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DARAWELD C

Bonding Agent for Masonry and Concrete Repair

Product Usage BONDING AGENT FOR CONCRETE

SOLUTION PROBLEM

Badly Pitted, Worn, Broken Soft, Punky, Scaly, Friable Covered with Grease, Oil, Foreign Matter Extremely Porous Smooth and Dense Newly Placed, Clean and Sound WIRE BRUSH only in extreme cases WASH WITH DETERGENT AND RINSE ACID ETCH AND RINSE PAINT OR SPRAY WITH Daraweld C SOAK WITH WATER if dry SCRUB IN Daraweld C GROUT LEVEL WITH GROUT OR TOPPING MIX

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With Daraweld C, not all concrete surfaces in need of repair have to be chipped or scarified. Daraweld C patches can be feather-edged. Daraweld C cuts back on labor and preparation time ­ yet gives bonded repair ­ thoroughly dependable through the years of wear, weather, and moisture.

Application Information GENERAL REPAIR WORK

Shallow Patching and Thin Resurfacing (not more than 1/2 in. deep) of Worn, Broken, Scaled or Spalled Concrete Surfaces Steps, Sidewalks, Driveways, Floors, Walls, Ramps, Roads, Bridges, Abutments

METHOD

Thoroughly pre-mix cement and sand. In a separate container combine Daraweld C with an equal quantity of water and add to the cement/sand mixture. Mix to a creamy consistency. Do not overmix. Scrub this bonding layer onto surface with a stiff bristle brush of corn broom in a layer no more than 1/8 in. thick. Level with remaining material while bonding layer is still soft and plastic. Follow same method as above for bonding layer. Level with plain cement mortar or concrete topping and finish to desired grade. Add air entraining admixture to topping mix for maximum durability if overlay will be exposed to freezing and thawing. Mix materials until blended into thin paste. On horizontal surfaces, pour paste into crack to overflowing and cut off with trowel when stiff. On vertical surfaces, paint cracks with paste, then fill with grout as prescribed above for Shallow Patching. Paint crack with straight Daraweld C, making sure coating extends beyond edges. Scrub in grout with stiff brush. Fill with remaining material and finish with trowel.

MATERIALS

1 part 5 parts 2 parts 1 part Daraweld C Cement Mason's Sand Water*

Bonding Grout for Thick Patches and Overlays Same applications as above and to bring Highway Sections up to Grade Filling Fine Cracks Walls, Floors, Pavements, Structures, Concrete Products

Same materials and proportions as above.

1 part 1 part 1 part

Daraweld C Cement Water*

Repairing Wide Cracks Same applications as above.

1 part 1 part 1.5 parts 0.5 part

Daraweld C Cement Mason's Sand Water*

*Water content specified for above application is approximate. Add more water where necessary for proper consistency.

BONDING APPLICATIONS

Bonding Concrete to Asphalt

METHOD

Scrub standard Daraweld C grout onto asphalt surface with stiff brush or corn broom. For thick overlay, top with mortar or concrete topping while grout is still plastic. When dry, surface can be painted with cement paint. (See "Painting" section that follows). When walls or slabs are poured in stages, apply standard Daraweld C grout over the surface of each pour to obtain integral bond with subsequent pours.

MATERIALS

1 part 5 parts 2 parts 1 part Daraweld C Cement Mason's Sand Water*

Bonding Construction Joints

Same materials and proportions as above.

FLOOR APPLICATIONS

Protecting Floors Against Mild Acid Attack Laundries, Dairies, Degreasing Pits, etc.

METHOD

For porous floors exposed to acids, corrosive agents, cleaning fluids. Bring the mixture to a paint consistency. Apply with a stiff broom or spray equipment. For best results, apply at least two coats, allowing 24 hours between coats. Apply with scrubbing brush, then swirl to get a rough finish. This application has been extremely successful in providing safe, sure footing on surfaces normally slippery when wet. Pour on and distribute evenly with squeegee. Sop up puddles with cloth or sponge, since a heavy concentration of the material may seal soft. Floor must be closed to traffic for 24 hours to allow for thorough drying. For porous surfaces a second coat is recommended. Apply Daraweld C grout and level to desired grade. Allow 24 hours for curing. Apply tile cement directly on new surface, lay tile. With straight Daraweld C, glue tapered wooden strips, narrow edge up, to concrete floor. Apply Daraweld C grout between strips and level. To adhere plaster tile, brush or squeeze Daraweld C as received on wood or concrete surface. Prime with dilute Daraweld C first if surface is dusty and porous concrete.

MATERIALS

1 part Daraweld C 5 parts Lumnite Cement 2.5 parts Portland Cement 1 part Water* Caution: See Note Below. 1 part 5 parts 5 parts 1.5 parts 1 part 2 parts Daraweld C Cement Mason's Sand Water* Daraweld C Water*

Non-Skid Floor Treatments Sidewalks, Patios, Garages, Swimming Pools, Industrial Floors, Aircraft Hangers Dustproofing Floors

Leveling for Floor Tile Before Application of Vinyl and Asphalt Tile

1 part 5 parts 10 parts 2 parts 1 part 5 parts 10 parts 2 parts Straight

Daraweld C Cement Mason's Sand Water* Daraweld C Cement Mason's Sand Water* Daraweld C

Anchoring Nailing Strips to Concrete Floors Before Application of Wood Finish Flooring

Layering Plaster Floor Tile On Wood or Concrete Floors

WALL APPLICATIONS

Repairing Walls With Gunite Mortar

METHOD

The use of Daraweld C increases adhesion of Gunite applications. When added to the mix water, Daraweld C also tends to decrease rebound during application, and allows quicker finishing. To mix Daraweld C and water, use a large open drum. Supply gun direct from drum. An alternate method is to first spray or brush surface with a 1:1 solution of Daraweld C and water. Apply Gunite mortar as usual, while bonding coat is still tacky.

MATERIALS

1 part 1 part Daraweld C Water*

Patching Stucco Walls

Scrub in Daraweld C paste, and level with stucco mortar. If entire wall is to be resurfaced, scrub in Daraweld C grout and apply finish mortar coat while grout is still tacky. If wall is to be repainted, refer to "Painting" section which follows. A two-coat application of Daraweld C paste will prevent steam and water from penetrating concrete block walls in commercial and industrial processing areas. Each coat calls for different proportions of materials. Both applications should be scrubbed on, with a 24-hour interval between coats.

1 part 5 parts 1 part

Daraweld C Cement Water*

Steamproofing Concrete Block Walls Commercial Laundries, Car Washes, Poultry Processing Plants, etc.

First coat: 1 part 3 parts 3 parts

Daraweld C Cement Water*

Second coat: 1 part Daraweld C 1 part Cement 1 part Water*

*Water content specified for above application is approximate. Add more water where necessary for proper consistency. Note: Check setting time of Lumnite-Portland cement combination before making batch. Set may vary from very fast to very slow with different brands of cement.

MORTAR

Additive for Paving Mortar

METHOD

Daraweld C is widely used as an admixture in mortar for setting and grouting common or architectural brick used for patios, plazas, walkways and similar placements. The use of Daraweld C provides excellent adhesion to the setting bed and a strong and durable mortar joint. Gray or white Portland cement with or without mineral oxide color or prepared masonry cements may be used to effect matching or contrasting color. Mixed as described, the mortar (grout) is spread and leveled on the prepared substrate and the brick set thereon. After the setting bed has hardened, the joints between the bricks can be filled with mortar containing Daraweld C.

MATERIALS

1 part Daraweld C 1 part Water* Cement, lime, sand proportions to conform to standard ASTM specifications.

PAINTING & FINISHING

Redressing and Coloring Concrete Floors

METHOD

Mix grout, color as desired with mineral oxide. Apply with stiff brush to 1/16 in. thickness, or just thick enough to prevent sand from rolling under trowel. Finish with steel trowel. Use stiff bristle brush, apply with scrubbing action. Increasing the Daraweld C content in the mix will give a dense, semigloss texture that can be colored or painted. One coat is sufficient except where severe water seepage occurs. (See "Waterproofing" section that follows.) Mix dry and wet ingredients separately. Add dry mixture to liquid to get paint consistency. Add color for desired color. Proper proportions of gray and white Portland cement will give matching color for concrete blocks. Apply with scrubbing action. Caution: Do not attempt to apply cement paint over earlier coat of oil paint. The addition of Daraweld C to white cement mortar produces a highly durable striping material. Mix dry and wet ingredients separately. Combine mixtures just before application. Scrub onto clean asphalt surface.

MATERIALS

1 part 5 parts 2.5 parts As req. 1 part 1 part 5 parts 10 parts 2 parts 1 part 5 parts 10 parts 2 parts As req. 1 part 5 parts 2.5 parts 1 part As req. Daraweld C Cement (white) Mason's Sand Color Water* Daraweld C Cement Mason's Sand Water* Daraweld C Cement Mason's Sand Water* Color Daraweld C Cement (white) Mason's Sand Water* Color

Finishing Concrete Block Walls

Painting Concrete Blocks, Brick or Sandstone

Striping Asphalt Surfaces

SPECIAL APPLICATIONS

Repairing and Making Special Joints in Concrete Pipe

METHOD

Daraweld C can be used to patch broken or specially sectioned pipe at the casting plant and in the field. Mix and scrub thin paste, nesting the broken sections together until paste is cured. Small breaks and/or cracks can be filled with this same paste mix, with 2 parts mason's sand added. Daraweld C's acid-alkali resistance makes it an excellent protective compound. It was successfully used to stop seepage of corrosive waste through concrete pipe at the Atomic Energy Commission installation at Oak Ridge, Tennessee. Daraweld C is ideal for repairing the holes created by removal of test specimens. Core test holes of 5 in. diameter, repave, with a 17/8 in. Daraweld C patch, showed no break in the bond after 50 cycles of freezing and thawing. Scrub on Daraweld C mixture. A patch in the form of a band of belt approximately 3 ft wide and 1/4 in. thick has worked especially well around leaking construction joints in concrete tanks. Prestressed concrete slabs and beams damaged during handling or by other causes (fire included) can be repaired with Daraweld C. Just scrub on standard Daraweld C grout. If necessary, trowel on a thicker coat at cracks, corners or surface indentations. Daraweld C can be used to fill holes for eyebolts or hooks attached on the site.

MATERIALS

1 part 5 parts 1 part Daraweld C Cement Water*

Preventing Corrosion and Seepage of Concrete Pipe

1 part Daraweld C 3 parts Lumnite Cement 6 parts Mason's Sand 1 part Water* Caution: See Note Page 2. Add 20% Daraweld C by weight of specified cement. Reduce water equal to volume of Daraweld C added. 1 part 3 parts 1.5 parts 0.5 part 1 part 5 parts 2 parts 1 part Daraweld C Cement Mason's Sand Water* Daraweld C Cement Mason's Sand Water*

Plugging Core Test Holes

Repairing Leaking Construction Joints

Reclaiming Prestressed Concrete

WATERPROOFING

Waterproofing Coating Exterior Masonry Above and Below Grade, Cellar Floors, Machinery Pits, Ceramic Wash Basins, etc.

METHOD

Two or three coats of Daraweld C grout are required for successful waterproofing applications. Mix materials to brushable consistency. Scrub each coat into surface with stiff brush. Apply second and third coats at 24-hour intervals. To stop water seepage through cellar floors, machinery pits, etc., install a sump pit to drain off standing water. Repair bad spots with hot patches. Sop up all puddles before applying grout.

MATERIALS

1 part 3 parts 6 parts 1 part Daraweld C Cement Mason's Sand Water*

*Water content specified for above application is approximate. Add more water where necessary for proper consistency.

Mixing Grout

Thoroughly pre-mix cement and fine mason's sand. In a separate container combine Daraweld C with a recommended quantity of water and add to the cement-sand mixture. Even when the grout is machine-mixed, which we recommend, the dry and wet ingredients should be mixed separately. Daraweld C grout should have the consistency of heavy cream. Do not overmix, or whip air into the grout. Overmixing can cause blistering in surface coatings. Mix until ingredients appear to be normally blended. Use enough Daraweld C in plastic mix. Quantities smaller than specified will lessen bond strength. Make up in small batches. Daraweld C grout will stiffen and become hard to apply within 30 to 40 minutes after mixing. Make up only what you can use in this period. Do not retemper.

Topping Mixes

Limit the amount of water used in topping mixes. A dry, low water content mix will result in a dense, hard floor surface. Use maximum-size aggregate consistent with depth of overlay. Apply and level topping material while Daraweld C bonding layer is still soft and plastic. Topping should be dry enough to require considerable tamping for compaction. The tamping will also provide better intimate contact between the bonding grout and the topping. Screed a little high for compaction. Don't forget that straight Portland cement mortar or concrete toppings exposed to freezing and thawing should be properly air entrained with Darex AEA® or Daravair®. No entrained air is required for the Daraweld C bonding grout.

Hydration and Curing

The patch area must be damp. A too-dry surface will draw water out of the grout too swiftly to allow proper hydration of the cement. Excessive troweling or finishing on thin patches or overlays will prevent proper curing. Proper curing of the new patch or overlay will greatly improve its compressive strength and abrasion resistance, and will prevent excessive shrinkage.

Surface Cleaning

Oil and grease should be removed by washing with a strong solution. Sand blasting and water blasting, chipping or scarification have been found to be acceptable methods to remove unsound surface mortar. A thorough rinse with clear water prior to the application of the Daraweld C bonding grout is recommended. If muriatic acid is used to remove unsound surface mortar, before applying the Daraweld C overlay the area must be thoroughly rinsed with clear water to remove all of the acid. Safety procedures as recommended by the manufacturer of the acid should be strictly adhered to.

Applying Grout

Scrub Daraweld C bonding grout onto surface with a stiff bristle brush or broom in a layer not more than 1/8 in. thick. Work briskly to break through surface tensions and entrained air. In thin patches less than 1/2 in. deep, level with Daraweld C grout while bonding layer is still soft and plastic.

Finishing

In thin resurfacing work, wood floating immediately after screeding will make for a stronger bond and minimum shrinkage. For a smooth surface, a single pass with a steel trowel is recommended. Do not overfinish. Excessive steel troweling will cause desiccation, or drying-out. The tamped topping mixes used in thicker overlays can be finished normally.

Visit our web site at: www.graceconstruction.com

printed on recycled paper

W. R. Grace & Co. - Conn., 7221 West Parkland Court, Milwaukee, WI 53223 Tel: (414) 354-4400 Fax: (414) 354-5088

DARAWELD C, DAREX AEA and DARAVAIR are registered trademarks of W. R. Grace & Co. - Conn. We hope the information here will be helpful. It is based on data and knowledge considered to be true and accurate and is offered for the users' consideration, investigation and verification, but we do not warrant the results to be obtained. Please read all statements, recommendations or suggestions in conjunction with our conditions of sale, which apply to all goods supplied by us. No statement, recommendation or suggestion is intended for any use which would infringe any patent or copyright. W. R. Grace & Co. - Conn., 62 Whittemore Avenue, Cambridge, MA 02140. In Canada, Grace Canada, Inc., 294 Clements Road West, Ajax, Ontario, Canada L1S 3C6. This product(s) may be covered by patents or patents pending. Copyright 2001. W. R. Grace & Co. - Conn. MP-054B Printed in USA 12/01 FA/GPS/3M

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MP-054B>Daraweld C