TROKEN FCM PCC/SPCC repair mortar

Troken FCM is a single-component PCC/SPCC repair mortar, class R4*. This polymer-modified, cement-based material can be applied both manually and by wet spraying (shotcreting). Thanks to the use of carefully selected aggregate and microsilica, as well as synthetic fiber reinforcement, it is ideal for repairing concrete defects, leveling the surfaces of prestressed and dynamic concrete and reinforced concrete structures, and restoring reinforcement cover. It is ideal for both indoor and outdoor applications.

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

Troken FCM – properties:

• High adhesion and durability: Troken FCM product bonds perfectly with concrete and also provides durability class R4!
• Ease of application: thanks to its consistency, the preparation is suitable for both manual and wet spray application (gunning).
• Versatility: Troken FCM can be applied to horizontal and vertical surfaces as well as ceilings.
• Protection: The product's high airtightness and low shrinkage ensure long-lasting protection of the protected areas. Troken FCM 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 FCM – application:

Troken FCM is ideal for and reinforced concrete structures exposed to dynamic loads and/or prestressed, for both indoor and outdoor use. It is also resistant to various chemicals, such as water, de-icing salt, oil, petroleum products, as well as corrosion, chemical attack, and weather conditions!

• The product is perfect for repairing and leveling concrete in structures with the highest requirements, such as: bridges, viaducts, tunnels, viaducts, retaining walls, reinforced concrete chimneys, production halls, stadiums, water reservoirs and locks.
• Structures: concrete and reinforced concrete, including prestressed and/or dynamically loaded.
• Reprofiling of concrete surfaces and restoring and increasing the reinforcement cover.
• Surfaces: horizontal, vertical and ceilings, in both monolithic and prefabricated structures.
• Carrying out large concrete repairs using the wet spraying method (wet shotcreting).
• Repairs cracks, scratches, crevices, and holes, as well as smooths and seals concrete surfaces. Creates an excellent base for protective coatings and paints.

Step-by-step application - for Troken FCM1 and Troken FCM2 products:

Troken FCM1 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 has corroded, it is necessary to chisel 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 elements, etc.). 

2. Steel protection:

• Two layers Troken CBL mortar should be applied to the cleaned reinforcing steel to ensure proper protection.

3. Concrete preparation: 

• 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. 

4. Concrete substrate requirements: 

• Average tensile strength of concrete: >1.5MPa.
• The concrete should be moistened before application, but not very wet.
• When applying manually, it is recommended to apply an additional, thin layer of Troken FCM1 as a bonding layer, which will increase the adhesion of the concrete. Then, apply the main layer immediately using the wet-on-wet method. If the bonding layer is not applied wet and dries, remove it and repeat the process! Alternatively, for weak surfaces, Troken CB L

5. 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 Troken FCM1 and 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 FCM1 mass: 

• Troken FCM1 mortar is supplied in dry form and requires 10 to 16% water by weight (example: for a 25 kg bag, add 2.5 to 4 liters of water). 
• Pour approximately 2/3 of the required water into the container, then gradually add Troken FCM1 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.

Troken FCM2 substrate preparation: 

1. Surface preparation: 

• Expose the corroded areas by chiseling away the coating by 1.5 cm or until you reach the non-corroded areas. 
• If more than half of the rod has corroded, it is necessary to chisel 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 elements, etc.).

2. Steel protection:

Two layers Troken CBL mortar should be applied to the cleaned reinforcing steel to ensure proper protection.

3. Concrete preparation:

• 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.

4. Concrete substrate requirements:

• Average tensile strength of concrete: >1.5MPa.
• The concrete should be moistened before application, but not very wet.
• Immediately before applying the mortar, remove excess water and apply a bonding layer of Troken CBL material.
• If the concrete is dry, porous, or has a high water absorption rate, it is recommended to wet it with water for 24 hours before applying the bonding agent. The same procedure is recommended in harsh conditions, such as high temperatures, intense sunlight, or intense winds. 
• The same preparation should be used for substrates made of mineral cement-based mortars.

5. 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 Troken FCM2 and 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 FCM2 mass: 

• Troken FCM2 mortar is supplied in dry form and requires 10 to 16% water by weight (example: for a 25 kg bag, add 2.5 to 4 liters of water).
• Pour approximately 2/3 of the required water into the container, then gradually add Troken FCM2 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.

Differences between Troken FCM1 and Troken FCM2: