Product Data Sheet Safety Data Sheet Show all documents

Sika MonoTop®-4012

High-performance, more sustainable, Class R4 concrete repair mortar

Sika MonoTop®-4012 is a one-part, cementitious, fibre reinforced, low shrinkage repair mortar. It contains recycled raw materials and can reduce the carbon footprint application activity calculations.

  • Uses recycled raw materials.
  • Layer thickness 6 to 120 mm.
  • Sulphate resistant.
  • Hand and machine application (wet spray technique).
  • Easy to apply.
  • Very low shrinkage.
  • Dust reduced for a cleaner, healthier environment. 
  • Good resistance to sea water.
  • Does not require a bonding primer.
  • Can be safely used in contact with steel (very low chloride content). 
  • Low permeability.
  • EuroClass A1 reaction to fire rating.
  • Class R4 of EN 1504-3. 
  • Resistant to sulfuric acid attack (exposure classes XWW1 and XWW3). 
  • Drinking Water Certified.
Sika MonoTop®-4012
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Product Data Sheet Safety Data Sheet Show all documents

Usage

Sika MonoTop®-4012 is used to repair all types of reinforced concrete structures and components for:
  • Buildings.
  • Civil engineering structures.
  • Dams.
  • Marine structures.
  • Suitable for interior or exterior applications.
  • Sewage and waste water treatment plants.
The product is used for:
  • Restoration work (Principle 3, method 3,1 and 3,3 of EN 1504-9). Repair of spalling and damaged concrete in infrastructure and superstructure works.
  • Structural strengthening (Principle 4, method 4,4 of EN 1504-9). Increasing the bearing capacity of the concrete structure by adding mortar.
  • Preserving or restoring passivity (Principle 7, method 7,1 and 7,2 of EN 1504-9) - Increasing cover with additional mortar and replacing contaminated or carbonated concrete. 
 

Advantages

  • Uses recycled raw materials.
  • Layer thickness 6 to 120 mm.
  • Sulphate resistant.
  • Hand and machine application (wet spray technique).
  • Easy to apply.
  • Very low shrinkage.
  • Dust reduced for a cleaner, healthier environment. 
  • Good resistance to sea water.
  • Does not require a bonding primer.
  • Can be safely used in contact with steel (very low chloride content). 
  • Low permeability.
  • EuroClass A1 reaction to fire rating.
  • Class R4 of EN 1504-3. 
  • Resistant to sulfuric acid attack (exposure classes XWW1 and XWW3). 
  • Drinking Water Certified.

Packaging

25 kg bag

Colour

Grey powder

Product Details

Sustainability / Certifications / Approvals

ENVIRONMENTAL INFORMATION

  • Conforms with LEED v4 MR credit: Building product disclosure and optimisation — Environmental Product Declarations (option 1).

  • Conforms with LEED v4 MR credit: Building product disclosure and optimisation — Sourcing of raw materials (option 2).

  • Conforms with LEED v4 MR credit: Building product disclosure and optimisation — Material ingredients (option 2).

  • Specific Environmental Product Declaration (EPD) in accordance with EN 15804. EPD independently verified by BRE Global. 

     

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.

  • Specific electrical resistivity DIN EN ISO 12696, Sika MonoTop®-4012, OST. 

 

       

       

        

  • Tensile bond strength after vibrational stress DAfStb guideline, Sika MonoTop®-4012, Kiwa, Test report No. P 11864-1-E.

  • Sulphate Resistance ÖNORM B 3309-1, Sika MonoTop®-4012, HARTL, No. 013108/2. 

  • Drinking Water Certificate: Water Regulations Advisory Scheme Ltd (WRAS) Approval Number: 2305560. 
Product Information

Chemical Base

Sulphate resistant and replacement cement, selected aggregates and additives.

Shelf Life

12 months from date of production

Storage Conditions

The product must be stored in original, unopened and undamaged sealed packaging in dry conditions at temperatures between +5 °C and +35 °C. Protect the product from direct sunlight. Always refer to packaging.

Refer to the current Safety Data Sheet for information on safe handling and storage.

Maximum Grain Size

Dmax: 2 mm

Soluble Chloride Ion Content

≤ 0.05 %

(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

Sika MonoTop®-4012

High strength requirements

Levelling mortar

Sika MonoTop®-3020

Normal use

Sikagard®-720 EpoCem®

Demanding requirements
Technical Information

Abrasion Resistance

Wear Resistance Böhme, wet procedure

< 12 cm3/50 cm2

Compressive Strength

Class R4

(EN 1504-3)

Time

Compressive strength

1 day

~19 MPa

7 days

~43 MPa

28 days

~56 MPa

Modulus of Elasticity in Compression

≥ 20 GPa

(EN 13412)

Flexural Strength

Time

Tensile strength in flexure

1 day

~4.4 MPa

7 days

~7.0 MPa

28 days

~8.0 MPa

Tensile adhesion strength

≥ 2.0 MPa

(EN 1542)

Shrinkage

~500 μm/m (+20 °C / 65 % relative humidity at 28 days)

(EN 12617-4)

Restrained Shrinkage / Expansion

≥ 2.0 MPa

(EN 12617-4)

Electrical Resistivity

~32 kΩ·cm at 100% relative humidity @ 20°C

(ISO 12696)

Thermal Compatibility

≥ 2.0 MPa (Part 1 - Freeze-Thaw)

(EN 13687-1)

Capillary Absorption

≤ 0.5 kg∙m-2·h-0.5

(EN 13057)

Water Penetration under Pressure

~10 mm 

(EN 12390-8)

Chloride Ion Diffusion Resistance

Low: < 2000 coulombs

(ASTM C 1202)

Chloride diffusion coefficient: 4.8 x 10-12 m2/s

(EN 12390-11)

Carbonation Resistance

dk ≤ control concrete MC (0.45)

(EN 13295)

Reaction to Fire

EuroClass A1

(EN 1504-3)

Application

Application Information

Fresh mortar density

~2.1 kg/L

Layer Thickness

Orientation

Minimum

Maximum

Horizontal

6 mm

120 mm

Vertical

6 mm 

~85 mm (~120 mm in localised areas)

Overhead

6 mm 

~30 mm (~50 mm in localised areas)

Product Temperature

Maximum

+30 °C

Minimum

+5 °C

Ambient Air Temperature

Maximum

+30 °C

Minimum

+5 °C

Mixing Ratio

3.75 to 3.9 L of water for a 25 kg bag

Substrate Temperature

Maximum

+30 °C

Minimum

+5 °C

Pot Life

~60 minutes at +20 °C
Consumption

Consumption

~1.9 kg/m2/mm

Note: Consumption data is theoretical and does not allow for any additional material due to surface porosity, surface profile, variations in level, wastage or any other variations. Apply product to a test area to calculate the exact consumption for the specific substrate conditions and proposed application equipment.

Yield

25 kg of powder yields ~13.7 L of mortar
Application steps

EQUIPMENT

Select the most appropriate equipment required for the project:

SUBSTRATE PREPARATION EQUIPMENT

  • Mechanical hand-held tools.

  • High or ultra-high pressure water blasting equipment.

STEEL REINFORCEMENT EQUIPMENT

  • Abrasive blast cleaning equipment.

  • High pressure water blasting equipment.

MIXING EQUIPMENT

  • Clean mixing containers.

  • Small quantities: low speed electric single or double paddle mixer (< 500 rpm).

  • Large quantities: Forced action mixer.

APPLICATION EQUIPMENT

  • Hand applied: Plasterers hawk, trowel.

  • Wet Spray: All-in-one mixing and spraying machine or separate spraying machine and all associated ancillary equipment to suit application volumes.

FINISHING EQUIPMENT

  • Trowel (PVC or wooden).

  • Sponge.

Also refer to Site Handbook ‘Repair of Concrete Structures – Patch Repair and Spray Applications’. 

MIXING

HAND APPLIED AND WET SPRAY APPLICATION

  1. Pour the minimum amount of water into a suitable clean mixing container or equipment.
  2. Gradually add the powder to the water while stirring slowly.
  3. Mix thoroughly for at least for 3 minutes, add additional water if necessary. Note: Do not add more water than the maximum specified amount.
  4. Adjust to the required consistency to achieve a smooth consistent mix.
  5. Check the consistency after every mix.

APPLICATION

IMPORTANT

Protect from frost

Protect freshly applied material from freezing and frost to prevent cracking.

IMPORTANT

Application in the direct sun or strong winds

Avoid application in direct sun, strong winds or both to reduce the risk of the product cracking.

REINFORCEMENT CORROSION PROTECTION COATING

  1. Where a reinforcement coating is required, apply to the whole exposed circumference Sika MonoTop®-1010 or SikaTop® Armatec®-110 EpoCem®. Refer to the individual Product Data Sheets.

BONDING PRIMER

On a well prepared and roughened substrate or for a sprayed application, a bonding primer is generally not required.

When a bonding primer is required to achieve the required adhesion values, use Sika MonoTop®-1010 or SikaTop® Armatec®-110 EpoCem®. Refer to the individual Product Data Sheets.

REPAIR MORTAR MANUAL APPLICATION

IMPORTANT

Substrate pre-wetting

Insufficient substrate saturation prior to application will cause the mortar to not gain full mechanical properties.

  1. Only apply the product to stable, prepared substrates.
  2. Thoroughly pre-wet the prepared substrate for a minimum of 2 hours before application.
  3. Keep the surface wet and do not allow to dry.
  4. The final pre-wetted surface must achieve a dark matt appearance (i.e. saturated surface dry).

IMPORTANT

Sagging or slumping of built up layers

Allow each layer to slightly harden and remain wet before applying subsequent layers.

  1. Remove excess water from within the surface pores and cavities with a clean sponge.
  2. Make a scratch coat using the repair mortar.
  3. Apply the scratch coat over the complete substrate surface to form a thin layer to fill surface pores or cavities.
  4. IMPORTANT Do not apply as a 'feather edge'. Apply the repair mortar onto the scratch coat ‘wet-on-wet’ between the minimum and maximum layer thicknesses without the formation of voids.

REPAIR MORTAR SPRAYED APPLICATION - WET SPRAY

IMPORTANT

Substrate pre-wetting

Insufficient substrate saturation prior to application will cause the mortar to not gain full mechanical properties.

  1. Only apply the product to stable, prepared substrates.
  2. Thoroughly pre-wet the prepared substrate for a minimum of 2 hours before application.
  3. Keep the surface wet and do not allow to dry.
  4. The final pre-wetted surface must achieve a dark matt appearance (i.e. saturated surface dry).

IMPORTANT

Sagging or slumping of built up layers

Allow each layer to slightly harden and remain wet before applying subsequent layers.

  1. Remove excess water from within the surface pores and cavities with a clean sponge.
  2. Place the wet mixed repair mortar into the spraying equipment.
  3. Spray the repair mortar onto the pre-wetted substrate between the minimum and maximum layer thicknesses without the formation of voids.

SURFACE FINISHING

IMPORTANT

Adding water during surface finishing

Do not add water during the surface finishing as this can cause discolouration and cracking.

  1. Allow mortar to surface harden.
  2. Surface finish to the required surface texture using a stainless steel, steel, PVC or wooden float.

COLD WEATHER WORKING

Store bags in a warm environment and use warm water to assist with achieving strength gain and maintaining physical properties.

HOT WEATHER WORKING

Store bags in a cool environment and using cold water to assist with controlling the exothermic reaction to reduce cracking and maintaining physical properties.

CURING TREATMENT

  • Protect fresh mortar immediately from premature drying using an appropriate curing method, such as curing compound, moist geotextile membrane or polythene sheet.

  • Curing compounds must not be used when they could adversely affect subsequently applied products and systems.

 

CLEANING OF TOOLS

Clean all tools and application equipment with water immediately after use. Hardened material can only be removed mechanically.

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