requirements:

• Average tensile strength of concrete: >1.5MPa.
• The concrete should be moistened before application, but not very wet.
• The Troken CBL adhesive layer should be applied to the previously wetted concrete. The material should be rubbed into all cracks and irregularities. If excessive slippage occurs when rubbing in the mortar, this indicates either over-wetting the substrate or improper cleaning. Repair mortar or new concrete should then be applied immediately using the wet-on-wet method. If the Troken CBL layer is not applied wet and dries, remove it and repeat the process!
• If excessive slippage occurs when rubbing in the mortar, this indicates that the substrate is too wet or not properly cleaned. In this case, stop work, remove excess mortar from the substrate, and reapply to a properly prepared substrate according to the instructions above and in the product data sheet.

3. Final Instructions:

• It is necessary to check whether the prepared surface meets the above requirements in terms of cleanliness, roughness and humidity.
• It is necessary to follow the detailed instructions contained in the technical data sheets of the Troken CBL .
• After application, the technical condition of the installed cover should be checked regularly and, if necessary, maintenance repairs should be carried out.

Preparation of Troken CBL mass:

• Troken CBL mortar is supplied in dry form and requires 20 to 21% water by weight ( example: for a 25 kg bag, add 5 to 5.25 liters of water ).
• Pour approximately 2/3 of the required water into the container, then gradually add Troken CBL and mix thoroughly. A low-speed mixer (300-400 rpm) or a counter-rotating mixer is recommended.
• Mix the resulting mass thoroughly for about 3 minutes, then add the remaining water and mix for another 2-3 minutes until a uniform consistency is obtained.
• Mortar ready for application.