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Fast Setting Cement FSC-4000

TEST METHODS

Fast Setting Cement FSC-4000: Is a quick-setting, low shrinkage, extendable, cement that can be used from 1/2 inch to 6 inches thick when mixed with sand and from 2 inches to 24 inches thick when mixed with sand and stone.  Follow ASTM test methods and guide line to choose and prepare your batch design and proper mix ratios. Contact EST Inc. for further technical assistances.

  1. Compressive strength of extended material per ASTM C109 (Mod.):

1 hour*            2000 psi
3 hour              4400 psi
1 day               5500 psi
28 day            6000 psi
*after final set

  1. Flexural strength of extended material per ASTM C78 (Mod.):

 5 hour              500 psi
1 day               650 psi
28 day             750 psi

  1. Bond strength of extended material per ASTM C882 (Mod.):

 1 day               1200 psi
20 day            2500 psi

  1. Freeze/thaw of extended material per ASTM C666:

1000 cycles     1.10% loss
Dynamic modulus 88%

  1. Scaling resistance per ASTM C672:

Number of cycles                Relative Modulus                  Remarks

72                                            97.9                             Slight scaling

180                                          89.1                             Loss of surface fines

252                                          84.1                             Increased loss

300                                          82.4                             Moderate scaling

  1. Modulus of Elasticity of extended material per ASTM C469:
    28 day            4,000,000
  2. Shall meet ASTM C150, ASTM C597, and ASTM C1157
  3. Shall be non-metallic with no added chlorides.
  4. Nano Catalyst-X and water should be pre measured to add to the (Mix) repair material per EST Inc.’s recommendations to slow down the set time, increase fluidity and strength, speed up the set time, increase bond strength, reduce plastic and crazing cracks, lighten the color of the mix, or darken the color of the mix.

Sand and coarse aggregate shall meet ASTM C33 and water shall be potable. Prepare surface, mix, place, and cure per manufacturer’s recommendations. Small field test must be performed to determine proper mix and batch design before perusing large area and projects.

MIXING GUIDE

References for ASTM Compliances Specification:

  1. ASTM C33-03 Standard Specification for Concrete Aggregates.
  2. ASTM C78-02 Standard Test Method for Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading.)
  3. ASTM C150-04 Standard Specification for Portland cement.
  4. ASTM C109/C109M-02 Standard Test Method for Compressive Strength of FSC- 4000 Cement Mortars. (Using 2-in. Cube Specimens)
  5. ASTM C469-02 Standard Test Method for Static Modulus of Elasticity and Poisson’s Ratio of Concrete in Compression.
  6. ASTM C597-02 Standard Test Method for Pulse Velocity through Concrete.
  7. ASTM C666/C666M-03 Standard Test Method for Resistance of Concrete to Rapid Freezing and Thawing.
  8. ASTM C672/C672M-03 Standard Test Method for Scaling Resistance of Concrete Surfaces Exposed to Deicing Chemicals.
  9. ASTM C1157-03 Standard Performance Specification for Hydraulic Cement.
  10. ASTM C882-99 Standard Test Method for Bond Strength of Epoxy-Resin Systems use with concrete.

DELIVERY, PACKAGING, STORAGE AND HANDLING:

Delivery: Super Sacks of this product to jobsite and distributors in 2 ton poly bags on pallets in enclosed truck trailers Reflecting manufacturer’s name, product name, and batch number.

Storage:  Store material in a dry area off the ground protected from rain, snow, and other sources of moisture. Protect material from temperature extremes. Store bulk sand and coarse aggregate in a well-drained area, on a clean, solid surface and cover to prevent contamination with foreign matter.

SURFACE PREPARATION:

  1. The perimeter of the area to be repaired shall be saw-cut slightly undercutting the sound concrete (without cutting reinforcing steel) or chipped perpendicular to the surface to a minimum depth of 2 inches.
  2. Mechanically remove unsound, contaminated concrete to a minimum depth of 2 inches.
  3. The aggregate fractured surface shall have a minimum profile of 1/8 inch.
  4. Concrete must be free of materials such as paint, oil, curing compound, bond breaker, etc. that will inhibit bonding.
  5. If placed directly on the subgrade, the subgrade must be well compacted. [Note to specifier: State the compaction you require.]
  6. Clean reinforcing steel by sandblasting or other mechanical means to achieve a white metal finish. [Note to specifier: Add special requirements concerning replacement of reinforcing that has lost too much cross-sectional area.]
  7. Thoroughly clean extraneous material such as dirt, loose chips, and dust from concrete surface. If compressed air is used, it need be free of oil.
  8. Concrete surface shall be saturated with potable water and standing water shall be removed from surface to achieve a Saturated, Surface Dry (SSD) condition.

MIXING:

  1. Organize personnel and equipment before mixing.
  2. Use 3 to 5 quarts of water per 50 pound bag of repair material. [Note to specifier: Less water means more strength and more water means a more flow-able consistency.]
  3. Mixed material should have a temperature of about 70°F. Warmer material will set faster than expected and cooler material will have slower strength gain. Control the mixed temperature by protecting the bags of repair material from temperature extremes and adjust the mixed temperature by using hot or cold water.
  4. Place 100 pounds of sand and 100 pounds of coarse aggregate in the mixer. Mix 16 fl-oz of Nano catalyst-X into 1.4 gallons of water and add that water to the mixer. Add cement and then mix for 2 to 3 minutes to achieve a uniform, lump-free consistency.
  5. Add as much as 6 gallons of water to bring the mix to a slump of 6 inches ± 1 inch.
  6. Do not add any other admixtures. Do not add sand, aggregate, or cement.Do not re-temper.

PLACEMENT:

  1. Place repair material onto the Saturated, Surface Dry (SSD) substrate.
  2. Place repair material only if surface and ambient temperatures are above 45°F and rising.
  3. Protect adjacent surfaces with drop cloths, waterproof paper, or other means to maintain them free of material splashes, water, and debris.
  4. Place repair material immediately after mixing.
  5. Work repair material firmly into sides and bottom of repair area to achieve good bond.
  6. Do not featheredge repair material.
  7. Do not wait for bleed water, since there will probably be none. Begin final finishing as soon as possible.

CURING:

  1. Begin water cure when repair area begins to lose its moist sheen and keep continuously wet until 1 hour after final set.

CLEAN UP:

  1. Clean mixer immediately after use or add mix water and begin mixing immediately for the next batch. Do not allow buildup of hardened repair material in the mixer, since this creates inefficient mixing and the heat generated accelerates later batches.
  2. Clean all tools immediately after use.
  3. Clean excess material from surrounding areas immediately.

HELPFUL TIPS:

  1. 15-35% of Fast Setting Cement FSC-4000 can be blended with Portland Cement
  2. FSC-4000 does not shrink as it cures – it is a cement that expands and fills in void spaces as it cures
  3. Regular Portland cement becomes pasty when mixing and applying – FSC-4000 maintains form while applying and curing
  4. The Fast Setting Cement FSC-4000 grabs onto the surface as it cures due to Nano fusion chemistry – the cement expands with the Nano needles
  5. Pot life is 10 to 15 minutes at 70°F
  6. 680lbs of Cement and Concrete Mix yields 1 yard of concrete
  7. 100 lbs of FSC-4000 Cement requires 40-45lbs of water to mix
  8. Pre-packed product – comes in super sacks that are 2 tons each
  9. Needs 3-4 weeks lead time
  10. Can be prepackaged in 88lbs paper bags – minimum requirement is 35 bags/pallet for shipping
  11. Cure color is slightly lighter than regular Portland Cement
  12. While curing, FSC-4000 will generate heat; we require that the cement stays cool and wet for 1-1/2 hours until final cure
  13. Will reach a minimum of 3000psi in 1-1/2 hours
  14. Can walk or drive on cured surface after 1-1/2 hours
  15. Most large jobs are suggested to be done at night time
  16. Use 1 lbs of citric acid  to 3 lbs of water to create a solution to clean equipment used in the cement laying process