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FX-262 Repair Mortar

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FX-262

FX-262 was used in the following case studies:

DESCRIPTION:

FX-262 Repair Mortar is a shrinkage-compensated, fiber-reinforced cement mortar that contains a migratory corrosion inhibitor. FX-262 contains FX-32 Silica Fume which improves the properties and offers high strength and superior performance for structural concrete repair. FX-262 is specially designed for concrete or masonry substrates and can be applied vertically or overhead by low-pressure spraying and hand troweling.

WHERE TO USE:

For use on vertical and overhead repair of concrete and masonry.
In structures such as bridges, parking garages and tunnels
Piers, sea walls and other marine structures
Manhole, wet well, sewer and lift station repairs

ADVANTAGES:

One component, quality controlled for uniform results
Easy to use—requires only the addition of potable water for mixing
No additional bonding agent required.
Sprayable with low waste—virtually no rebound.
High early and ultimate compressive, flexural and bond strengths.
Silica fume formulation for a denser matrix and extremely low permeability.
Migratory corrosion inhibitor

PACKAGING:

FX-262 Repair Mortar is supplied in 55 lb. moisture-resistant bags which yield approximately 0.45 sq. ft. of mortar. This will cover approximately 5.4 sq. ft. at a 1" thickness before waste and rebound.

PHYSICAL PROPERTIES:

Unit Weight	135 lb./ft. (2.275 kg/m)
Working Time	30-45 minutes
Set Times (hr/min) (ASTM C 266)	Initial Set - 2:00 Final Set - 6:00

	1 DAY PSI (MPa)	7 DAY PSI (MPa)	28 DAY PSI (MPa)
Slant Shear Bond Strength (ASTM C 882, Modified)	1,000 (6.9)	1,250 (8.62)	1,700 (11.72)
Drying Shrinkage at 28 days (ASTM C 157, Modified)			0.09%
Splitting Tensile Strength (ASTM C 496)	400 (2.7)	500 (3.4)	700 (4.8)
Flexural Strength (ASTM C 348)	800 (5.5)	900 (6.2)	1000 (6.9)
Compressive Strength (ASTM C 109)	4000 (41.3)	7500 (51.7)	8500 (58.6)

Salt Scaling Resistance, 50 Cycles (ASTM C 672)	None
Ability to Resist Chloride Ion Penetration (ASTM C1202)	<400 coulombs

SURFACE PREPARATION:

Concrete: Perform surface preparation in compliance with ICRI Technical Guideline No. 03730 "Guide for Surface Preparation for the Repair of Deteriorated Concrete Resulting from Reinforcing Steel Corrosion". Remove all unsound or delaminated concrete providing a minimum of 1/4" (6 mm) substrate profile and 3/4" (20 mm) clearance behind corroded reinforcing steel. The perimeter of the area to be patched should sawcut to a minimum depth of 1/4" (6 mm) to prevent featheredges. After concrete removal and prior to placement, mechanically abrade the concrete surface to remove all bond-inhibiting materials from the concrete substrate and to provide additional mechanical bond. Presoak the prepared concrete surface to provide a saturated, surface dry (SSD) condition.

Corroded Reinforcing Steel: Remove all oxidation and scale from the exposed reinforcing steel in accordance with ICRI Technical Guideline No. 03730 "Guide to Surface Preparation for the Repair of Deteriorated Concrete Resulting from Reinforcing Steel Corrosion". For additional protection from future corrosion, coat the prepared reinforcing steel with FX-408 Epoxy Zinc Rich Primer.

MIXING:

Add 0.7 to 1.1 gallon of potable water per 55 lb. bag of FX-262 Repair Mortar. Mechanically mix using a mortar mixer of an appropriate size. Pour approximately 90% of the mix water into the mixing container, start mixer and charge with the bagged material. Add the remaining mix water as required. Mix for 3 to 5 minutes until a homogeneous consistency is achieved. For economical purposes when lift thickness exceeds 1 inch, dry pea gravel or #7 stone may be added to the grout mix.

APPLICATION:

On very porous or weak surfaces, use FX-752 Bonding Agent as a primer. To improve bond, apply FX-752 Bonding Agent at a rate of 100 square feet per gallon (9 m²) on smooth surfaces, 60 square feet on rough (6 m²). Must apply topping while FX-752 is tacky; if dry, recoat.

For spray applications, contact Fox representative for equipment recommendations. Remove all excess water from the saturated substrate and apply while taking proper consideration for compaction around reinforcing steel. If applying by hand, substrate surface shall be soaked with clean water to provide a saturated surface dry (SSD) condition. FX-262 Repair Mortar must be placed before the bond coat dries. When applying with multiple lifts, scratch the preliminary lift before initial set. Apply the next lift after the preliminary lift has reached final set. If the succeeding lift is not to be immediately placed, keep the surface continually moist. Cut-off or level as required matching the original concrete elevation. Finish the final surface as required.

Application Thickness:
Vertical 3/8 to 2" (10 to 50 mm) per lift
Overhead 3/8 to 1 1/2" (10 to 40 mm) per lift

CURING:

Damp curing or use of a curing compound such as FX-15, that meets the ASTM C-309 standard, may be necessary to prevent rapid drying of FX-262. Curing compounds may need to be removed prior to coating. For manhole applications, replace manhole cover as soon as mortar application is complete.

LIMITATIONS:

Minimum application thickness is 3/8" (10 mm). Do not mix partial bags. Minimum ambient and surface temperatures should be 45 °F (7 °C) and rising at the time of application.

STORAGE AND SHELF LIFE:

Unopened bags have a shelf life of 18 months when stored under cover in dry conditions between 45 and 90°F (7 and 32°C).

CAUTION:

WARNING! CONTAINS FREE SILICA & PORTLAND CEMENT. DO NOT BREATHE DUST. May cause delayed lung injury (silicosis). Follow O.S.H.A. safety and health standards for crystalline silica (quartz). Cement powder or freshly-mixed concrete, grout or mortar may cause skin injury. Avoid contact with skin and wash exposed skin areas promptly with water. If any cement powder or mixture gets into the eyes, rinse immediately and repeatedly with water and get prompt medical attention.

FOR INDUSTRIAL USE ONLY. KEEP AWAY FROM CHILDREN. 4/2012