Product Data Sheet Show all documents
Sikacrete®-401 Rapid

Sikacrete®-401 Rapid

Fast Setting Class R4 Dry Sprayed Micro-Concrete for Large Volume Repairs

Sikacrete®-401 Rapid is a cement based, polymer modified, one-component, fast setting repair mortar containing silica fume and high range water-reducing agents, meeting the requirements of Class R4 of EN 1504-3. Formulated for machine applications using the dry spray process with set accelerators.

  • One component, ready to use.
  • Non-silica aggregates, so no risk of alkali silica reactivity (ASR).
  • Easy and quick to set up.
  • Low rebound losses and dust formation during the spraying process.
  • High build - layer thicknesses in one application overhead up to 100mm are possible without any additional mesh reinforcement.
  • Rapid strength gain.
  • Very low shrinkage. 
  • Overcoatable with Sika® reprofiling / levelling / smoothing mortars and coatings.
  • EN 1504-3 Class R4.
  • Fast Initial and final set times.
  • Ideal for limited possession work, or tidal applications. 
Product Data Sheet Show all documents

Usage

  • Large scale repairs of weathered, cracked, spalling and / or damaged structural concrete.
  • Highway works. 
  • Bridges (columns, piers, sofits, beams, parapets, abutments, etc.).
  • Marine structures (quays, piers, jetties, sea walls, docks, dry docks, marinas, offshore platforms, cofferdams, caissons, etc.).
  • New construction. 
  • Lining and structural enhancement of mines and tunnels.
  • Viaducts and culverts.
  • Faςades and retaining walls. 
  • Embankment and rock stabilisation.
  • Encasing steel sections.
  • Buildings.
  • Fire damaged structures.
  • Cooling towers, chimneys and pylons.
  • For exterior and interior use.
  • In place of Class R1, R2 and R3 mortars.
  • Particularly suited to limited possession and tidal works. 
 
  • Concrete restoration (Principle 3, Method 3.3 of EN 1504-9): Restoring the original concrete to the originally specified profile and function. Restoring the concrete structure by replacing part of it by spraying concrete or mortar.
  • Structural strengthening (Principle 4, Method 4.4 of EN 1504-9): Increasing or restoring the structural load bearing capacity of an element of the concrete structure by adding mortar or concrete.

Advantages

  • One component, ready to use.
  • Non-silica aggregates, so no risk of alkali silica reactivity (ASR).
  • Easy and quick to set up.
  • Low rebound losses and dust formation during the spraying process.
  • High build - layer thicknesses in one application overhead up to 100mm are possible without any additional mesh reinforcement.
  • Rapid strength gain.
  • Very low shrinkage. 
  • Overcoatable with Sika® reprofiling / levelling / smoothing mortars and coatings.
  • EN 1504-3 Class R4.
  • Fast Initial and final set times.
  • Ideal for limited possession work, or tidal applications. 

Packaging

25 kg bags

Colour

Grey powder

Product Details

Sustainability / Certifications / Approvals

APPROVALS / STANDARDS

CE marking and declaration of performance based on EN 1504-3 Products and systems for the protection and repair of concrete structures — Structural and non-structural repair.
Product Information

Chemical Base

Portland cement, redispersable polymers, selected aggregates, silica fume and additives

Shelf Life

6 months

Storage Conditions

Store properly in original unopened, sealed and undamaged packaging in dry and cool conditions

Maximum Grain Size

Dmax: ~2mm

Density

~2300 kg/m3

(EN 12190)

NOTE: Hardened density determined after 28 days.

Soluble Chloride Ion Content

<0.01%

(EN 1015-17)
System information

System Structure

Layer

Product

Function

Bonding Primer / Reinforcement Corrosion Protection

Sika® MonoTop®-1010

Normal Use

SikaTop® Armatec®-110 EpoCem®

Demanding Requirements

Concrete Repair Mortar

Sikacrete®-401 Rapid

High Performance Requirements

Levellling / Smoothing MortarSika® MonoTop®-3020Normal Use
Sikagard®-720 EpoCem®Demanding Requirements

In addition to the above, Sika® also offer Sikagard® Anti-Carbonation protective coatings and the following Ancillary Products for Corrosion Management:

  • Sika® FerroGard®-903+ Liquid Corrosion Inhibitor
  • Sika® Margel VPI 580 Capsule Corrosion Inhibitor
  • Sika® Galvashield® Galvanic Anodes
  • Sika® Ebonex® Cathodic Protection Anodes
Technical Information

Compressive Strength

1 Day

~35 MPa

3 Days

~45 MPa

7 Days

~50 MPa

28 Days~60 MPa

Modulus of Elasticity in Compression

~33 GPa

(EN 13412)

Flexural Strength

28 Days

~9 MPa

Tensile adhesion strength

>2.0 MPa

(EN 1542)

Coefficient of Thermal Expansion

13.5 x 10-6 / oC

(EN 1770)

Electrical Resistivity

28 Days

~16 kΩcm

Capillary Absorption

~0.36 kg·m-2·h-0.5

(EN 13057)

Freeze Thaw De-Icing Salt Resistance

Good resistance with no visible changes after 50 cycles

(EN 13687-1)

Reaction to Fire

EuroClass A1

Application

Application Information

Layer Thickness

Minimum 15mm / Maximum 150mm (Vertical) and 100mm (Overhead)

Ambient Air Temperature

Minimum +3oC / Maximum +30oC

Substrate Temperature

Minimum +3oC / Maximum +30oC

Initial set time

~12 minutes

(EN 13294)

Final set time

~16 minutes

(EN 13294)

NOTE: Typical set time at 20oC. 
Consumption

Consumption

~2.3 kg/m2/mm

NOTE: This value is for guidance only, and actual use will depend on substrate roughness and thickness of layer applied. 
Application steps

MIXING

Sikacrete®-401 Rapid is fed into the dry process spraying machine which should be of suitable size for the repair areas to reduce wastage and rebound. The amount of water added is controlled by the nozzleman at the nozzle and should be sufficient to prevent lump and dust. Rebound will be increased with unsuitably sized spraying machine, compressor, nozzle type, dry mixture and thin layers.

APPLICATION

Reinforcement Corrosion Protection:

Where a reinforcement coating is required, the application of the repair mortar shall be applied when the the reinforcement coating has cured (minimum finger nail hard). Refer to the System Information above for compatible Sika® products and refer to the relevant Product Data Sheet(s) for more detailed information about the reinforcement corrosion product(s). The sprayed repair mortar shall be placed onto the pre-wetted substrate between the minimum and maximum layer thicknesses without the formation of voids and loose rebound material. Where layers are to be built up to prevent sagging or slumping, each layer should be allowed to stiffen before applying subsequent layers 'wet-on-wet'. When layers cannot be applied 'wet-on-wet', pre-wet the surface and allow to surface dry to a dark matt appearance. Sikacrete®-401 Rapid is finished by leaving ‘as shot’ or striking off with a straight edge and closing the surface with a semi stiff damp brush (thereby creating a 'brush finish'). Reference shall be made to EN 1504-10 for specific requirements, the Code of Practice for Sprayed Concrete issued by the Concrete Society and any other guidelines that are specific to the structure.

CURING TREATMENT

It is essential to cure Sikacrete®-401 Rapid immediately after application for a minimum of 3 days to ensure full cement hydration and to minimise cracking. Use polythene sheeting taped down at the edges or other approved method. Curing compounds shall not be used when they adversely affect subsequently applied products and systems. Reference shall also be made to EN 1504-10 for specific requirements.

Documents