MAPEGROUT

THIXOTROPIC
Shrinkage-compensated fibre-reinforced mortar for
concrete repair

WHERE TO USE
Surface repair of deteriorated concrete structures on both vertical and horizontal surfaces.

Some application examples

· Repairing deteriorated areas of concrete, corners of pillars and beams, edges of balconies damaged by the oxidation of
reinforcing steel.
· Reconstruction of reinforcing rod covers in reinforced concrete structures.
· Smoothing surface defects, such as gravel nests, new casting joints, holes created by formwork spacers, exposed rods,
etc.
· Filling of rigid joints.
· Repair of surfaces subjected to heavy abrasion (canals, industrial floors, ramps, etc.).
· Smoothing of diaphragm walls and tunnels.
· Repairing viaducts for highways, roads and railways.

TECHNICAL CHARACTERISTICS
Mapegrout Thixotropic is a ready-mixed powdered mortar composed of high-strength cements, selected aggregates,
special additives and synthetic fibres prepared according to a formula developed in the MAPEI Research & Development
laboratories.
When mixed with water, Mapegrout Thixotropic becomes an easily workable mortar with high thixotropic properties that
can be applied on vertical surfaces without sagging even in great thicknesses and with no need for formwork.
If Mapegrout Thixotropic is prepared by only adding water, it must be cured under damp conditions in order to guarantee
that the product expansive properties develop completely and correctly. Unfortunately, it is not easy to guarantee that
these conditions are created on site.
However, to guarantee that the expansive properties of Mapegrout Thixotropic are carried out in the open air, 0.25% of
Mapecure SRA, a special additive which has the property of reducing both plastic and hydraulic shrinkage, may be used to
great advantage when added to the mix.
Mapecure SRA has a very important role to play, in guaranteeing better curing of mortar. Also, when mixed with
Mapegrout Thixotropic, it may be considered a technologically advanced system, in that the additive has the capacity of
slowing down evaporation of the water and of promoting the development of hydration reactions.
Basically, Mapecure SRA behaves like an internal curing agent and, thanks to its interaction with some of the main
components which make up the cement, it helps to reduce shrinkage by between 20% and 50% compared with the
standard values of the product without the additive. This will obviously lead to a reduced risk of cracking.
Once hardened, Mapegrout Thixotropic has the following properties:
· very high flexural and compressive strength;
· modulus of elasticity, coefficient of thermal expansion and permeability to water vapour similar to those of high quality
concrete;
· waterproof;
· high adhesion to old concrete, provided it has been soaked with water beforehand, and also to reinforcing rods,
especially if they have been treated with Mapefer or Mapefer 1K;
· high resistance to abrasion.
Mapegrout Thixotropic meets the requirements defined by EN 1504-9 (“Products and systems for the protection and
repair of concrete structures - Definitions, requirements, quality control and evaluation of conformity - General principles
for the use of products and systems”) and the minimum requirements claimed by EN 1504-3 (“Structural and non
structural repair”) for structural mortars of class R4.

RECOMMENDATIONS
· Do not use Mapegrout Thixotropic on smooth concrete surfaces: roughen them well, and if necessary add reinforcing
rods.
· Do not use Mapegrout Thixotropic for anchors (use Mapefill).
· Do not use Mapegrout Thixotropic to repair structures by pouring into formwork (use Mapegrout Hi-Flow).
· Do not add cement, aggregates or additives to Mapegrout Thixotropic.
· Do not add water after the mix has started to set.
· Do not apply Mapegrout Thixotropic at temperatures below +5°C.
· Do not use Mapegrout Thixotropic if the packing has been damaged or if it has been opened beforehand.

APPLICATION PROCEDURE
Preparing the substrate
· Remove deteriorated and loose concrete until the substrate is solid, strong and rough. Any previous restoration work
which is not soundly bonded should also be removed.
· Clean the concrete and reinforcing rods until free of dust, rust, cement laitance, grease, oils and previously applied paints
by sand-blasting.
· Soak the substrate with water.
Before repairing with Mapegrout Thixotropic allow the excess water to evaporate. If necessary, use compressed air to
facilitate the removal of water.

Preparing the mortar

· Pour into the mixer the amount of water corresponding to the consistency required for the application (15.5-16.5% of the
powder).
· Start the concrete mixer and slowly and continuously pour Mapegrout Thixotropic into the water.
· If improved open-air curing of the mortar is required, add Mapecure SRA to the final mix at a dosage of 0.25% by weight
of the mortar (0.25 kg every 100 kg of Mapegrout Thixotropic).
· Mix for 1-2 minutes, checking the homogeneity of the mix while scraping any unmixed powder off the sides of the mixer;
remix for another 2-3 minutes.
· Depending on the quantity being prepared, a mortar mixer or a drilling machine with a stirrer attachment can be used.
The mixing must be carried out at low speed to avoid entraining an excess of air into the mix.
· Only in exceptional circumstances should the mortar be mixed by hand. In this case prepare small quantities and mix for
at least 5-6 minutes until the slurry is completely smooth and even.
It should be remembered that manual preparation requires greater quantities of water which are detrimental to some
characteristics of Mapegrout Thixotropic, such as mechanical strength, shrinkage, waterproofing, etc.
Mapegrout Thixotropic has a pot life of about 1 hour at +20°C.
The expansion of Mapegrout Thixotropic has been calculated to compensate for hygrometric shrinkage.
In order to be effective, the expansion must be countered with suitable reinforcement or formwork around the structure.
Without formwork, Mapegrout Thixotropic can only be applied in thicknesses greater than 3 cm if the surface has been
roughened and reinforcing rods have been placed, taking care to apply at least 2 cm of cover to the reinforcement.
Smaller thicknesses can be applied without reinforcing rods as long as the substrate is sufficiently rough to be able to
counter the expansion. This expansion phase is completed during the first days of curing.

Applying the mortar

The mix can be applied with a flat or gauging trowel with no need for formwork even on vertical surfaces or ceilings; the
maximum thickness allowed is 50 mm per coat.
Mapegrout Thixotropic can also be sprayed with a suitable piston or worm screw type rendering machine (Turbosol -
Putzmeister), excluding continuous mixing machines.
Apply Mapegrout Thixotropic after treating the reinforcing rods with Mapefer or with Mapefer 1K.
When a further coat of Mapegrout Thixotropic is necessary, it must be applied before the previous one has completely set
(not more than 4 hours at +23°C).
The repair process is complete when a smoothing coat of Mapefinish and a coat of Elastocolor Paint have been applied.
 Application with trowel Finishing with a sponge float 

PRECAUTIONS TO BE TAKEN DURING AND AFTER APPLICATION

· Only use bags of Mapegrout Thixotropic which have been stored on their original pallets.
· In hot weather, store the product in a cool place and use only cold water to blend the mortar.
· In cold weather, store the product in a place which is protected from frost at a temperature of +20°C, and use tepid water
to blend the mortar.
· After laying Mapegrout Thixotropic, we recommend that it is cured carefully, especially in hot or windy weather, to avoid
the water evaporating off too quickly and causing the formation of surface cracks due to plastic shrinkage. Spray water
on the surface after 8-12 hours of laying the mortar, and repeat the operation every 3-4 hours for at least the first 48
hours. As an alternative, after tamping the mortar, spread on a layer of Mapecure E anti-evaporation treatment in watery
emulsion with a low-pressure pump, Mapecure S solvent-based curing film for mortar and concrete, or Elastocolor
Primer solvent-based, high-penetration primer for absorbent substrates and curing agent for repair mortar. Mapecure E
and Mapecure S, as with all the best quality products in the same category which are currently available on the market,
impede bonding of successive dressing layers. Therefore, if a smoothing layer or paint is to be applied later, they must be
completely removed by sandblasting. If Elastocolor Primer is used as an anti-evaporation treatment, on the other hand,
a final protective layer of Elastocolor Paint or Elastocolor Rasante may be applied directly on the treated surface without
having to remove it.

CLEANING
Before hardening, the mortar can be cleaned from tools with water.
After setting, cleaning is very difficult and the mortar can only be removed mechanically.

COVERAGE
19 kg/m² per cm of thickness.

PACKAGING
25 kg bags.

STORAGE
Mapegrout Thixotropic may be stored for up to 12 months in its original packaging.
The product complies with the conditions of Annex XVII to Regulation (EC) N° 1907/2006 (REACH), item 47.
The product is available in special 25 kg vacuum-packed polyethylene bags which may be stored outside for the entire
construction phase of the site. Rain has no effect on its characteristics.

SAFETY INSTRUCTIONS FOR PREPARATION AND APPLICATION

Instructions for the safe use of our products can be found on the latest version of the Safety Data Sheet, available from
our website www.mapei.com.
PRODUCT FOR PROFESSIONAL USE.
TECHNICAL DATA (typical values)

PRODUCT IDENTITY

Strength class according to EN 1504-3: R4

Type: PCC

Consistency: powder

Colour: grey

Maximum aggregate size (mm): 2.5

Bulk density (kg/m³): 1,250

Dry solids content (%): 100

Chloride ions content: - minimum requirements ≤ ≤ 0.05

0.05% - according to EN 1015-17 (%):

PRODUCT APPLICATION DATA (at +20°C - 50% R.H.)

Colour of mix: grey

Mixing ratio: 100 parts of Mapegrout Thixotropic with 15.5-16.5 parts water
(approx. 3.8-4.1 l per 25 kg bag)

Consistency of mix: thixotropic

Density of the mix (kg/m³): 2,200

pH of the mix: > 12.5

Application temperature range: from +5°C to +35°C

Pot life of the mix: approx. 1 h

FINAL PERFORMANCE (16% mixing water - mixing and compacting according to EN 196-1)

Performance characteristic Test Minimum requirements according to EN Product performance

method 1504-3 for R4 class mortar

EN > 20 (after 1 day)

Compressive strength (MPa): ≥ 45 (after 28 days) > 45 (after 7 days)
12190 > 60 (after 28 days)
> 4.5 (after 1 day)
Flexural strength (MPa): EN 196/1 not required > 7.0 (after 7 days)
> 8.5 (after 28 days)
Modulus of elasticity in EN ≥ 20 (after 28 days) 26 (after 28 days)
compression (GPa): 13412
Bond strength to concrete
(MC 0.40 type substrate) EN 1542 ≥ 2 (after 28 days) > 2 (after 28 days)
according to EN 1766 (MPa):
depth of carbonatation ≤ reference
Resistance to accelerated EN concrete (MC 0.45 type with test passed
carbonatation: 13295 water/cement ratio = 0.45) according to
UNI 1766
 Capillary absorption EN ≤ 0.5 < 0.20
(kg/m²·h0.5): 13057

Thermal compatibility
measured as bonding EN
according to EN 1542 (MPa):
– freeze-thaw cycles with 13687/1  ≥ 2 (after 50 cycles) >2
deicing salts:  EN ≥ 2 (after 30 cycles) >2
– storm cycle: 13687/2 ≥ 2 (after 30 cycles) >2
– dry thermal cycle: EN
13687/4

Reaction to fire: EN Euroclass A1

13501-1

WARNING
Although the technical details and recommendations contained in this product data sheet correspond to the best of our
knowledge and experience, all the above information must, in every case, be taken as merely indicative and subject to
confirmation after long-term practical application; for this reason, anyone who intends to use the product must ensure
beforehand that it is suitable for the envisaged application. In every case, the user alone is fully responsible for any
consequences deriving from the use of the product.
Please refer to the current version of the Technical Data Sheet, available from our website www.mapei.com

LEGAL NOTICE
The contents of this Technical Data Sheet (“TDS”) may be copied into another project-related document, but the
resulting document shall not supplement or replace requirements per the TDS in force at the time of the MAPEI product
installation.
The most up-to-date TDS can be downloaded from our website www.mapei.com.
ANY ALTERATION TO THE WORDING OR REQUIREMENTS CONTAINED OR DERIVED FROM THIS TDS EXCLUDES THE
RESPONSIBILITY OF MAPEI.

302-5-2021-gb

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