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ATLAS BETONER CONCRETE AND FERROCONCRETE REPAIR SYSTEM
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| ATLAS BETONER is a concrete and ferroconcrete repair system. It can be used for repairs of ceilings, terraces, binding joists, columns, walls, stairs and other similar structural and finishing elements. ATLAS BETONER system is recommended for repairs of cracked surfaces or loosened pieces of concrete and reinforcement exposure. The repair technology consists in applying successive cement mortar layers that provide damages elements with appropriate load capacity, resistance and appealing look. ATLAS BETONER system is based on three mortars that form the successively applied layers. These include:
- ATLAS ADHER – the contact layer
- ATLAS FILER – the levelling layer
- ATLAS ENDER – the finishing layer
All mortars included in the system are frost- and water-proof. They are suitable for indoor and outdoor use. ATLAS BETONER system can be additionally complemented with elements of ATLAS WODER E system (if a watertight protective layer is to be prepared) and ATLAS MYKOS agent (if organic contamination such as algae, fungi, lichen, moss needs to be removed). To provide additional anticorrosion protection of reinforcement, use protective paint for steel. |
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Stages of repairs using ATLAS BETONER system
Before starting work it is necessary to assess the technical condition of repaired elements and clearly determine reasons of damages. ATLAS BETONER system is designed for surface repairs. If more serious defects happen e.g. loss of load capacity, use other repair methods appropriate to the type of damage.
Concrete substrate preparation
Concrete substrate should be stable, even and structurally sound i.e. strong enough (stripping strength: at least 1.5 MPa); it should be free from anything that may weaken mortar adhesion. Remove any loose concrete layers as well as dust, dirt, lime, oil, fat, wax, remains of emulsion and oil paint. Concrete substrate that are damaged, dirty, or chemically or biologically corroded should first undergo special treatment such as shot blasting, milling, mould removal etc.
Reinforcing steel preparation
If exposed reinforcement is corroded, hammer concrete off the bar until “healthy” parts are visible. Clean exposed elements of reinforcement e.g. by sanding, removing rust and any other dirt up to SA 2 degree of purity. Moreover, in case of bars surface of which is completely or mostly uncovered, hammer off concrete around them so that a new covering (at least 1.5 cm thick) made of ATLAS FILER mortar can be prepared. After conclusion of hamming and cleaning, carefully de-dust the repaired element, best blow through or wash with water under pressure. Cover cleaned bars with ATLAS ADHER as soon as possible before rust appears again. Before application of ATLAS ADHER, reinforcement can be covered with paint coats that provide additional anticorrosion protection.
Contact layer
(up to 1 mm thickness) - ATLAS ADHER
ATLAS ADHER is to ensure appropriate adhesion of repair mortars to surface of existing concrete. The liquid consistency of appropriately prepared mortar enables to use it with a brush or a paintbrush. Immediately before application of ATLAS ADHER mortar, slightly wet the substrate with water. Do not leave pools! Distribute the mortar evenly on the substrate, rubbing in firmly. It is important that the applied mortar layer goes slightly beyond the area of repaired surface. Depending on weather, substrate absorptivity and capabilities of the repairing team, select the size of covered surface so that the next layer made of ATLAS FILER or ATLAS ENDER can be applied on the contact layer using the wet-on-wet method. If the contact layer dries before successive mortars are applied, the layer has to be prepared again.
If exposed reinforcement is corroded, hammer off concrete.
The liquid consistency of appropriately prepared ATLAS ADHER mortar enables to apply it with a brush or a paintbrush.
Levelling layer
(10÷50 mm thickness) - ATLAS FILER
ATLAS FILER is the main levelling layer of the system and a prime coat under ATLAS ENDER finishing mortar layer or other finish. If there are no special requirements as to surface smoothness, repair work may conclude with ATLAS FILER mortar as the final finish. Apply the mortar evenly on the substrate covered with wet ATLAS ADHER mortar. Use a float made of steel or a rule to apply the mortar and press it strongly to the substrate, in particular, filling defect. Depending on the application of the levelling layer, smooth its surface with a float made of steel or make it coarse using a float with a sponge. It is possible to begin levelling layer use (walk on it) and finish its finishing layer of ATLAS ENDER after about 24 hours. The moment of commencement of other work depends on the type of anticipated covering and should be consistent with requirements of manufacturer. Approximate times of successive work commencement are as follows:
- ceramic tiles – after 2÷3 weeks
- coat materials – after ca. 3÷7 days
- PVC covering or wood flooring – after the mortar completely dries
Finishing layer
(3÷10 mm thickness) - ATLAS ENDER
ATLAS ENDER mortar is the final finishing layer of ATLAS BETONER system. Distribute the mortar on ATLAS FILER levelling layer (at least 24 hours after its application) or, in case of small repairs, on freshly applied ATLAS ADHER layer (“wet on wet” method). The mortar needs to be evenly distributed on the surface (pressing it on to the substrate) and then smoothed using a float made of steel. Float the surface using a moist float with a sponge. Reduce heating of the room in which work is underway. It is acceptable to begin finishing layer use after about 24 hours, whereas any load can be placed on it after ca. 14 days. Additional surface finish with various coats may be commenced after ca. 3÷7 days.
Maintenance
Protect the surface during work and immediately afterwards from precipitation and drying too quickly. The drying time of individual layers depends on the substrate absorptivity and ambient thermal conditions and humidity. To ensure convenient setting conditions, as needed, sprinkle the fresh surface with water or cover it with foil. Conduct maintenance work for ca. 3 days. If work is conducted in a room, reduce its heating. Conduct all work in accordance with good construction practice and instructions contained in Technical Sheets of individual mortars. |
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| ATLAS BETONER has been given the Technical Approval no. AT-15-6583/2004 by Building Research Institute. |
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