Stone Mason^® UP2000

Surface preparation

Remove all unsound, loose, debonded concrete, dust dirt, form release agents, contaminants, efflorescence or any other material that might impair proper bonding. For best results deteriorated concrete should be removed to allow a minimum clearance of 25 mm (1”) behind reinforcing steel allowing the mortar to be forced in behind the steel. Remove all rust from steel reinforcement to a near white metal specification. Remove all unsound concrete using hand-held tools. If possible maintain a minimum depth of 6 mm (1/4”) across the entire patch. For traffic areas define the edge of the patch area with a sawcut to a minimum depth of 6 mm (1/4”). Replace all missing or badly corroded reinforcing. Overhead or cantilevered details may require the installation of additional steel mesh or reinforcing bars; (check with Structural Engineer). Pre-wet the surface to be patched to a saturated, surface dry condition. In some substrates this may require an overnight soaking.

Mixing for minor patches

Mix 1 part Acryli-Bond to 3 parts clean potable water to form mixing liquid. In a clean mixing container, place 2.8 litres (3 qts) mixing liquid and slowly add 22.7 Kg (50 lb.) bag of UP2000 Structural Patching Mortar while mixing. Mix only long enough to thoroughly wet all the powder. Add more mixing liquid if necessary. Do not over mix. Overmixing will reduce strength and density. Do not mix more material than can be placed before initial set. Do not retemper. Discard all material that has set before it can be placed. Build in 50 mm (2”) layers at one time.

Mixing for large scale patches

UP2000 Structural Patching Mortar may be extended with clean, surface dry aggregate. For best results choose aggregates that closely match the aggregates in the host concrete. Aggregates should be pea gravel, limestone or sandstone composition under 10 mm (3/8”) in size. Dry mix the aggregates and the UP2000 Structural Patching Mortar before UP2000 STRUCTURAL PATCHING MORTAR 03930 3-100 adding any mixing solution. Rate of addition must not exceed 6.8 Kg (15 lb.) of aggregate to 22.7 Kg (50 lb.) of powder. In this manner up to 3 bags and 20.4 Kg (45 lb.) of aggregate can be mixed at one time, providing that this volume can be placed before it takes the initial set. For best results clean out the mixing container between batches to completely remove all material. This will avoid introducing hardened material into the next batch.

Application

Brush apply a coat of freshly mixed mortar to the properly prepared and prewetted surface, scrubbing the mortar vigorously into the substrate. Immediately apply fresh mortar to the still wet brush coat with firm trowel pressure. It is possible to place UP2000 Structural Patching Mortar in 25 mm (1”) increments on vertical patches. and 50 mm (2”) on horizontal surfaces. As material hardens, scratch the layer. Apply second layer after the first layer has taken an initial set. Using this technique build the patch out above the final profile required. Shave the surface of the patch back working from the centre out to the edges to ensure a match with the original profile. Use a wet sponge float for final finishing. On large patches it may be necessary to use a straight edge to achieve the architectural aesthetics required. Since most patches are topcoated with a finish it will be important that the texture of the finished patch matches the surrounding texture of the host material. In normal conditions, keep the patch moist by misting with water until final set is achieved. In hot (above 26°C / 80°F), dry, windy conditions, cover fresh patches with wet burlap and then cover that with heavy polyethylene sheathing. If cold temperatures are encountered use heated water, warmed UP2000 Structural Patching Mortar and Acrylic Bond. After the patch has been finished cover with an insulated blanket or provide warm-air heat. To obtain a waterproof topcoat apply two coats of U-Seal mixed with Acryli-Bond.

Limitations

Do not apply to substrates covered by actively flowing water. Do not apply to unsound, cracked concrete or concrete surfaces which are not free from contaminants. Do not apply over moving cracks, control joints or expansion joints. Do not apply to frozen or frost-filled surfaces. Do not apply when temperatures are below 5°C (40°F) unless cold weather precautions are observed. Do not apply in immersed areas unless a waterproof protective topcoat is applied prior to re-immersion.

Caution

Contains corrosive which may cause eye injury, and silica sands which may cause lung cancer. If product gets into eyes, flush repeatedly with water and seek medical attention promptly. Avoid skin contact. If contact occurs, wash exposed skin with water. Protective eyewear should be worn.  AVOID CONTACT WITH EYES.

First Aid Treatment

Cement when mixed with water results in a solution of calcium hydroxide. If splashed in eyes or skin, flush thoroughly with water.

The consumer shall satisfy themselves of the suitability of this product for the intended purpose. Weather, applicator's skill and surface conditions are beyond manufacturer's control. We, therefore, limit our liability to replacement of defective material only, within one year of proof of purchase.