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Shotcrete Dry

Concrete renovation

Shotcrete Dry

Filler material for concrete renovation

Product description

Marlon Shotcrete Dry is a cement-based factory-mixed dry mortar product intended for dry spraying, with sand and stone material that satisfy the requirements for environmental class E (see DS/EN 206 DK NA:2020). Marlon Shotcrete comes in the types 0-2 mm, 0-4 mm and 0-8 mm, with and without fibre.

Benefits
  • Used as filler material in bearing constructions
  • Well-suited for shotcreating of up to 80 mm in one work process
  • Contains dust-bonding additive
  • Comes with and without fibre
  • Requires only the addition of water
Applications

Marlon Shotcrete Dry is used for different tasks such as reinforcement of bearing concrete constructions on bridges, beams, slabs and columns and for renovation and repair of balconies, facades or areas and constructions that are difficult to access, where traditional concreting work is not practical. Marlon Shotcrete can be made to order based on grain size, fibre and even colour.

Preparation

The surface must be well-suited and washed clean of any oil, grease, cement dust and other loose particles through chipping, sandblasting or the like. Reinforced iron, if any, must be cleaned of rust and chlorides. Reinforced iron must be fixed and unable to vibrate. The surface must be watered down and rendered slightly absorbent or coated in a suitable, approved material that will ensure the best possible adhesion. Marlon recommends having the surface approved by a consultant or inspector before spraying begins.

Mixing

The dry product is poured into a container that is connected to a concrete pump, which feeds the material to the spray head, where the correct volume of water and any accelerators or retarders are added.

It is important to add the proper amount of water, so the mixture has the right consistency – neither too thin nor too dry - upon spraying. Otherwise, this could lead to poor compression, which will reduce the strength and adhesion. There is also a risk of poor envelopment of reinforced iron, “nests” and large recessions that need getting rid of.

Application

The spraying normally takes place from bottom to top, while the nozzle is moved perpendicular on the surface. With reinforcement, however, the nozzle is slanted to ensure that the armouring is encased optimally.

To achieve the best results when using injection concrete, it is important to:

  • use specially trained staff
  • use machines and equipment that are in good working condition.
  • use good and suitable materials.

Generally, Shotcrete 0-2 is applied in 10 mm thickness, 0-4 in 50 mm thickness and 0-8 in up to 80 mm.

Aftercare

Newly sprayed surfaces must not be subjected to loads and should be protected as quickly as possible from drying using close-fitting plastic film, sealer or another suitable curing method.

Limitations

Marlon Shotcrete Dry should not be used at temperatures under +5°C. Sprayed surfaces do not tolerate frost during the curing and cementation period.

Cleaning

Clean tools with water immediately after use. Hardened Shotcrete can only be removed mechanically.

Inspection

Marlon Shotcrete dry is subject to internal inspection according to Marlon’s quality assurance system. Subsequent measuring and mixing at the site of application is not included in quality control.

Product information

Manufacturer
Marlon Tørmørtel A/S
Virkelyst 20
DK-8740 Brædstrup

Material type
Product type CC. Cement-based dry concrete/mortar for wet application.

Environmental class
Extra aggressive.

Cement type
Portland cement, CEM I 52,5 N (LA).

Filler material
Oven-dried and sorted silica sand, cl. E.

Additives
Plasticiser and dust-bonding additives. Optionally, 6 mm polypropylene fibre (approx. 1.3 kg per m³).

Added water
0-2: Approx. 3.1 l per 25 kg sack.
0-4: Approx. 2.8 l per 25 kg sack.
0-8: Approx. 2.7 l per 25 kg sack.

Layer thickness
0-2: 5-10 mm. Guideline.
0-4: 10-50 mm. Guideline.
0-8: 20-80 mm. Guideline.

Yield
1,000 kg dry mortar corresponds to approx. 500 l wet mortar.

Particular properties
Contains no additives that diminish electrical resistance in connection with cathodic protection.

Packaging type
25 kg plastic sacks and big bags.

Storage
12 months in dry and suited conditions in unopened packaging.

Egenskaber Values Method
Compressive strength, 28 days > 45 MPa DS/EN 12190
Bending tensile strength, 28 days > 6 MPa DS/EN 12190
Density Approx. 2100 kg/m³ DS/EN 1015-7
Adhesive strength < 2 MPa DS/EN 1542
Resistivity < 10 k0hm APM 219
Capillary porosity (v/c ratio) 0.35-0.40 DS 423.42
Chromate content < 2 mg/kg cement DS/EN 1015-17
Free contraction < 1 ‰ DS/EN 12617-4
Frost/thaw Particularly good SS 137244

 


 

Information    
Item no. 0-2 10360  
Item no. 0-4 10315  
Item no. 0-4 w. fibre 10320  
Item no. 0-8 10325  
Item no. 0-8 w. fibre 10326  
Pr no. 2257214  
Version 07.14 replaces 11.12  

 


 

Marlon Tørmørtel A/S
Virkelyst 20
8740 Brædstrup
Year 14
DoP 1000315
EN 1504-3
1073-CPR-171-01
Concrete repair product for construction repairs. CC mortar based on hydraulic cement.

 


 

Compressive strength > 45 MPa Class R4
Adhesion ≥ 2.0 MPa
Chloride content ≤ 0.05 weight %
Fire-resistance Class A1
Carbonatization Passed
Elastic modulus ≥ 20 GPa
Thermal compatibility Part 1 ≥ 2.0 MPa
Capillary absorption ≤ 0.5 kg x m-2 x h-5
Hazardous substances In accordance with section 5.4