Product Data Sheet Show all documents
SikaEmaco® 440

SikaEmaco® 440

(former MEmaco S 440)

Low-dust, pourable and pumpable, pre-exetended, self-consolidating repair mortar

SikaEmaco® 440 is a low-dust, one-component, shrinkage-compensated, self-consolidating repair mortar. It is designed for large volume repairs, including structural elements in applications from 38 mm (1.5 in)  to full depth.

  • The dual expansion system compensates for shrinkage in plastic and hardened states
  • Low-dusting for added worker comfort and safety
  • High early strength allows early form removal
  • Low permeability protects against carbon dioxide and chloride intrusion
  • Excellent freeze/thaw resistance for durability in cold, wet environments
  • Flowability makes it ideal for placement by pumping or pouring into congested locations
  • Self-consolidation minimizes honeycombing without vibration
Product Data Sheet Show all documents

Usage

  • Interior and exterior
  • Large-volume structural repairs
  • Repair or replacement of concrete elements
  • Formed horizontal, vertical, and overhead repairs

Substrates
  • Concrete
 

Advantages

  • The dual expansion system compensates for shrinkage in plastic and hardened states
  • Low-dusting for added worker comfort and safety
  • High early strength allows early form removal
  • Low permeability protects against carbon dioxide and chloride intrusion
  • Excellent freeze/thaw resistance for durability in cold, wet environments
  • Flowability makes it ideal for placement by pumping or pouring into congested locations
  • Self-consolidation minimizes honeycombing without vibration

Packaging

25 kg (55 lb) polyethylene-lined bags

Product Details

Product Information

Composition / Manufacturing

Proprietary blend of cement, graded aggregate, shrinkage-compensating agents, and additives

Shelf Life

1 year when properly stored

Storage Conditions

Store in unopened containers in cool, clean, dry conditions

Density

Fresh wet density 2,275 kg/m3 (142 lb/ft3)

(ASTM C138)
Technical Information

Compressive Strength

51 mm (2 in) cubes

1 day

17.2 MPa (2500 psi)
7 days34.5 MPa (5000 psi)
28 days41.4 MPa (6000 psi)

76 mm x 152 mm (3 in x 6 in) cylinders

28 days

34.5 MPa (5000 psi)

Tensile Strength in Flexure

28 days7.9 MPa (1150 psi)

Shear Strength

28 days20.7 MPa (3000 psi)

Shrinkage

28 days

0.035 % (350 μstrain)

(ASTM C157, (unmodified))

21 days

0.0611 % (611 μstrain)

(ASTM C157, (modified))

Coefficient of Thermal Expansion

9.9 cm/cm/°C x 10-6 (5.5 in/in/°F x 10-6)

Design Considerations

Dust reduction for SikaEmaco® 440 vs. control

70 %

(DIN55992-2)

Potential Alkali-Silica Reactivity

<  0.10 % Aggregate (Innocuous expansion)

(ASTM C1260)

Freeze thaw resistance

100 % RDM 

(ASTM C666)

Splitting Tensile Strength

28 days

3.4 MPa (500 psi)

(ASTM C496)

Application

Application Information

Flowability

Slump Flow*635 mm (25 in)

Visual Stability Index

0 (Highly Stable - No Bleeding)
J-Ring Slump Flow* 625 mm (24.5 in)
Passing Ability10 mm (0.5 in)  No visible blocking

*2.6 L (0.68 US gal) water per 25 kg (55 lb) bag, with minimum water addition
Consumption

Yield

Approx. 0.012 m3 (0.43 ft3) per 25 kg (55 lb) bag
Application steps

SURFACE PREPARATION

Concrete

Concrete must be structurally sound and fully cured (28 days). Saw cut the perimeter of the area being repaired into a square with a minimum depth of 13 mm (½ in). Refer to current ICRI Guideline no. 310.2R for surface preparation requirements to permit proper bond.

  

Reinforcing Steel

Remove all oxidation and scale from the exposed reinforcing steel in accordance with ICRI Technical Guideline No. 310.1R. For additional protection from future corrosion, coat the prepared reinforcing steel with SikaTop® Armatech® 110 EpoCem®.

MIXING

Ensure that SikaEmaco® 440 is thoroughly mixed; a forced-action mixer is essential. Mixing in a suitably sized container using an appropriate paddle with a slow-speed (400–500 rpm) heavy-duty drill is acceptable. Do not use free-fall mixers.

Measure 2.6 L (0.68 US gal) of potable water and pour 2.3 L (0.61 US gal) into the mixer. With the machine in operation, add one (1) full 25 kg (55 lb) bag of SikaEmaco® 440 and mix for one (1) minute before adding the rest of the water. Always add powder to the water. The quantities mixed may be scaled up as required. Mix for an additional 2–3 minutes to obtain a smooth consistency. When using the drill-and-paddle mixing method, place the complete 2.6 L (0.68 US gal) of water in the mixing drum. With the paddle rotating, add one (1) full 25 kg (55 lb) bag of SikaEmaco® 440 and mix for three (3) minutes to reach a smooth, even consistency.

Note: Depending on the ambient temperatures and the desired consistency, additional water may be added. The total water content should not exceed 2.7 L (0.71 US gal) per 25 kg (55 lb) bag.

 

APPLICATION

Build forms in accordance with ACI 347R. Keep the unrestrained surface area of the repair to a minimum. Saturate the prepared concrete substrate by filling the prepared formwork with clean water 24 hours before placement. Immediately before the placement of SikaEmaco® 440, completely drain this water and seal the drainage outlets, leaving the substrate saturated surface-dry (SSD) with no ponded water remaining. In jobsite circumstances where the formwork cannot be filled with water to achieve an SSD surface, the prepared concrete substrates must be thoroughly hosed down with clean water to achieve an equal level of saturation. Apply the repair material with sufficient pressure to ensure intimate contact with the substrate. A long open-time bonding agent such as SikaEmaco® P 124 may be used in place of a saturated substrate. In such a case, place the SikaEmaco® 440 before the bonding agent becomes tack-free. Immediately after mixing, pump or pour the SikaEmaco® 440 into the formed area. The material does not require vibrating. The recommended application range of SikaEmaco® 440 is from 4 to 29 °C (40 to 85 °F). Follow ACI 305 and 306 for hot or cold weather guidelines.

CURING TREATMENT

Leave the formwork in place until the compressive strength reaches 17.2 MPa (2500 psi)  or a strength specified by the engineer. Cure with an approved curing compound compliant with ASTM C309 or preferably ASTM C1315. If the repair area will receive a coating, wet curing is recommended.

CLEAN UP

Clean tools and equipment with clean water immediately after use. Cured material must be removed mechanically.

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