Sika MonoTop®-4012
Cementitious R4 concrete repair mortar containing recycled waste materials
Sika MonoTop®-4012 is a 1-part, cementitious, fibre reinforced, low shrinkage repair mortar. It contains recycled waste materials and can reduce the carbon footprint application activity calculations.
- Uses recycled waste materials
- Layer thickness 6–120 mm.
- Application up to 120 mm in 1 layer
- Sulphate resistant
- Hand and machine application (wet spray technique)
- Easy to apply
- Very low shrinkage behaviour
- Does not require a bonding primer
- Low permeability
- A1 fire rating
- Class R4 of EN 1504-3
- Restoration work (Principle 3, method 3.1 and 3.3 of EN 1504-9). Repair of spalling and damaged concrete in infrastructure and superstructure works.
- Structural strengthening (Principle 4, method 4.4 pf EN 1504-9). Increasing the bearing capacity of the concrete structure by adding mortar.
- Preserving or restoring passivity (Principle 7, method 7.1 and 7.2 of EN 1504-9) - Increasing cover with additional mortar and replacing contaminated or carbonated concrete
Areas of Application
Sika MonoTop®-4012 may only be used by experienced professionals. Repairs to all types of reinforced concrete structures and components for:- Buildings
- Civil engineering structures
- Marine structures
- Dams
- Structures requiring a Class R4, R3, R2 or R1 mortar
- Interior and exterior use
Advantages
- Uses recycled waste materials
- Layer thickness 6–120 mm.
- Application up to 120 mm in 1 layer
- Sulphate resistant
- Hand and machine application (wet spray technique)
- Easy to apply
- Very low shrinkage behaviour
- Does not require a bonding primer
- Low permeability
- A1 fire rating
- Class R4 of EN 1504-3
- Restoration work (Principle 3, method 3.1 and 3.3 of EN 1504-9). Repair of spalling and damaged concrete in infrastructure and superstructure works.
- Structural strengthening (Principle 4, method 4.4 pf EN 1504-9). Increasing the bearing capacity of the concrete structure by adding mortar.
- Preserving or restoring passivity (Principle 7, method 7.1 and 7.2 of EN 1504-9) - Increasing cover with additional mortar and replacing contaminated or carbonated concrete
Color
Grey powder
Product Details
SUSTAINABILITY
- Conformity with LEED v4 MRc 2 (Option 1): Building Product Disclosure and Optimization – Environmental Product Declarations
- Conformity with LEED v4 MRc 3 (Option 2): Building Product Disclosure and Optimization - Sourcing of Raw Materials
- Conformity with LEED v4 MRc 4 (Option 2): Building Product Disclosure and Optimization - Material Ingredients
- IBU Environmental Product Declaration (EPD)
APPROVALS / CERTIFICATES
- CE Marking and Declaration of Performance to EN 1504-3 - Concrete repair product for structural repair
Composition
Sulphate resistant and replacement cement, selected aggregates and additives
Shelf life
12 months from date of production
Storage conditions
The product must be stored in original, unopened and undamaged packaging in dry conditions at temperatures between +5 °C and +35 °C. Always refer to packaging.
Maximum grain size
Dmax: 2 mm
Soluble chloride ion content
≤ 0,05 % | (EN 1015-17) |
System structure
Bonding primer/ Reinforcement corrosion protection
Sika MonoTop®-1010 | Normal use |
SikaTop® Armatec®-110 EpoCem® | Demanding requirements |
Concrete repair mortar
Sika MonoTop®-4012 | High strength requirements |
Levelling mortar
Sika MonoTop®-3020 | Normal use |
Sikagard®-720 EpoCem® | Demanding requirements |
Compressive strength
Class R4
Time | Compressive strength |
1 day | ~19 MPa |
7 days | ~43 MPa |
28 days | ~56 MPa |
Modulus of elasticity in compression
≥ 20 GPa | (EN 13412) |
Tensile strength in flexure
Time | Tensile strength in flexure |
1 day | ~4,4 MPa |
7 days | ~7,0 MPa |
28 days | ~8,0 MPa |
Tensile adhesion strength
≥ 2,0 MPa | (EN 1542) |
Shrinkage
~500 μm/m (+20 °C / 65 % relative humidity at 28 days) | (EN 12617-4) |
Restrained shrinkage / expansion
≥ 2,0 MPa | (EN 12617-4) |
Thermal compatibility
≥ 2,0 MPa (Part 1 - Freeze-Thaw) | (EN 13687-1) |
Coefficient of thermal expansion
~16 × 10-6 1/K | (EN 1770) |
Reaction to fire
Euro class A1 | (EN 1504-3 cl. 5.5) |
Capillary absorption
≤ 0,5 kg/(m2·h0,5) | (EN 13057) |
Chloride ion diffusion resistance
Low - < 2000 coulombs | (ASTM C 1202) |
Carbonation resistance
dk ≤ control concrete MC(0,45) | (EN 13295) |
Electrical resistivity
< 100 kΩ·cm | (EN 12696) |
Application
Mixing ratio
3,75 to 3,9 L of water for 25 kg bag
Fresh mortar density
~2,1 kg/l
Layer thickness
Horizontal | min.6 mm / max. 120 mm |
Vertical | min. 6 mm / max. 85 mm |
Ambient air temperature
+5 °C minimum / +30 °C maximum
Substrate temperature
+5 °C minimum / +30 °C maximum
Pot Life
~60 minutes at +20 °C
Consumption
~2,10 kg/m2/mm
Consumption depends on the roughness and absorbency of the substrate.
This figure is theoretical and does not allow for any additional material due to surface porosity, surface profile, variations in level or wastage etc.
Yield
25 kg of powder yields ~13,7 L of mortar
EQUIPMENT
Select the most appropriate equipment required for the project:
Substrate preparation
- Mechanical hand held tools
- High / ultra-high pressure water blasting equipment
Steel reinforcement
- Abrasive blast cleaning equipment
- High pressure water blasting equipment
Mixing
- Small quantities - low speed electric single or double paddle mixer (<500 rpm). Mixing Container.
- Large quantities or machine application - suitable forced action mixer
Application
- Hand applied – Plasterers hawk, trowel
- Wet Spray - All in one mixing and spraying machine or separate spraying machine and all associated ancillary equipment to suit application volumes
Finishing
- Trowel ( PVC or wooden),sponge
Also refer to Site Handbook ‘Repair of Concrete Structures – Patch Repair and Spray Applications’
MIXING
Hand applied and wet spray application
Pour the minimum recommended clean water quantity into a suitable mixing container / equipment. While stirring slowly, add the powder to the water and mix thoroughly for at least for 3 minutes adding additional water if necessary to the maximum specified amount and adjust to the required consistency to achieve a smooth consistent mix. The consistency must be checked after every mix.
APPLICATION
Strictly follow installation procedures as defined in method statements, application manuals and working instructions which must always be adjusted to the actual site conditions.
Reinforcement corrosion protection coating
Where a reinforcement coating is required, apply to the whole exposed circumference Sika MonoTop®-1010 or SikaTop® Armatec® 110 EpoCem® (Refer to Product Data Sheet(s)).
Bonding primer
On a well prepared and roughened substrate or for a sprayed application, a bonding primer is generally not required. When a bonding primer is required to achieve the required adhesion values, use Sika MonoTop®-1010 or SikaTop® Armatec® 110 EpoCem® (Refer to respective Product Data Sheets). Apply repair mortar onto bonding primer “wet on wet”.
Repair Mortar
Hand application
Thoroughly pre-wet the prepared substrate (2 hours recommended) before application. Keep the surface wet and do not allow to dry. Before application remove excess water, e.g. with a clean sponge. The surface must appear a dark matt appearance without shining and surface pores and cavities must not contain water.
When manually applying by hand, first make a scratch coat by firmly scraping the repair mortar over the substrate surface to form a thin layer and fill any pores or cavities in the surface. Ensure the whole surface to be repaired is covered by the scratch coat. The repair mortar must be applied onto the wet scratch coat between the minimum and maximum layer thicknesses without the formation of voids. Where layers are to be built up, to prevent sagging or slumping, each layer should be allowed to harden before applying subsequent layers “wet on wet”.
Sprayed application - Wet Spray
The wet mixed Sika MonoTop®-4012 must be placed into the spraying equipment and applied onto the pre-wetted substrate (pre-wet procedure as hand application) between the minimum and maximum layer thicknesses without the formation of voids. Where layers are to be built up, to prevent sagging or slumping, each layer must be allowed to harden before applying subsequent layers “wet on wet”.
Surface finishing
Finishing for all types of application must be carried out to the required surface texture using suitable finishing tools as soon as the mortar has started to harden.
Cold weather working
Consider storing bags in a warm environment and using warm water to assist with achieving strength gain and maintaining physical properties.
Hot weather working
Consider storing bags in a cool environment and using cold water to assist with controlling the exothermic reaction to reduce cracking and maintaining physical properties.
CURING TREATMENT
Protect fresh mortar immediately from premature drying using an appropriate curing method, e.g. curing compound, moist geotextile membrane, polythene sheet, etc.
Curing compounds must not be used when they could adversely affect subsequently applied products and systems.
CLEANING OF EQUIPMENT
Clean all tools and application equipment with water immediately after use. Hardened material can only be mechanically removed.