Colabile

Colabile is a ready-to-use, fiber-reinforced, gray-colored mortar based on high-strength special cements, selected aggregates and special additives. Its self-levelling power makes it possible to carry out repairs and volumetric reinstatements in large thicknesses by pouring into formworks, achieving perfect and fast filling without the need for vibration. A slight expansion in both the plastic and post-hardening phases makes it possible to compensate for shrinkage by ensuring perfect plugging of every interstice with considerable improvement in final adhesion characteristics, while avoiding cracking. The mortar, although fluid, is cohesive and does not undergo phenomena of component separation. It guarantees high mechanical properties with particular reference to flexural strength, an important parameter for workmanlike repairs of reinforced concrete. Colabile is a structural repair product for concrete structures by means of hydraulic mortar of type PCC and class R4 according to EN 1504-3, in addition Colabile is a mortar with excellent resistance to penetration of chloride ions, determined according to EN 13396.

Instructions for use

Preparation
The substrate must be clean and well keyed. Hammer and scrape the substrate to remove all loose, crumbling or non-cohesive material until a clean, resistant surface is revealed. Remove all traces of carbonated concrete from the reinforcement. Clean thoroughly using a dry or wet sand blaster to expose the bare metal. To protect against rust and corrosion, apply Restauro Ferri on the reinforcement. The day before casting, wet the substrate until the water stops soaking in.

Mixing the product
Mix Colabile with approximately 14 to 16% water (about 3.5 to 4.0 litres per 25 kg bag) depending on the consistency required. Do not use more than 4 litres for 25 kg of product. Pour approximately 3/4 of the total amount of water in the cement mixer and, while the mixer is moving, add the dry premixed mortar, pouring it in uniformly and continuously. Mix until smooth and free of lumps. Then add the rest of the water until you obtain the required consistency. For small quantities, a mechanical stirrer (low-speed drill with mixer attachment) may also be used, following the same procedure. Whatever the type of mixer used, avoid incorporating an excessive amount of air in the mixture. Very small quantities may be mixed by hand using a bucket and trowel. In this case, more water may be needed in proportion and the end quality may not be as good in terms of mechanical properties (shrinkage and risk of cracking).

Application
The mixture prepared in this way has a pot life of about 30 minutes under normal conditions (+20 °C). Higher temperatures reduce pot life. Wet the surface again until it is saturated and let the excess water evaporate or remove it with a sponge. Pour the mixture into the forms smoothly and from one side only so that the air can escape from the other side. Use iron rods or bars to help fill in narrow gaps or crevices. Vibrating is not necessary. For thicknesses greater than 2 cm, the mortar must be reinforced with galvanized mesh and this must have a cover of at least 1 cm. For final layers more than 4 cm thick, electro-welded mesh may also be used. For layers 1 to 2 cm thick, reinforcement mesh is not necessary but the substrate must be well keyed so as to counter expansion. For cavities larger than 3-4 cm, dilute Colabile up to a maximum of 50% by weight of fine gravel (3-7 mm) i.e. 2 parts Colabile to 1 part fine gravel. In practical terms this means approximately 3 buckets of fine gravel for every 100 kg (equal to four 25 kg bags) of Colabile. This changes some of the characteristics of the product such as the amount of water required for the mix which is reduced from approximately 14% of the product to approximately 10% of the product when diluted with gravel. Mechanical performance in terms of compression resistance is reduced by approximately 5% to somewhere in the order of 60 MPa. Pourable can also be pumped with suitable piston or worm plastering machine such as Turbosol or Putzmeister, excluding continuous mixing machines.

Cleaning
The tools used for laying can be cleaned with water before the mortar hardens; afterwards cleaning can be carried out only by mechanical removal.

Storage

Colabilevmust be stored in a dry, protected place. Unopened in its original bags, the product can be stored for at least 12 months.

Warnings

• To avoid cracking caused by excessively rapid evaporation of the water in the mixture in hot weather and to promote expansion to compensate for shrinkage, the surface of Colabile castings and repairs must be kept wet for at least 48 hours and must be protected from wind and direct sunlight.
• For surface finishing details, general rules of good practice in the application of cementitious mortars apply.
• As with all cement-based products, do not apply at temperatures below +5 °C.