TROKEN CBL PCC/SPCC repair mortar

Troken CBL is a one-component PCC/SPCC class R4* repair mortar containing corrosion inhibitors. It is a material modified with cement-based polymers that can be applied both manually and by wet spraying (shotcreting). Thanks to the use of carefully selected micro-silica and the mentioned corrosion inhibitors, it is an ideal solution for protecting exposed steel reinforcement, creating an adhesive layer between the old and new layers of concrete, as well as between concrete and repair compounds. It is perfect for dynamic structures based on concrete and reinforced concrete, both indoors and outdoors.

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

Troken CBL – properties:

• Wide range of applications: Troken CBL is perfect for anti-corrosion protection of exposed reinforcement bars, as well as for creating an adhesive layer between repair masses and new concrete in concrete and reinforced concrete structures that are exposed to dynamic loads and/or are prestressed. The product is suitable for indoor and outdoor use. The preparation is also resistant to water and various types of chemicals such as defrosting salt, oil, petroleum products, as well as to corrosion, chemical aggression and weather conditions!
• High adhesion and durability: Troken CBL product bonds well with concrete and ensures durability in the R4 class!
• Ease of application: thanks to its consistency, the preparation can be applied both manually and by wet spraying (shotcreting).
• Versatility: Troken CBL, thanks to its high plasticity and workability, can be applied to both horizontal and vertical surfaces as well as ceilings.
• Protection: high tightness of the preparation, resistance to carbonation, as well as its low shrinkage, allow for long-term protection of the protected places. At the same time, Troken CBL has breathable properties thanks to the permeability of water vapor.
• 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 the repair mortar and concrete: bridges, viaducts, overpasses, tunnels, culverts, retaining walls, reinforced concrete chimneys, cooling towers and ventilators, silos, pylons, poles, production halls, warehouses, stadiums, sewage treatment plants , quays, reservoirs, dams, locks, weirs, canals.
• Structures: concrete and reinforced concrete, including prestressed and/or dynamically loaded structures.
• Surfaces: horizontal, vertical and ceilings, both in monolithic and prefabricated structures.
• Carrying out large concrete repairs using the wet spraying method (wet shotcreting).

Substrate preparation

For reinforcing steel, perform the following steps:

1. Surface preparation:

• You should expose the corroded parts by chipping away at the cover until you reach non-corroded areas.
• If more than half of the bar's circumference has been corroded, it is necessary to forge the entire circumference to a depth of approximately 1 cm beyond the bar.
  It is necessary to remove all contaminants that reduce adhesion (dirt, dust, loose elements, 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 properly protect it.
• 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, perform the following steps:

1. Concrete preparation:

• The concrete base should be dry, rough and have aggregate exposed to a depth of 2 mm.
• It is necessary to thoroughly clean the concrete of all contaminants, such as: dust, traces of lime, chemicals, bituminous substances or other elements that cover the concrete substrate and reduce its adhesion.
• Corroded or damaged concrete should be chipped away to a healthy, durable base.
• 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 it cannot be very wet.
• Troken CBL adhesive layer should be applied to previously moistened concrete. The material should be rubbed into all gaps and irregularities. If there is too much slippage when rubbing the mortar, it means that the substrate is too wet or it has not been properly cleaned. Then, immediately apply the repair mortar or new concrete using the wet-on-wet method. If no wet application is performed and the Troken CBL layer dries, remove it and repeat the process!
• If there is too much slippage when rubbing the mortar, it means that the substrate is too wet or it has not been properly cleaned. In such a case, stop work, remove excess mortar from the substrate and reapply it to a properly prepared substrate in accordance with the instructions above and in the product's technical data sheet.

3. Final instructions:

• 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 lagging should be regularly checked and, if necessary, maintenance repairs should be made.

Preparation of Troken CBL mass:

• Troken CBL mortar is delivered dry 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. It is recommended to use a low-speed mixer (300-400 rpm) or a counter-rotating mixer.
• 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.