How To Apply MasterEmaco® T 545 Repair Mortar

BASF MasterEmaco T 545 Chemical Action Repair Mortar packaged in a 50 pound bag
BASF MasterEmaco T 545 Chemical Action Repair Mortar packaged in a 50 pound bag

Watch how to apply MasterEmaco T 545 chemical action repair mortar (Video Transcript). Then learn more about the materials, tools and accessories required to do the job safely and efficiently.

MasterEmaco T 545 Repair Mortar Application Video Transcript

  • Concrete must be structurally sound and fully cured. Surface should be prepared following current ICRI Guideline No. 310.2R surface preparation guide.
  • Add 4 pints (1.9 L) of potable water into a clean mixing container
  • Gradually sift in powder, 1/3 of the bag at a time, while mixing continuously at a slow speed
  • Mix material for 90 seconds to ensure a uniform, lump-free consistency
  • Work material firmly into the bottom and sides of patch. Avoid feather edging.
  • Placement time is approximately 5 minutes
  • Level MasterEmaco T 545 and screed to the elevation of surrounding concrete. Minimal finishing is required.
  • No curing is required. Protect from rain immediately after placing.
  • Refer to the MasterEmaco T 545 technical data guide for more information.

Repair Mortar Application Materials, Tools and Accessories

Materials, Tools and Accessories – Shown

  • Protective Gloves – 4-mil nitrile, disposable glove
  • Protective Clothing – Long-sleeve sweatshirt
  • MasterEmaco T 545 Repair Mortar – Very rapid-setting, chemical action, repair mortar
  • Mixing Container
  • Cordless Drill
  • Mixing Paddle
  • 2″ x 4″ Screed Board.

Precautionary Accessories – Not Shown

Refer to the MasterEmaco T 545 Safety Data Sheet (SDS) for more information.

  • Eye Protection
  • Face Protection
  • Respiratory Protection – In case of inadequate ventilation.

Citations

Last Modified: September 13, 2019

How To Apply MasterEmaco® P 124 Primer

BASF MasterEmaco P 124 Steel Reinforcement Primer & Bonding Agent packaged in a 6-gallon kit
BASF MasterEmaco P 124 Steel Reinforcement Primer & Bonding Agent packaged in a 6-gallon kit

Watch how to apply MasterEmaco P 124 steel reinforcement primer and bonding agent (Video Transcript). Then learn more about the materials, tools and accessories required to do the job safely and efficiently.

MasterEmaco P 124 Primer Application Video Transcript

  • Concrete must be structurally sound and fully cured
  • Remove all oxidation and scale from the exposed reinforcing steel in accordance with Technical Guide No. 310.1R
  • Surface to be repaired must be saturated-surface dry (SSD) prior to the application of MasterEmaco P124, when used as a bonding agent with ICRI Technical Guide No. 310.1R
  • Precondition all components to 70 degrees Fahrenheit (21 degrees Celsius)
  • Pour contents of Part A and Part B into a clean mixing bucket
  • Blend the components for 2 minutes
  • Slowly add all of Part C. Use the appropriate drill to thoroughly mix the components.
  • Apply MasterEmaco P 124 using a stiff brush or broom
  • Work the bonding agent thoroughly into the substrate
  • When applying to rebar, two coats of 10 mils (0.25 mm) are required
  • Protect the bonding agent from direct sunlight and temperature above 95 degrees Fahrenheit (35 degrees Celsius)
  • Refer to the MasterEmaco P 124 technical data guide for more information.

Primer Application Materials, Tools and Accessories

Materials, Tools and Accessories – Shown

  • Protective Gloves – 4-mil nitrile, disposable glove
  • Protective Clothing – Long-sleeve sweatshirt
  • MasterEmaco P 124 Primer – Water-based epoxy-cementitious bonding agent, also used to coat and protect rebar
  • Cordless Drill
  • Paddle – Jiffy Mixer or similar
  • Drill Attachment/Brush
  • Brush.

Precautionary Accessories – Not Shown

Refer to the MasterEmaco P 124 Safety Data Sheet (SDS) for more information.

  • Eye Protection
  • Face Protection
  • Respiratory Protection – In case of inadequate ventilation.

Citations

Last Modified: August 30, 2019

Fort Casey Restoration – Whidbey Island, WA

Coastal artillery gun at Fort Casey State Park, Whidbey Island, Washington
Fort Casey Coastal Gun Battery – Whidbey Island, Washington

Project Name: The Fort Casey and Battery Moore Project

Fort Casey History

Located on Whidbey Island in Washington State, Fort Casey was one of 29 locations chosen for updated reinforcement. As a part of what was known as the “Triangle of Fire”, Fort Case, Fort Worden and Fort Flagler had to defend the entrance of the Puget Sound. Construction began in 1897 and ended in 1901 but the fort was equipped and used for training until the mid-1940’s.

In 1955, Washington State Parks acquired Fort Casey and opened it up for public use. With the help of some government funds, the fort grounds had regular maintenance but other parts of the Battery Moore section were in major need of some repairs. Most of the original concrete showed major signs of damage due to substantial corrosion of the reinforcing steel.

Finally in 2006, the Washington State Parks department made a budget of $600,000 to begin a full structural overhaul on the Battery Moore. The restoration was going to return the structure to its original glory while adding some modern elements along the way and with the use of batteries, lights and speakers it would turn the Battery into a live action example of how Fort Casey operated in the early 1900’s.

Phase 1 of the Repair

The engineering and architect team inspected and developed a scope of work for the impending repairs. After a full survey was performed, the focus was not only on repairing the existing structures but also about protecting against the brutal salt air from the Puget Sound. With all of this in mind, the design team put together a scope of work for Phase 1 that included repairs on gun emplacements 3 and 4 with gun emplacements 1 and 2 to be done in Phase 2.

During Phase 1, after the concrete preparation was completed, the repair work began with the cathodic protection on the existing square bar steel reinforcement. This was crucial to the project as the original concrete was mixed using local sand and aggregates directly from the sound. The existing concrete showed high levels of chloride so any materials used had to prevent future corrosion. All repair mortars were highly polymer modified and included integral corrosion inhibitors to protect the surrounding steel. There was also a significant amount of epoxy injections performed on many of the vertical surfaces while fiber-reinforced polymer (FRP) materials were used to strengthen the deteriorated columns.

Phase 2 of the Repair

Over the next 10 years, additional funding had to be secured to begin Phase 2, which came out to approximately $200,000 (a third of the Phase 1 budget). To repair 1 and 2 of the gun emplacements, the scope of work had to be paired down significantly. With another 10 years of deterioration to take into consideration, the focus of Phase 2 was mainly to restore the structural integrity of the Battery Moore.

When Phase 2 began, the team noted that there were areas with extreme cracking and some critical areas on the verge of collapse. While preparing the concrete, the source of existing concrete aggregate needed to be addressed. Large, rounded river rocks (some 4 inches in diameter) were used throughout the gun emplacements. In conjunction with this system, the existing concrete became extremely soft. As the crew removed the deteriorated concrete, some areas became so fragile that they would disintegrate on impact with an electric chipping hammer. No heavy equipment was used in the prep work due to the fragile structural capacity of the existing concrete. With most of the square steel reinforcement intact after sand blasting, the existing reinforcement was coated with epoxy rebar stirrups to support the repairs.

Sika® Product Solution

Both Phase I and Phase II of the Fort Casey restoration project used these Sika products:

  • SikaQuick® VOH and SikaTop® 123 for the vertical and overhead repairs
  • Sikagard® 705 L to permeate the concrete substrates using silane technology
  • Sikadur® 31 to bond concrete and seal cracks around injection ports
  • Sikadur 52 to seal concrete slabs and protect against water, chlorides and other elements that cause deterioration
  • Sikaflex® 1A to seal all vertical and horizontal joints.

Conclusion

Sika was honored to contribute products to help aid in the restoration of this historical landmark. Overall, the impact of both repair phases were very extensive but the contractor was able to restore the Battery Moore into a safe and education public area. People are now able to wander the grounds and begin to feel the sense of what it was like to work and live in Fort Casey during both World Wars.

Citations

Last Modified: January 27, 2019