ADHESIVES – SEALANTS – CHEMICAL PRODUCTS FOR BUILDING

MAPEI CFRP SYSTEM

INSTALLATION GUIDELINES

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MAPEI NEW ZEALAND LTD, 30 Fisher Crescent, Mt Wellington
PO Box 12-326 Penrose, Auckland, NEW ZEALAND
Tel: 09 921-1994 Fax: 09 921-1993 E-mail: enquiries@mapei.co.nz Website: www.mapei.co.nz
Mapei CFRP System
Application Guidelines
1.0 Introduction
This document offers a guide to the application of CFRP System in the strengthening of
concrete, steel and timber structures. It addresses strengthening by the application of
carbon fibre reinforced polymers (CFRP), aramid fibre reinforced polymers (AFRP),
glass fibres reinforced polymers (GFRP) and precured FRP system externally to the
structures.

2.0 Mapei Mapewrap system

The Mapei CFRP system is a system comprising of Mapewrap C UNI AX 300 or
Mapewrap C UNI AX 600 fabrics and Mapewrap Primer 1 SP and Mapewrap 31 SP
epoxy saturant.

3.0 General Requirements

No special precautions need to be taken when the application temperature is between 5C
and 35C.
The structure must be protected from rain, dust and debris.
The products must be stored in a dry place

4.0 Substrate preparation

A substrate capable of transferring the loads from the FRP to the concrete is a pre-
requisite for strengthening with laminates. It is recommended that the concrete substrate
has a tensile strength > 1.5MPa
4.1 Substrate repair
All problems associated with the condition of the original concrete and concrete substrate
that can compromise the integrity of the FRP system must be addressed before surface
preparation begins.
4.1.1 Corrosion related deterioration
The substrate must be cleaned from oils, grease and surface deposits by mechanical
grinding.
Deteriorated concrete must be removed by annual or pneumatic breaker. Rusted
reinforcement must be cleaned and treated with Mapefer 1k anti corrosion primer.
Spalled concrete shall then be reinstated using suitable repair mortar such as Mapegrout
Hi-Flow SP or Mapegrout T60.

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MAPEI NEW ZEALAND LTD, 30 Fisher Crescent, Mt Wellington
PO Box 12-326 Penrose, Auckland, NEW ZEALAND
Tel: 09 921-1994 Fax: 09 921-1993 E-mail: enquiries@mapei.co.nz Website: www.mapei.co.nz
4.1.2 Cracks
Any cracks that are wider than 0.3mm that affect the performance of the externally
bonded FRP system through delamination or fibre crushing should be repaired by
injection using a suitable low viscosity epoxy resin such as Epojet LV or equivalent.
Smaller cracks, broken edges and drilled holes exposed to aggressive environments
should be sealed using Adesilex PG1.
4.2 Surface preparation
Surface preparation for Mapewrap CFRP system which is a bond critical application
should be in accordance with recommendation of ACI546R and ICRI03730.
The concrete substrate to which the FRP is to be applied should be freshly exposed and
free of loose or unsound materials. Materials with low compressive strength and
modulus, like plasters, that can reduce the effectiveness of the FRP system should be
removed. The substrate should be grinded to remove laitance, dust, dirt, oil curing
compound and existing coatings. Form lines should not exceed 1mm.
The concrete surface should have a roughened profile and dry to receive the epoxy
adhesive.

5.0 Preparation of materials

5.1 Mapewrap C UNI AX 300 or Mapewrap C UNI AX 600 carbon fabric.
The Mapewrap C UNI AX 300 or Mapewrap C UNI AX 600 should be cut as per the
desired length.
The fabric shall be stored in a clean and dry area on the job site.
5.2 Mapewrap Primer 1 SP
Mapewrap Primer 1 SP is an epoxy primer used for consolidating and enhancing the
bond strength of the CFRP plate to the substrate.
Mix the primer in the ratio 3:1 (A:B) by weight for 1 – 2 minutes until a homogeneous
mix is achieved
Mix only the quantity of epoxy which can be used within its pot life of 60 minutes at
23oC.
Epoxy which has exceeded its potlife shall be discarded.
5.3 Epoxy saturant – Mapewrap 31 SP
Mapewrap 31 SP is a two component epoxy product with a mix ratio of A:B (3:1)
Mix Part B into Part A with a slow speed mixer until a uniform consistency is obtained.
Mix only the quantity of epoxy which can be used within its pot life of 60 minutes at
23C.
Epoxy which has exceeded its pot life shall be discarded.
Partial mix is not recommended. Where partial mix are necessary, a precision electronic
scale should be use to get the right mix ratio of A:B (3:1) by weight.

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MAPEI NEW ZEALAND LTD, 30 Fisher Crescent, Mt Wellington
PO Box 12-326 Penrose, Auckland, NEW ZEALAND
Tel: 09 921-1994 Fax: 09 921-1993 E-mail: enquiries@mapei.co.nz Website: www.mapei.co.nz
6.0 Installation of Mapewrap C Uni Ax 300 or Mapewrap C Uni Ax 600
Prime the concrete surface to receive the fabric with Mapewrap Primer 1SP.
Saturate the Mapewrap C UNI AX 300 or Mapewrap C UNI AX 600 with Mapewrap
31 SP .
While the primer is still tacky ( < 6 hours depending on ambient temperature), install the
Mapewrap C UNI AX300 or Mapewrap C UNI AX 600 as per the orientation in the
drawing.
The saturated FRP fabric can be installed immediately after the application of the
Mapewrap Primer 1 SP.
Excess epoxy and entrapped air should be removed using ribbed roller.
For subsequent layers, surface to receive the fabric must be coated with a fresh layer of
Mapewrap 31 SP.
Lap splices are required only in the direction of the fibres. Lapping length shall be at least
200mm.
For long spans, all lap splices must be staggered, unless noted otherwise by the Engineer.

7.0 Protection
The installed fabrics can be protected with Mapelastic, a two component, flexible
cementitious coating, plasters, skim coat or Elastocolor, an acrylic based coating or with
a fire resistant coating.
To enhance the bond of the protective layer on the FRP system, dry silica sand shall be
broadcasted on the surface of the FRP system in the final coat of saturant to form
mechanical key.
The protective coating can be applied 24 hours after the FRP installation.

8.0 Quality Assurance and Quality Control

8.1 Qualification of Contractors/Applicators
The strengthening works must be performed by a team of qualified workers trained in
FRP application
The supervisor must be qualified on all aspects of the applied techniques including
surface preparation and must be present on site during works at all times
Workers installing the FRP system shall wear identification tags which show that they
have been trained in the application techniques.
8.2 Incoming Materials
The FRP fabrics and epoxy materials must be delivered to site in a properly labelled box
with the supplier’s name, material’s name, type, product components, weight, batch
number, expiry date and quantity clearly specified.
The above record must be properly maintained for traceability purposes.
The FRP fabrics must be properly cut to length and stored in a dry place.
Damaged FRP fabric should not be used
Epoxies which have passed its shelf life should not be used.

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MAPEI NEW ZEALAND LTD, 30 Fisher Crescent, Mt Wellington
PO Box 12-326 Penrose, Auckland, NEW ZEALAND
Tel: 09 921-1994 Fax: 09 921-1993 E-mail: enquiries@mapei.co.nz Website: www.mapei.co.nz
8.3 Quality control and Inspection of CFRP Installation
Ensure that the substrate is properly prepared and cleaned
Location exposed to rain, dust, debris must be protected using protective sheet, canvas or
other barriers
Ensure that the FRP are laid in the correct orientation as specified in the drawing. Fabric
misalignment of more than 5 degrees from that specified on the design drawings should
be reported to the Engineers for evaluation and acceptance.
Make sure that primer and epoxy saturant is applied on the entire concrete surface that is
to receive the fabric
The installed fabric must be cured for at least 24 hours before any subsequent works can
begin
Perform an acoustic tapping test of the installed FRP fabric to check for voids 24 hours
after installation
Samples should be prepared separately and make concurrently during installation of the
laminates for the purpose of conducting a pull out test. The bond test shall be evaluated
by direct tensile testing according to an acceptable code. The bond failure should be
located inside the concrete. The test shall be carried out by an independent testing agency
and the frequency of the test shall be as agreed with the Engineers.

9.0 Precaution against/action for damages of FRP fabric strengthening

system
Minor damages of the fabric should be repaired by bonding CFRP patches over the damaged
area. The FRP used should possess the same characteristics as the original fabric.

10.0 Safety requirements

All the epoxies used are classified as irritants. Prolong skin contact must be avoided. Also
respiratory ailments can occur with prolong exposure to the epoxies fumes. Therefore
mask and rubber waterproof protective gloves and goggles are required when working in
close proximity to epoxies.
In case of irritation from skin contact, wash thoroughly with soap and water and apply a
soothing balm. If the epoxy comes into contact with the eye, wash immediately with
water. Consult a doctor immediately.
For respiratory problems, move away from the work area and breathe fresh air.

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MAPEI NEW ZEALAND LTD, 30 Fisher Crescent, Mt Wellington
PO Box 12-326 Penrose, Auckland, NEW ZEALAND
Tel: 09 921-1994 Fax: 09 921-1993 E-mail: enquiries@mapei.co.nz Website: www.mapei.co.nz