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Weber - Saint-Gobain

webercem spray DS

webercem spray DS
webercem spray DS

Product Benefits

● Repairs to large areas of structural concrete ● Repairs of highway structures: bridge columns, piers, deck soffits, beams, abutments, parapets, retaining walls, tunnels and viaducts ● Repairs of marine structures: jetties, piers, quays, seawalls, concrete offshore platforms, docks and drydocks ● Repairs of fire damaged concrete structures ● Sealing of mine roadways and tunnels ● Structural enhancement of mineshafts ● Structural encasement of steel sections, pylons, chimneys, cooling towers ● Rock and embankment stabilisation

Polymer-modified, dry-spray, structural repair concrete

Product Features

About this Product

webercem spray DS is a pre-bagged, ready-to-use, polymer-modified, cementbased structural concrete. It contains graded inert limestone aggregates and dust suppressants. The formulation has been designed specially for dry process spray application to give high strength, low rebound and wastage, and to maximise the application thickness. 

Conformity testing to BS EN 1504-3 has confirmed that webercem spray DS meets the requirements for a Class R4 repair product. 

Features and Benefits

  • Economical - low rebound
  • Safe to use and handle. Relatively low dust emission, no siliceous aggregates, no caustic accelerators
  • High-build - up to 150 mm thickness can be applied in one pass on vertical and overhead faces encapsulating existing steel reinforcement
  • Rapid strength gain
  • Low permeability to water and chlorides
  • Complies with Highways Agency specifications for repairs to highway structures
  • Class 4 repair product meeting the requirements of BS EN 1504-3

Technical Services

weber's Customer Services Department has a team of experienced advisors available to provide on-site advice both at the specification stage and during application. Detailed specifications can be provided for specific projects or more general works. Site visits and on-site demonstrations can be arranged on request.

Technical helpline
Tel: (01525) 722110
Fax: (01525) 718988

Sales Contact

weber products are distributed throughout the UK through selected stockists and distributors. For UK sales enquiries and overseas projects, contact weber's Sales office.

Sales office
Tel: (01525) 722100
Fax: (01525) 718988

Documentation

Send or download the documents

You can either send the documents to an email address, or download it

Preparation & Application

Preparation

As with all repairs and applications it is essential to apply to a clean, sound surface free from all grease, oil, dust and loose material.

Concrete - Concrete substrates must be adequately prepared by a suitable mechanical method such as scabbling, grit blasting, water jetting or needle gunning, or by such other means as appropriate. Concrete must be carefully prepared to give a clean, freshlyexposed surface. The outer limits of concrete patches should be cut square to avoid feather edges.

Old concrete surfaces contaminated with oil or grease must be cleaned with a suitable detergent. Care must be taken to ensure that the oil or grease is removed from the surface and not simply spread over a larger area.

Steel Substrates - Reinforcing bars should be exposed leaving a clear gap at least 25mm behind the bars to allow for full encapsulation. Steel bars should be free of loose rust and grease. Ideally they should be grit blasted to a uniform grey metal finish to achieve first quality to BS 7079-A1 followed by degreasing with a suitable solvent.

Additional mesh reinforcement - Where there are no exposed bars and where the thickness of the sprayed concrete is 50mm or greater, then mesh reinforcement must be provided. Mesh helps to evenly distribute stresses due to thermal movement or shrinkage and reduces the risk of cracking especially on corners. The mesh should be designed and fixed in accordance with the guidelines of the Code of Practice for Sprayed Concrete published by the Concrete Society.

Reducing suction - Before using webercem spray DS, the concrete substrate must be thoroughly prewetted for at least 30 minutes and then all surplus water removed. Water from the spray nozzle followed by high pressure air is the method commonly adopted.

Application

Guidelines on the method of working are detailed in the Code of Practice for Sprayed Concrete published by the Concrete Society and should be strictly observed.

webercem spray DS should be emptied from the bags directly into the hopper of the dry process spraying machine. The equipment should be balanced so as to produce a steady stream of material with minimal pulsing.

The amount of water added at the spraying nozzle will be controlled by the nozzleman - too low an addition will increase rebound and dust emission; too wet a mix will slump. The correct amount of water can be judged by the appearance of the sprayed concrete; any glossiness of the surface should be avoided.

In case of a long delay between applied coats of the sprayed concrete, the surface of the newly applied hardened concrete should be water jetted using maximum air pressure and water flow through the nozzle to ensure that any laitance and all weak or loose material has been removed.

The surface should be allowed to drain before proceeding with the next coat.

webercem spray DS can be applied down to 15 mm thickness but, because of the higher cement content, (due to aggregate loss through rebound) there is the likelihood of greater shrinkage. The recommended minimum thickness is 25 mm. The recommended minimum thickness for protection over steel is 40 mm.

Finishing - Any necessary trowelling or profiling should be done immediately after spraying has finished. 

An 'as-sprayed' appearance is recommended, but if overcoating is to follow, finish with a wooden float or damp sponge. Avoid the use of steel floated finishes as these normally result in crazing and cracking. The effect is, however, much less with this product.

Packaging, Health & Safety

Packaging

webercem spray DS is supplied in 25kg polylined paper sacks.

Coverage / Yield

Approximately 11·5 litres per 25kg bag, but allowance must be made for rebound and profiling.

Storage and Shelf Life

When stored unopened in a dry place at temperatures above 5°C, shelf life is 12 months from date of manufacture.

Health and Safety

Contains cement (Contains chromium (VI). May produce an allergic reaction. Harmful by inhalation. Irritating to eyes and skin. Keep out of the reach of children. In case of contact with eyes, rinse immediately with plenty of water and seek medical help. After contact with skin, wash immediately with plenty of soap and water. Wear suitable protective clothing, gloves and eye/face protection.