Thoro® Structurite 100

Thoro Structurite 100 is a shrinkage compensated repair mortar for hand or spray application. Large areas are easily

repaired in thicknesses of 5 to 40 mm.

A rough surface profile prior to the application of this repair mortar ensures a durable bond and a successful repair of the

concrete structure.

Product benefits:• Thoro Structurite 100 meets the requirements of a class

R4 mortar according EN 1504-3

• Can be trowel and spray applied

• Shrinkage compensation ensures full positive contact

with host concrete and load transfer in structural repair

situations

• Reduced risk of cracking due to plastic and post cure

shrinkage compensation

• No separate primer required

• Can be spray-applied; rapid application of large

quantities

• Low rebound when spray applied. Savings in material

cost

• Low permeability; gives excellent resistance to attack

by aggressive elements

• Carbonation resistant

• Excellent freeze-thaw resistance

• Sulphate resistant

Technical data:• Pot-Life: 60 minutes at 20 ºC

• Compressive strength: ≥ 50 MPa after 28 days

• Adhesion strength: ≥ 2.0 MPa

• Modulus of elasticity: 28 GPa

• For layer thickness: 5 – 40 mm

(if > 20 mm in areas > 1 m2, secondary reinforcement

is advised)

Thoro® specification guide

Selecting the right product for each application…

With this specification guide you can easily find which product to be used for your needs. Following scheme and tables

summarise the main features of the described products to assist the right product selection. Contact your nearest

BASF Construction Chemical technical office or your nearest Thoro distributor for further or detailed advice.

Thoro Structurite R4 Thoro Structurite LightThoro Crete SL

Thoro Structurite 100ThoroStructuritePrimer

Thoro Structurite FR

Thoro Crete HS

Thoro Structurite Level

Thoro Crete SL

Product Type of material Certified according

Thoro Structurite R4 PCC mortar EN 1504-3/Class R4

Thoro Structurite 100 CC mortar EN 1504-3/Class R4

Thoro Structurite FR CC mortar EN 1504-3/Class R4

Thoro Structurite Light PCC mortar EN 1504-3/Class R3

Thoro Structurite Level PCC mortar EN 1504-3/Class R2

Thoro Crete HS PCC mortar EN 1504-3/Class R4

Thoro Crete SL PCC mortar n.a.

Thoro Structurite Primer PCC mortar EN1504-7/Class AP

Product selection

Thoro Structurite R4 √ √ √ √ √ √ √

Thoro Structurite 100 √ √ √ √ √ √

Thoro Structurite FR √ √ √ √ √ √

Thoro Structurite Light √ √ √ √ √ √

Thoro Structurite Level √ √ √ √ √ n.a. n.a.

Thoro Structurite Primer √ √ n.a. n.a. n.a. n.a. √

Thorocrete HS √ √ √ √ √ n.a. n.a.

Thorocrete SL √ √ √ √ √ n.a. n.a.

Thoro Structurite R4 ca. 20 minutes – 11 MPa 45 MPa ≥ 2.3 MPa

Thoro Structurite 100 ca. 60 minutes – 16 MPa 50 MPa ≥ 2.5 MPa

Thoro Structurite FR ca. 30 minutes – 25 MPa 55 MPa ≥ 3.5 MPa

Thoro Structurite Light ca. 30 minutes – 12 MPa 30 MPa ≥ 1.5 MPa

Thoro Structurite Level ca. 45 minutes – 10 MPa 35 MPa ≥ 0.8 MPa

Thoro Crete HS ca. 20 minutes 15 MPa 30 MPa 55 MPa ≥ 2.4 MPa

Thoro Crete SL ca. 20 minutes – 10 MPa 35 MPa ≥ 2.0 MPa

vert

ical

/ o

verh

ead

Pot Life @

20 ºC

Compressive

Strength after

2 Hours (*)

Compressive

Strength after

1 Day (*)

Compressive

Strength after

28 Days (*)

Adhesion

(*)

horiz

onta

l

thix

otro

pic

flow

able

cold

clim

ate

(fr

eeze

/ th

aw)

hum

id c

limat

e

(thun

der

/ sh

ower

)

hot c

limat

e

(dry

cyc

les)

carb

onat

ion

re

sist

ance

corr

osio

n in

hibi

tor

in

side

n.a. = not applicable

Products Typical Consistency Exposure Conditions Rebar Application Protection

Product Hardening Strength

(*) These values are typical values and not warranted minima

THORO STRUCTURITE 100

Shrinkage compensated, fibre reinforced, thixotropic repair mortar for trowel or wet-spray application Description of product THORO STRUCTURITE 100 is pre-bagged one component product in powder form comprising sulphate resistant Portland cement. When mixed with the correct amount of water, it provides a rheoplastic, non-segregating high strength mortar, with excellent bond to steel reinforcement and to concrete. THORO STRUCTURITE 100 is chloride free and contains polyacrylonitrile fibres. THORO STRUCTURE 100 meets the requirements of a class R4 mortar according EN 1504-3. Uses All types of structural repair, can be applied by trowel

or wet spray. Repair of reinforced or pre-stressed beams or

columns. Repairs in marine environments. Repair of structural members subjected to repetitive

loading. Repairs in industrial areas, especially those

containing mineral oils, lubricants etc. Repair of structures subjected to sulphates

contaminated environments. Benefits Shrinkage compensation ensures full positive contact

with host concrete and load transfer in structural repair situations.

Reduced risk of cracking due to plastic and/or post cure shrinkage.

No separate primer required, only a slurry coating procedure must be respected.

Can be spray-applied; rapid application of large quantities.

Low rebound; when spray applied, rebound is minimal with subsequent saving in material cost.

Excellent thixotropic and rheoplastic properties allow placement in difficult areas to be executed.

Low permeability; gives excellent resistance to attack by aggressive elements.

Can be built up in layers of up to 40 mm.

Cert. Nr BB-563-0013-0011-001 Cert. Institute BCCA Product data Typical physical properties(a) declared value Maximum grain size 1,5 mm Modulus of elasticity 28.000 N/mm² (EN 13412) Capillary water Absorption ≤0,5 kg/m2 x h-0.5 (EN 13057) Chloride ion content ≤0,05 % (EN1015-17) Mechanical properties Compressive strength 1 d.. 16 N/mm² (EN 12190) 28 d. 50 N/mm² Flexural 28 d. 7 N/mm² (EN 12190) Adhesive Bond 28 d. 2,6 N/mm² (EN 1542) Adhesive Bond after 28 d. 2,2 N/mm² Freeze/Thaw (EN 13687-1) (a) Typical values. All tests were carried out with 4,0 litres

water/25 kg powder under temperature controlled conditions of 21°C.

Colours Grey. Coverage One bag of THORO STRUCTURITE 100 mixed with 4 litres of potable water will yield approx. 13,5 dm³ of mortar, which will cover 1 m² at 13 mm average thickness. ± 1,8 kg powder/dm³. Packaging THORO STRUCTURITE 100 is supplied in 25 kg moisture resistant bags. Storage Store under cool, dry conditions and clear of the ground. Shelf life: minimum 9 months when stored as recommended in unopened bags. Application Substrate preparation It is essential that the substrate to be repaired is sound, clean and free of all contamination. The damaged areas of concrete to be removed should be clearly identified. The edges of the area should be square cut to a depth of 5 mm. Feather edging is not permitted and a minimum thickness of 10 mm must be maintained over the whole repair area. The substrate should be prepared to provide a rough surface having a 3 mm amplitude. JUST SANDBLASTING IS NOT ACCEPTABLE. If unsound concrete is found to extend beyond the pre-marked area, consult the engineer in charge. Subject to his approval cut out as necessary to clean sound concrete. If reinforcement is corroded, ensure that the back of the steel has been exposed. Reinforcement should have all rust removed by the use of power tools, abrasive blasting (wet or dry). Reinforcing steel should be exposed and cleaned around its whole circumference. Steel should be prepared to Swedish Standard SIS 05-900 : 1967 - SA 2. If required, extra protection to the reinforcement can be provided by the use of THORO STRUCTURITE PRIMER. Severely corroded reinforcement may require replacement and the engineer must be consulted. Positioning of secondary reinforcement Where the application of THORO STRUCTURITE 100 is to exceed 20 mm in thickness, fix a welded metal mesh 50 mm x 50 mm x 3 mm to the concrete substrate, spacing the mesh away from the substrate. The required cover of the THORO STRUCTURITE 100 to this mesh is preferably min. 20 to max. 40 mm. For repairs in excess of 40 mm deep - and which are applied in separate layers

- an additional mesh may be required in each of those layers of THORO STRUCTURITE 100 as they are applied. At all times, minimum cover to the welded metal mesh must be at least 10 mm, preferable 20 mm. Water saturation After placement of the welded mesh (if required), thoroughly saturate the surface of the concrete to be prepared to provide a saturated, surface dry condition. Poor quality concrete may require soaking for a significant length of time. Extreme situations may require up to 24 hours of saturation. Any surface water should be removed using an oil free compressed air jet. Mixing Wet density 2,10 kg/dm³ Pot life 60 minutes Initial setting time ca. 180 minutes Final setting time ca. 240 minutes Mixing liquid, potable water Trowel mortar ± 3,8 lt / 25 kg powder Spray mortar ± 4,2 lt / 25 kg powder The brush applicable bonding slurry requires 10% to 15% more water than for the trowel mortar is required. Hand mixing of THORO STRUCTURITE 100 is not recommended. For small mixes, a variable speed electrical or air driven drill with a helical stirrer can be used. Best results are obtained using a forced action mixer. Pour the minimum amount of mixing water into the mixer (start with approx. 75 - 80%). Start the mixer and add the THORO STRUCTURITE 100 powder rapidly and continuously. Mix for 3 to 4 minutes after all the powder has been added until the mortar is homogeneous and lump free. Add water, if necessary, within the given limits, until the required consistency is achieved. Mix for a further 2 - 3 minutes. Ambient temperature and relative humidity will affect the amount of water required. DO NOT ADD WATER TO RETEMPER. Slurry coat Add a small amount of water to a part of the mixed trowel mortar. Mix till a lump free brushable consistency has been achieved. Application THORO STRUCTURITE 100 can be used when the ambient temperature is between 5 and 30°C. Take the necessary precautions when working under cold, hot or windy conditions, e.g.: - using warm mixing water when working in cold

conditions; - protect with plastic sheets to prevent plastic

shrinkage cracking in warm/windy conditions. After mixing, THORO STRUCTURITE 100 can either be sprayed or trowel applied; the THORO representative can recommend suitable spraying units. The surface of the mortar should be levelled using a wooden float. Final finishing may be done with a wooden, plastic or synthetic sponge trowel, depending on the finish required.

Trowelling after spray application should start once the mortar has started to stiffen. This is indicated when the surface is only lightly marked by pressure from the fingers. Curing Good curing is essential. Particular care is required in hot/windy conditions. Fog spray all applications after initial set has taken place for as long as practicable. Single-coat curing membranes are subjected to approval by the THORO representative. Curing by covering the work with a properly secured plastic sheet is acceptable as well. In cold conditions cover with insulated tarpaulin, polystyrene or other insulating material. After minimum 3 days (preferably 7 days, depending on the potable water) a protective coating like THORO LASTIC S or THORO LASTIC TF may be applied. Setting and hardening times will vary, dependent upon ambient temperatures and conditions.

Clean up and spillages Not hardened material may simply be removed with water. Water will suffice for cleaning of tools as well. Health and safety For full info on Health and Safety matters regarding this product, the relevant Health and Safety data sheet should be consulted (available on request). THORO STRUCTURITE 100 should be handled to minimize dust formation; use light mask if excessive dust is unavoidable. Cement powders when wet or moistened can cause burns to skin and eyes, which should be protected during use. Accidental splashes of the material to the skin or eyes should be immediately washed off with clean water. If accidentally ingested, seek medical attention.

Thoro

BASF Belgium Coordination Center Comm. V.- Business Belux – Construction Chemicals Nijverheidsweg 89 B-3945 Ham

www.thoro.com Tel. +32 11 34 04 32 Fax +32 11 40 13 92

B.T.W./T.V.A. BE 0862.390.376

RPR/RPM Antwerpen

Your distributor:

Important note: Whilst all reasonable care is taken in compiling technical data on the company’s products, all recommendations or suggestions regarding the use of such products are made without guarantee since the conditions of use are beyond the control of the company. It is the customer’s responsibility to make sure that each product is appropriate for the purpose for which he intends to use it and that the actual conditions of use are suitable. This edition replaces all previous editions.