Method of Waterproofing With MAXURETHANE FLEX W

RECOMENDACIÓN TÉCNICA / TECH.
RECOMMENDATION
WATERPROOFING AND PROTECTIVE R-IT-06/04

SYSTEM FOR ANAEROBIC TANKS:
RT_098_00
MAXURETHANE FLEX SYSTEM Page 1 / 27
DEPARTAMENTO TÉCNICO / TECHNICAL DEPARTMENT
DRIZORO S.A. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

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e-mail: info@drizoro.com – Web site: www.drizoro.com
RECOMENDACIÓN TÉCNICA / TECH. RECOMMENDATION
R-IT-06/04
WATERPROOFING AND PROTECTIVE
SYSTEM FOR ANAEROBIC TANKS: RT-098-00
MAXURETHANE FLEX SYSTEM
Page 2 / 27
DRIZORO S.AU. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

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INDEX
1. INTRODUCTION
2. DESCRIPTION OF THE SYSTEM
3. PHASES OF THE WORK

3.1. Treatment of out-standing points
3.1.1. Passing pipes
3.1.2. Concave corners
3.1.3. Anchoring of elements
3.1.4. Cold joints and non-active fissures/cracks
3.1.5. Active fissures/cracks
3.1.6. Form tie wire holes, voids and other damages
3.2. Treatment of expansion joints
3.3. Structural repair and levelling of concrete
3.3.1. Preparation of the substrate
3.3.2. Treatment of steel reinforcements (rebar’s)
3.3.3. Structural repair of concrete elements
3.3.4. Levelling of concrete surfaces
3.4. Waterproofing of the concrete surfaces
3.4.1. Characteristic of the substrate
3.4.2. Application of the waterproofing membrane
4. PROPOSED MATERIALS
4.1. Joints sealants and water-swelling materials
4.2. Concrete repair mortars and systems
4.3. Waterproofing materials and systems
4.4. Protective materials
5. SPECIFICATION LIST
6. TECHNICAL DRAWINGS

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1. INTRODUCTION
The aim of present document is describe a suitable polyurethane-based waterproof coating

system for anaerobic tanks at wastewater treatment plants, wherein a high level of chemical attacks
can be expected because of the fact the aggressiveness of the liquid media. MAXURETHANE® FLEX
is a two-component, 100% solids and solvent free synthetic and liquid waterproofing system that
cures to form a resilient, fully bonded and flexible membrane.
2. DESCRIPTION OF THE SYSTEM

The proposed system for the waterproofing and protection of concrete in a anaerobic tank
provided by DRIZORO® enables a proper surface protection of concrete, masonry o metal structures in
newly built constructions and a complete repair and surface protection for old constructions, which are
damaged to a variable extent. System is composed of the following procedures and materials
- Treatment and clearing of the surface to be coated.

- Treatment of outstanding points; corners, expansion joints, cold joints, cracks, passing
pipes, etc.
- Priming of the surface with an epoxy-based primer.
- Protection of the waterproofing membrane with a flexible polyurethane-based liquid coating
with very good chemical and mechanical strength.
Regarding products to be used in the waterproofing and protective system for anaerobic tanks:
- Sealants and other materials for joints:

o Water swelling profiles: MAXJOINT® W-SEAL
o Cement-based sealant: MAXJOINT® ELASTIC
o Polysulphide-based sealant: MAXFLEX® 900
o Polyurethane—based sealant: MAXFLEX® 100 LM
- Passivation materials for reinforcing steels: MAXREST® PASSIVE.
- Repair mortars:
o Short setting time: MAXREST®
o Normal setting time: MAXRITE® -S
- Waterproofing and protective material: MAXURETHANE®FLEX
Table I shows materials for waterproofing of anaerobic tanks. Options are given in which the
use of different materials provides the most suitable system.

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Table I.- DRIZORO® waterproofing and protective system for anaerobic tanks
JOB PROPOSED SYSTEM
1. a) MAXJOINT ELASTIC + MAXURETHANE FLEX with DRIZORO VEIL

G-45.
Treatment of outstanding points: 2. MAXJOINT W SEAL + MAXREST + MAXURETHANE FLEX with
1. Passing pipes DRIZORO VEIL G-45.
3. MAXREST or MAXPLUG + MAXURETHANE FLEX with DRIZORO VEIL
2. Concave corners G-45.
3. Anchoring (small elements) 4. MAXGRIP or MAXGROUT
4. Cold joints, non-active fissures/cracks a) MAXREST + MAXURETHANE FLEX with DRIZORO VEIL G-45
5. Active fissures/cracks b) MAXBETON
6. Form tie wire holes, voids, etc. 5. MAXFLEX 100 LM or MAXFLEX 900 + MAXURETHANE FLEX with
DRIZORO VEIL G-45.
6. MAXREST or MAXPLUG + MAXURETHANE FLEX with DRIZORO VEIL
G-45
Treatment of expansion joints:
1. Standard expansion joints 1. MAXCEL + PRIMER 900 + MAXFLEX 900
2. Big gaps/expansion joints 2. MAXEPOX JOINT + MAXFLEX XJS
Structural repair and levelling of concrete:
1. Steel reinforcement 1. MAXREST PASSIVE
2. Structural concrete elements 2. MAXREST or MAXRITE range
3. Levelling of concrete surfaces 3. CONCRESEAL -5 or MAXEPOX CEM
Waterproofing of the concrete surfaces:
1. Surfaces 1. MAXEPOX PRIMER + MAXURETHAN FLEX
3. PHASES OF THE WORK
3.1 TREATMENT OF OUT-STANDING POINTS
Outstanding points mean passing pipes, concave corners, anchoring of small elements, cold
joints and non-active fissures/cracks and active fissures/cracks. Because of the fact that those points
are a break in concrete continuity where leaks may occurs, special treatment system must be applied.
Table II resumes the most suitable procedures for the repair and waterproofing of these outstanding
points.
Table II.- DRIZORO® Products for treatment of outstanding points in a waterproofing and
protective system for anaerobic tanks
JOB PROPOSED SYSTEM
Treatment of outstanding points: 1. a) MAXJOINT ELASTIC + MAXURETHANE FLEX with FG veil

1. Passing pipes b) MAXJOINT W SEAL + MAXREST + MAXURETHANE FLEX with FG
veil
2. Concave corners 2. MAXREST or MAXPLUG + MAXURETHANE FLEX with FG veil
3. Anchoring (small elements) 3. a) MAXGRIP or MAXGROUT b) MAXBETON
4. Cold joints and non-active cracks 4. MAXREST + MAXURETHANE FLEX with FG veil
5. Active cracks 5. MAXFLEX 100 LM or MAXFLEX 900+ MAXURETHANE FLEX with FG
6. Form tie wire holes, voids and etc. veil
6. MAXREST or MAXPLUG + MAXURETHANE FLEX with FG veil

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3.1.1. Passing pipes
Joints between concrete and pipe form a good route for water infiltration, so these transitions
always require the application of watertight systems.
a. Plastic or small size pipes: An oversized cut out must be opened around the pipe and then,
apply MAXJOINT® ELASTIC around the perimeter of the pipe, filling the gap between the
pipe and the concrete, finishing with a cove around the pipe.
b. Big size pipes: An oversized cut out must be opened around the pipe and then, apply the
suitable polyurethane-based adhesive continuously without a break to the place wherein
the suitable MAXJOINT® W-SEAL water-swelling profile is going to be placed, i.e. water-
swelling profile is applied on the adhesive and then is rolled down around the pipe for
positive adhesion. Area must be patched with any structural repair mortar such as
MAXREST® (MAXPLUG® if running water is present) and then, a cove around the pipe
must be done.
Finally, provide a waterproofing finish, placing around the pipe-wall joint a MAXURETHANE® FLEX
waterproof coating reinforced with a 45 g/m2 glass-fibre veil strip (DRIZORO® VEIL G-45). Two coats
of waterproofing and polyurethane-based coating with a load of 0,3-0,4 kg/m2 per coat are
recommended (see Figure 1).
Work description
Unit Description
m Tight sealing of passing PVC/plastic/small size pipes in walls or concrete slabs. Make a groove around the
®
pipe with a 3 cm width and of 5 cm in thickness. Fill the groove with MAXJOINT ELASTIC cement—based,
moisture tolerant elastic mortar-sealant, finished in a concave shape. Wire brush thoroughly, remove dust and
®
contaminant and dampen (prime) the surface with water, prior to the application of MAXJOINT ELASTIC.
®
Waterproof the area with two coats of MAXURETHANE FLEX including a glass-fibre veil with at least 10 cm on
the surface and around the passing pipe.
Work description
Unit Description
m Tight sealing of passing metal pipes in walls or concrete slabs. Make a groove around the pipe with a 3 cm
®
width and 10 cm in depth. Fasten to pipes the suitable MAXJOINT W-SEAL water-expansion profile (for example;
®
H-2005) tiring wire or using MAXFLEX 100 HM polyurethane-based sealant-adhesive. Fill the groove with
® ®
MAXREST non-shrinkage and quick setting structural repair mortar (or MAXPLUG if water is present) finished in
a concave shape. Clean and damp the surface, prior to the application of the repair mortar. Waterproof the area
®
with two coats of MAXURETHANE FLEX including a glass-fibre glass veil with at least 10 cm on the surface and
around the passing pipe.

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Option a) Small size pipes or plastic pipes:

1+2 MAXJOINT ELASTIC
3. Preparation of the surface
4. MAXURETHANE FLEX reinforced with glass-fibre veil
2
Consumption: 0,3–0,4 kg/m
2
5. MAXURETHANE FLEX: 0,3–0,4 kg/m
Option b) Big size pipes or metal pipe

1. Suitable adhesive + MAXJOINT W SEAL
2. MAXREST / MAXPLUG
4. MAXURETHANE FLEX reinforced with glass-fibre
2
veil. Consumption: 0,3–0,4 kg/m
2
5. MAXURETHANE FLEX : 0,3–0,4 kg/m
Figure 1.- Tight sealing of passing pipes

3.1.2. Concave corners
Any concave corner or concrete slab-wall joint should be opened with a chisel in about 3 x 4
cm, avoiding “V” shape and then, this groove must be made and filled with the MAXREST® repair
mortar. The grooves should be made in a shape of a cove. This procedure allows getting a sealing for
the joint because repair mortar supplies a suitable and continuous surface in order to control the
thickness of the waterproofing membrane which is going to be applied (Figure 2).
Work description
Unit Description
m Sealing of wall-slab encounters. Open a 30x30 mm groove along the wall-slab joint. Fill the groove with
®
MAXREST non-shrinkage and quick setting structural repair mortar, finished in a concave shape. Clean and
®
dampen the surface, prior to the application of the MAXREST repair mortar. Waterproof the area with two coats
®
of MAXURETHANE FLEX including a glass fibre veil with at least 10 cm on the surface and along the concave
corner or encounter.
1.- Opening of a groove along the corner and patching with

®
MAXREST
st ®
2.- 1 coat of MAXURETHANE FLEX reinforced with
2
polyester fibre veil. Consumption: 0,8–0,9 kg/m
nd ®
3..- Finalization. 2 coat of MAXURETHANE FLEX
2
Figure 2.- Detail of treatment of concave corners

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Once the repair mortar have set, a 30 cm wide waterproof coating strip of MAXURETHANE®
FLEX reinforced with a DRIZORO® VEIL G-45 (45 g/m2) glass-fibre veil strip should be applied along
the wall-slab joint/junction. Apply a first coat of the waterproofing material with a load of 0,3-0,4 kg/m2
and then, place the polyester veil when material is still fresh. Allow to cure the application of
MAXURETHANE® FLEX for at least 6 to 12 hours and then, apply the second coat with the same
load, see Figure 2.
3.1.3. Anchoring of small elements
Basements have several elements, which are placed on walls and slabs. A good treatment for
these outstanding points will avoid problems in the future. According to the size of the element to be
anchored and position (horizontal/vertical), a specific anchoring mortar should be used.
a) Horizontal surfaces
i. Small elements, i.e. from 10 mm to 16 mm size, are anchored with the MAXGRIP® quick-
setting, non-shrink, cement-based anchoring mortar.
ii. Big elements require MAXGROUT® non-shrink, high strength grout.
b) Vertical surfaces. Small elements, i.e. stairs, etc., are anchored with a fast setting, non-
shrink, thixotrophic and fixing mortar such as MAXBETON® or MAXPLUG®.
Work description
Unit Description
m Anchoring of elements. Drill holes in sound concrete to accept the head of bolts. Place anchor bolts in the hole
®
and pour a MAXGRIP quick-setting, non-shrink, cement-based anchoring mortar in the hole.
3.1.4. Cold joints and non active fissure/cracks
Along cold joints, non-active cracks or fissures (from 0,3 mm) on concrete substrate, grooves
should be opened with at least to 2 cm in deep (i.e. perpendicular direction to the surface) and with a
thickness from 1 cm to 2 cm. These grooves and other defects should be filled with any DRIZORO®
repair mortar with a short setting time such as MAXREST® or MAXPLUG® (if running water leaks are
presents), see Figure 3.
Once repair mortar has been set or cured respectively, along the cold joint, crack or fissure, a
30 cm wide waterproof coating strip of MAXURETHANE® FLEX with a coverage of about 0,8-0,9
kg/m2. With the first coat still fresh, place a 6-8 cm wide strip of polyester-fibre veil. Once cured this
application, a second coat of MAXURETHANE® FLEX will be applied with a coverage of 0,8-0,9
kg/m2.
Work description
Unit Description
m Repair of cold joints or non-active cracks. Make a groove of 2 cm in depth with a thickness from 1 to 2 cm
®
along the joint/cracks and fill it with MAXREST structural mortar without shrinking and then level the surface.
Clean and dampen the surface, prior to the application of the repair mortar. Waterproof the area with two coats of
®
MAXURETHANE FLEX including a fibre glass veil h with at least 10 cm on the surface along the joint/cracks.

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1.- Opening of a groove along the corner and

®
patching with MAXREST
st ®
2.- 1 coat of MAXURETHANE FLEX
reinforced with glass-fibre veil
2
3.- Finalization:
nd ®
2 coat of MAXURETHANE FLEX
2
Figure 3.- Repair of cold joints/non-active cracks (>0,3 mm) using the MAXREST® structural repair
mortar and then waterproofing with MAXURETHANE® FLEX reinforced with glass-fibre veil.
For cracks/fissured subjected to hydrostatic pressure, open a groove along the crack with at
least to 10 cm in deep (i.e. perpendicular direction to the surface) and with a thickness of about 1 cm
and then, place a MAXJOINT W-SEAL water-swelling circular profile type RC-10. To ease the
placement, tools without cutting edges must be used in order to do not damage the water sealing
material. The edges of this groove, the gap and other defects should be patched with any DRIZORO®
repair mortar with a short setting time such as MAXREST® or MAXPLUG® (if running water leaks are
presents), see Figure 4.
3
1.- Opening of a groove along the corner and
then, insert the MAXJOINT® W-SEAL water-
2
swelling profile.
2.- Patching with MAXREST®.
1 3.- Waterproofing with MAXURETHANE®
FLEX reinforced with glass-fibre veil.
Figure 4.- Repair and sealing of cracks subjected to hydrostatic pressure by placing the MAXJOINT®
W SEAL water-swelling profile, patching with MAXREST® and final waterproofing with
MAXURETHANE® FLEX reinforced with glass-fibre veil
3.1.5. Active cracks (subjected to movements)
For active cracks/fissures (from 0,03 mm), grooves should be opened with at least to 2 cm in
deep (i.e. perpendicular direction to the surface) and with a width from 1 cm to 2 cm. These grooves
and other defects should be filled with an elastomeric polyurethane sealant such as MAXFLEX® 100
LM. Prior to the sealant application a suitable primer such as PRIMER 1 must be used in order to
improve the adhesion (See Figure 5). Also, a polysulphide-based elastomeric sealant such as
MAXFLEX® 900 + PRIMER 900 can be used.

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Work description
Unit Description
m Sealing of active cracks with polyurethane-based elastomeric sealant. Make a groove of 2 cm in depth with
a thickness from 1 to 2 cm along the cracks and primer the surfaces of the joint edges with PRIMER 1 and then
®
seal it with MAXFLEX 100 LM polyurethane-based elastomeric sealant. Wire brushes thoroughly, remove dust
and contaminant, clean and dry the surface, prior to the application of the elastic sealant. Waterproof the area
®
with two coats of MAXURETHANE FLEX including a fibre glass veil with at least 10 cm on the surface along the
joint/cracks.
1.- Polyurethane-based sealant.

PRIMER 1 + MAXFLEX® 100 LM or
PRIMER 900 + MAXFLEX® 900
2.- 1st coat of MAXURETHANE® FLEX
reinforced with glass-fibre veil
Consumption: 0,3–0,4 kg/m2
3.- Finalization.
2nd coat of MAXURETHANE® FLEX
Figure 5.- Repair of active cracks (subjected to movements) with MAXFLEX®100 LM.
The suitable sealant should be applied in a single way, pressing the material against the
edges and the bottom of the joint to prevent the air bubbles. To seal big cracks (maximum width; 25
mm), it is advisable to use a closed cell polyethylene joint backing rod, such as MAXCEL® with a
diameter 25% greater than the width of the joint.
Once sealant has cured (about 3-4 days), along the cold joint, crack or fissure, a 30 cm wide
waterproof coating strip of reinforced MAXURETHANE® FLEX shall be placed. Thus, apply a first
coat of MAXURETHANE® FLEX with a coverage of about 0,3-0,4 kg/m2. With this first coat still fresh,
set a 6-8 cm wide strip of the DRIZORO® VEIL glass fibre veil (45 g/m2). Once cured this application,
a second coat of MAXURETHANE® FLEX shall be applied with a coverage of 0,3-0,4 kg/m2
3.1.6. Form tie wire holes, voids and other damages
The realization of concrete walls with steel casing provide an optimal surface for placing the
waterproof coat however, the apparition of passing pipes through the wall is inevitable, due to the
attachment of both casings are required. Sometime, other damages are present, i.e honeycombs,
voids, etc. These points should be threaded for both sides of wall, however is in the interior area
where more attention is required. The system for sealed of these elements is the followings:
- Make a groove around the hole, voids or damage with a minimum thickness of 3 cm and
those; if required remove the PVC cone and any visible part of the PVC tube.
- These grooves should be patched with any DRIZORO® structural repair mortar with a
short setting time such as MAXREST® and flat surface must be provided. In the case of
running water leaks, the use of MAXPLUG® quick-setting mortar is highly recommended.
- Once repair mortar is set, the waterproofing will be placed. Apply two coats of
MAXURETHANE® FLEX, the first coat will include with a glass fibre veil covering a
surface of 20 X 20 cm approximately

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Work description
Unit Description
Tight sealing of form tie wire holes, voids, and other damages. Provide an oversized cut out with a depth of
®
3 cm around the passing pipe and patch the area with MAXREST non-shrinkage and quick setting structural
repair mortar. Clean and damp the surface, prior to the application of the mortar. Waterproof the area with two
®
coats of MAXURETHANE FLEX including a fibre glass veil with at least 10 cm around of form tie wire hole
surface.
3.2. TREATMENT OF EXPANSION JOINTS
Expansion joints are a break in concrete continuity where leaks may occur. These points always
require the application of watertight and flexible sealants/systems. In practice, there is often a need to
repair expansion gap with a structural repair mortar. The rule is then to clear the expansion gap and
fill it in with a suitable sealing material (elastic sealant or elastic band), which enables both parts of
the structure to work in the scope of loads assumed, maintaining its tightness.
Table III.- Products for treatment of expansion joints
JOB PROPOSED SYSTEM

Treatment of expansion joints:
1. Standard expansion joints 1. MAXCEL + MAXFLEX 900
2. Big gaps/expansion joints 2. MAXEPOX JOINT + MAXFLEX XJS
The edges of the expansion joints should be properly cleared to a sound base and then,
defects of substrate should be patched, filled and repaired with any structural repair mortar such as
MAXREST® (up to 3 cm thick). In the case of active leaks, the use of MAXPLUG® is highly
recommended. Once repair jobs have been finished, expansion joints should be sealed with a
suitable sealant. To calculate the most suitable joint width, the following general formula must be
applied:
Joint depth to be sealed with sealant will not be less than half of the joint width
That is to say, a 2 cm wide joint will required a sealant depth of at least about 1 cm. It is also
advisable to use a polyethylene foam joint backing rod such as MAXCEL® with a section diameter
1,25 times the joint width.
After hardening of repair mortars, expansion gaps should be filled with any suitable sealing
material (expansion putty or elastic filler), which enables both parts of the structure to work on the
scope of loads assumed, maintaining its tightness. For sealing of expansion joints subjected to
permanent immersion conditions, a flexible polysulphide-based sealant such as MAXFLEX® 900 and
its suitable primer PRIMER 900 can be used (See Figure 6).
Work description
Unit Description
m Sealing of expansion joints with polysulphide-based elastomeric sealant. Repair the joints edges with
®
MAXREST non-shrinkage and quick setting structural repair mortar. Clean and damp the surface, prior to
the application of the repair mortar. Apply masking tape where required before priming. Prime the surfaces
®
of the joint edges with PRIMER 900 using a paint brush before applying MAXFLEX 900 polysulphide-
based elastomeric sealant. Clean and dry the surface, prior to the application of the elastic sealant. Place
®
MAXCEL into the joint gap with a diameter 25% bigger than width of joint and minimum thickness of 10
mm.

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1.- Polyurethane foam joint backing rod

MAXCEL®
2.- Sealant
PRIMER 900 + MAXFLEX® 900
3.- 1st coat of MAXURETHANE® FLEX
reinforced with glass-fibre veil.
4.- Finalization
2nd coat of MAXURETHANE® FLEX
Figure 6.- Repair of the edges of the joints with MAXREST® and sealing of the expansion gap using
an elastomeric polysulphide sealant such as MAXFLEX® 900. Primers are required for both sealants.
Sometimes both the width and the depth for expansion joints are too big to use any standard
flexible sealant. In these cases, the use of a thermoplastic elastomeric (TPE) strips is highly
recommended. This procedure is also suitable to waterproof expansion joints or big cracks subjected
to big movements. It is based on the use of an elastic system such as MAXFLEX® XJS, i.e. a rubber
band with lateral fleece edges, fixed to the substrate using the MAXEPOX® JOINT epoxy-based
mortar (See Figure 7 and 8).
Step 1: Pre-assemble all strip joints, mitres, crossings or corners before installation. Make sure
that all fleece edges are dry if MAXEPOX® JOINT is going to be used. If the substrate is wet,
MAXSEAL® FLEX will be used in order to provide enough adhesion.
Step 2: Base coat. In either case, watch the pot life of the product applied and follow the
instructions given in the respective technical bulletins carefully. Apply the base coat material on
the substrate in order to provide the strip with proper bonding. Approximate consumption for
MAXEPOX® JOINT is about from 0,8 to 1,0 kg/linear meter.
Step 3: Placing: Place the MAXFLEX® XJS strips with the white fabric strip facing down. Press
the fabric with a trowel well into the adhesive to allow it to soak.
Step 4: Top-coat: Apply the topcoat of adhesive “wet on wet”. The fabric strips must be
completely soaked and covered (2-3 mm.) with the adhesive. It is not advisable to cover the
rubber with the adhesive. MAXEPOX® JOINT should be sanded with silica sand.
Unions: Connections of MAXFLEX® XJS strips are done using an appropriate adhesive for
TPE.
Work description
Unit Description
m Sealing of big gap / expansion joints with TPE elastomeric band. Repair the joints edges with
®
MAXREST non-shrinkage and quick setting structural repair mortar. Clean and damp the surface, prior
to the application of the repair mortar. Apply the base coat material on the substrate in order to provide
®
the strip with proper bonding. Approximate consumption for MAXEPOX JOINT is about from 0,8 to 1,0
®
kg/linear meter. Place the MAXFLEX XJS strips with the white fabric strip facing down. Apply the
®
topcoat of adhesive “wet on wet”. Connections of MAXFLEX XJS strips are done using an appropriate
adhesive for TPE.

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1.- Base coat of MAXEPOX® JOINT

Consumption: 0,8-1,0 kg/linear meter
2.- Elastic band: MAXFLEX® XJS
3.- Top coat of MAXEPOX® JOINT

Figure 7a.- MAXFLEX XJS over big gaps
1.- Base coat of MAXEPOX® JOINT

2.- Elastic band: MAXFLEX® XJS
3.- Top coat of MAXEPOX® JOINT

Figure 7b.- MAXFLEX XJS over corners
Figure 7.- Elastic sealing system for big gaps/expansion joints
Figure 8.- Treatment of connection between concrete wall and concrete roof in an anaerobic tank.
a) Placing of MAXFLEX® XJS on the bonding base coat and b) Application of the top-coat on the
elastic band

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3.3 STRUCTURAL REPAIR AND LEVELLING OF CONCRETE SURFACES
In older structures, in which the existing damages cause weakening of the constructions, repairs
are necessary. Their effectiveness depends on the selection of the proper work technology. In practice,
all damages can be divided in the following groups:
- Point damages: rods sticking out of the concrete, tight transitions, damages, and cavities…
- Linear damages: fissures, cracks, expansion joints, cold/working joints …
- Surface damages: defects, cavities, peeling, etc …
Table IV shows the most suitable DRIZORO® products for repair jobs.
Table IV.- Products for repair jobs
JOB PROPOSED SYSTEM

Structural repair and levelling of concrete:
1. Steel reinforcements 1. MAXREST PASSIVE
2. Structural repair of concrete elements 2. MAXREST or MAXRITE range
3. Levelling and resurfacing of concrete surfaces 3. CONCRESEAL -5 or MAXEPOX CEM
3.3.1. Preparation of the substrate
A right surface preparation means a successful application for DRIZORO® products and
provides a long durability for the waterproof and protection coating. Surface preparation consists of:
- Removal of any damaged protective, maintenance or superficial coatings, as well as any

dirtiness (grease, dust, etc.);
- Removal of loose particles and coats of concrete, cream of concrete, dust, water;
- Removal all the substances that could affect negatively on the binding applied materials
with concrete or on the corrosion of concrete and reinforcing steel.
Suitable methods for preparation of concrete substrates (Bulk concrete removal, edge
conditioning and final surface cleaning) are:
- Mechanical method: chisels, pneumatic drills, needle pistols, sand blasting, etc.
- Hydraulic methods (suggested for materials requiring wet surfaces):
o Hydro monitoring – cleaning with pure water at pressure of approx. 150-200 bars.
o Hydro sandblasting – cleaning with water at pressure of 6 – 15 bars with an addition of
abrading material, e.g. sand.
- Thermal methods (suggested for cleaning greases, oils and bituminous materials):
Oxyacetylene firing plus final cleaning with mechanical or hydraulic methods.
- Chemical methods: solutions of acids (hydrochloric or phosphoric acids) or with salt
neutralising substances. After chemical cleaning, the surface must be properly washed with
water.
To provide a good surface of concrete substrate, i.e. clean and rough surface due to removal of
superficial small aggregates, a recommended pressure range for cleaning by hydraulic means should
be between 150 – 200 bars. This surface roughness is very suitable for the application of any structural
repair mortar or waterproof coating.

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Hydraulic methods consist of cold water spraying at high pressure by a high-pressure pump
equipped with a spraying gun. Water must be clean and the spraying procedure should be
homogeneous and continuous over the whole surface. During the cleaning job, many damaged or
weakly bounded areas are exposed which must be treated and refilled with any DRIZORO® structural
repair mortar.
Cleaning of concrete surface with clean water at high pressure. The pressure range for the
hydraulic equipment should be between 150 – 200 bars. Thus, a water jet is directly applied and in
perpendicular way to the surface. The whole surface should be treated and special attention should be
paid in the reinforcing o metal elements. With this pressure range, a good concrete surface cleaning is
achieved due to removing of superficial small aggregates. The final rough for this treated surface is very
suitable for the application of any structural mortar or levelling and cosmetic repair mortar.
Work description
Unit Description
2
m Cleaning the whole surface by water spraying at high pressure from 150 to 200 bars
3.3.2. Treatment of the steel reinforcements
Concrete surrounding the corroded reinforcing bars must be removed to fully exposure the full
circumference. Undercutting under reinforcing bar should not be less than 2 cm. The exposed steel
should be thoroughly cleaned of rust and scale using sandblasting or water blasting. When reinforcing
steel is heavily corroded and the diameter is reduced, i.e. in cases where the reinforcing bars has lost
more than 25% of its original cross section, a supplemental reinforcement can be lapped to adjacent
damaged bars.
Finally, the cleaned reinforcing bars are covered with MAXREST® PASSIVE one-component
anti-corrosion and protective liquid for neutralizing oxides. This material provides a passive film, which
protects the steel against new corrosion processes and diluted acid or alkali attacks.
Work description
Unit Description
2
m Treating of the steel reinforcements with oxide-converters. Remove the concrete surrounding the
rebar’s and undercut under rebar’s at least 2 cm. Clear the rust and scale using a metal wire brush
®
and cover the rebar’s with MAXREST PASSIVE one-component anti-corrosion and protective water-
based liquid for neutralizing oxides and provide a protective barrier, applying two coats with a total
2
consumption of 0,13 kg/m
3.3.3. Structural repair of concrete elements
Once concrete substrate has been cleaned, many damaged zones (voids, honeycombs,
cracks, fissures, peelings, rods sticking out of concrete, superficial structural steel) are exposed.
Thus, these cleaned areas should be repaired and patched with any structural repair mortar. To repair
damages in concrete structures, DRIZORO® provides different products, which have a specific
application (See Table V).

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Table V.- Structural repair mortars
MAIN CHARACTERISTICS
NAME OF THE
PRODUCT Setting time Application Corrosion
Polymers Fibres
Initial-Final Thickness (mm) Inhibitors
MAXREST® 20-25 min < 30 NO NO NO
MAXRITE® -S 3-7 hours 5-50 YES NO NO
MAXRITE® -F 3-8 hours 5-40 YES NO YES
- MAXREST® is a non-shrink, thixotrophic, quick setting, and structural repair mortar. It is

suitable product for repair and restoration of concrete structures, façades, cracks, fissures
and honeycombs. In addition, it can be used for restoration of damages lines and shapes
of concrete elements.
- MAXRITE® -S is a one-component, non-shrink, and thixotrophic, long-setting, polymer-

modified, structural repair mortar for large areas by wet or dry shotcrete methods or
manual applications. It is suitable product for repair of concrete structures and concrete
pipes, overlaying of floors or concrete slabs before the final coating.
- MAXRITE® - F is a one component thixotrophic shrinkage-compensated mortar, with

normal setting-time, made of special cements, selected aggregates, micro silica, polymers
and reinforced with polypropylene fibres. It is specially designed for structural concrete
repair, applied manually by towelling without the need for using any form work.
Selection of the way how to repair, materials and technology are decided from range and type of
damages, causes of damages, further use of the structure, etc. Thus, for small areas, a quick setting
mortar such as MAXREST® (thickness up 3 cm) can be used. When both hot temperatures and low
relative humidity are present and large areas have to be repaired, a mortar with a medium setting time
mortar such as MAXRITE® -S (thickness up 5 cm) must be used.
When cracks, voids and other damages goes to the depth and reach the steel bars in the
structure, concrete surrounding the corroded reinforcing bars must be removed to fully exposure the
full circumference. Undercutting under reinforcing bar should not be less than 2 cm exposed steel
should be thoroughly cleaned of rust and scale using sandblasting or water blasting. Also, an abrasive
blasting wire wheel or needle scaler can be used. Finally, the cleaned reinforcing bars are covered
with MAXREST® PASSIVE one-component anti-corrosion and protective liquid for neutralising oxides.
This material provides a passive film, which protects the steel against new corrosion processes and
diluted acid or alkali attacks.
Once the rebar has been treated, these grooves and other defects should be filled and
patched with any DRIZORO® repair mortar such as MAXREST® or MAXRITE®-S (see Figure 1). Prior
the application of any repair mortar, the concrete surface should be dampened and the reinforcing
elements should be treated following the above-mentioned instructions. DRIZORO® repair mortars
require the base concrete to be in a saturated, surface dry condition prior to application to prevent a
rapid loss of moisture from the repair mortar. So dampen the exposed concrete surface with clean
water until it becomes saturated but do not leave freestanding water. When using a bonding agent, a
saturated surface dry condition must not be provided.

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For an optimum bonding of any repair mortar, prepare bonding slurry (using a 10% more of
mixing water than the recommended amount) and then, apply this slurry by brush on the surface to be
repaired just before placing the repair mortar. This thin coat fills pores to ensure intimate contact and to
help prevent sloughing or sagging of repair materials on vertical surfaces and overhead surfaces.
Alternatively, a bonding agent such as MAXBOND® or MAXEPOX BOND® can be used (Consult at
Technical Department for this application).
While the bonding slurry is still fresh, i.e. before bonding slurry dries, apply successive coats
with a thickness of 30 mm per application for MAXREST® or a thickness of 50 mm per application for
MAXRITE® range repair mortars. Apply the material with adequate pressure. Thoroughly consolidate
the repair material into the corners of the patch and around any exposed reinforcement on the repair
zone. Full encapsulation of the reinforcement is important for long-term durability.
To improve the adhesion of the successive coats or lifts, scratch the surface of each coat with
the trowel. When repair mortar starts to harden, its surface can be scraped with a scrapping trowel,
sponge, etc. To avoid a quick drying process, which takes place under extreme conditions of wind,
humidity or temperature, spraying of water over the repaired area for at least the first hours after the
applications is recommended. Also, other common curing procedures can be used.
Optionally: Once the area to be repaired has been patched with any structural repair mortar,
apply a first coat of MAXURETHANE® FLEX with a coverage of about 0,8-0,9 kg/m2. With this first
coat is still fresh, place a of 6-8 cm wide strip of polyester-fibre or glass-fibre veil. Once cured this
application, a second coat of MAXURETHANE® FLEX will be applied with a coverage of 0,8-0,9
kg/m2.
Work description
Unit Description
2 ®
m Repair of concrete elements with structural mortars. Repair the cleared areas with MAXREST non-shrinkage
and quick setting structural repair mortar. Clean and dampen the substrate to a saturated, surface dry condition,
®
prior to the application of the MAXREST repair mortar. Apply a bond coat by brush and then, apply the mortar
with a trowel or wing pallet until get the original form with float finish.

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2. 3.
1. Remove any damaged and unsound concrete. Expose all corroded reinforcement, eliminate rust by wire
®
brush, and finally, treat the rebar with MAXREST PASSIVE.
2. Prior to application of any repair mortar, dampen the substrate.
3. Apply bonding slurry by brush. This slurry consists of five parts of powder and 1 part of water.
4. While the slurry is still fresh, apply the repair mortar:
®
i. MAXREST . Up to 3 cm thick
®
ii. MAXRITE -S. Up to 5 cm thick
®
iii. MAXRITE -F. Up to 4 cm thick
5. Scratch the surface with the trowel in order to improve the adherence for the next mortar coat.
6. Level the repaired area.
7. Finish the application as desired before the final hardening takes places.
Figure 9.- Application process for DRIZORO® structural repair mortars
3.3.4. Levelling and resurfacing of concrete surfaces
After the cleaning out, the concrete surface defects such as cracks, fissures, honeycombs,
holes, gravel pockets or honeycombs must be patched and filled with a cement-based cosmetic mortar
used for restoration and levelling of deteriorated surfaces up to 5 mm. Thus, suitable cosmetic mortar
versions are the following:
- CONCRESEAL® -5, Levelling and repair mortar for cosmetic restoration of mortars and
architectural concrete up to 5 mm.
- MAXEPOX® CEM is a three-component mortar composed of water-based epoxy-modified

resin and cements, which has been specially designed for repair, levelling and protection
of concrete surfaces, on vertical or horizontal, in coats up to 5 mm thickness.
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Work description
Unit Description
2
m Levelling and resurfacing of concrete element surfaces with cosmetic mortar (up to 5 mm thick). Repair
®
the cleared areas with CONCRESEAL -5 levelling and repair mortar for cosmetic restoration of mortars and
architectural concrete up to 5 mm.. Clean and damp the surface, prior to the application of the repair mortar.
Apply the mortar with a trowel or wing pallet until get the original form with float finish.
In order to level and prepare any dampen substrate prior to the application of epoxy or
polyurethane-based top-coatings, the use of MAXEPOX® CEM is highly recommended because of
the fact this products acts as a water vapour barrier (See Figure 10).
Work description
Unit Description
2
m Levelling and resurfacing of concrete element surfaces with epoxy/cement-based cosmetic mortar (up to
5 mm thick) prior to application of epoxy or polyurethane coatings. Repair the cleared areas with the
®
MAXEPOX CEM levelling and repair mortar for cosmetic restoration of mortars and architectural concrete up to
2
5 mm (1,95 kg/m ·mm). Clean and damp the surface, prior to the application of the repair mortar. Apply the
mortar with a trowel or wing pallet until get the original form with float finish.
WATERPROOF RESIN-BASED COATING:

®
MAXURETHANE FLEX (2 coats)
LEVELLING AND RESURFACING MORTAR:

® 2
MAXEPOX CEM (1,95 kg/m ·mm)
CONCRETE SURFACE:
(Solid and clean)
1. Concrete surfaces (wall, floor and ceiling) must be solid, free of dust and wet.. Prior to application of any
repair mortar, dampen the substrate.
® 2
2. Apply lifts of the MAXEPOX CEM by trowel with a thickness no greater than 5 mm (1,95 kg/m ·mm)
3. Apply the waterproofing epoxy or polyurethane-based coating after observing a setting time of about 24 h.
Figure 10.- Application of the MAXEPOX® CEM epoxy/cement levelling mortar prior to apply any
epoxy or polyurethane-based coating at anaerobic tanks
3.4. WATERPROOFING OF THE CONCRETE SURFACES
Once the above-mentioned steps have been carried out, i.e. cleaning and repair of the
surface, treatment for expansion/cold joints and pipe penetrations, waterproofing of the area should
be provided.
3.4.1. Characteristics of the surface

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Concrete decks or topping screeds are the constructive element that Substrates the
waterproofing membrane and drainage plane, formed by a levelling mortar that allows the drainage of
water. The base or Substrate should have the following characteristic:
a) Mechanical strengths. Base/Concrete deck or screed should not be deformed neither

degraded. Suitable mortars are those that complete the following characteristics:
Compression strength ≥ 8,0 MPa

Adhesion strength ≥ 1,5 MPa
Concrete must be fully cured, i.e. 28 days, structurally sound, clean and dry. Light concretes
are valid, however must have the same characteristics explained above. In works of reparation
of flat roofs covered with ceramic tiles, the waterproofing system is valid; however, the
elements must be in good conditions and fixed on the surface. Loose elements, badly adhered
or in bad conditions will be removed and area filled with any repair mortar such as MAXREST®
or MAXRITE® until get a flat surface. In addition, joints will be cleaned and repaired,
eliminating the loose concrete and using a pointing mortar such as MAXJOINT® FLEX.
b) Cleaning. All surfaces (new and old) to be coated must be clean, dry and without dust, oils
or grease, free of all traces of paint, laitance, loose particles, gypsum plaster or any other
material, which could affect to adhesion of the waterproof coating. In addition, concrete
surfaces must be totally cured before the waterproofing material application.
c) Levelling. On uneven surfaces or cracks will be necessary patched applying a leveling

mortar or any DRIZORO® patching material with a rough finishing in order to provide a proper
adhesion. Before applying any waterproofing membrane, observe a curing time of at least 7
days for these materials.
d) Roughness. When the surface is too smooth, provide roughness. So, maximum
roughness will be 0,2 mm. So, cracks and projections are not more height regarding to the half
surface of the base.
e) Porosity. In order to get a good adhesion of the waterproofing membrane, substrate

should have enough porosity.
f) Stability. Substrate has already had most of its retractions and the possible fissures have
been stabilized. This occurs in approximately one month in ceramic tiles and something more
than two months in concrete blocks.
g) Humidity. Substrate must be dry with a presence of humidity less than 5%.
h) Encounters/corners. Surface of the base will not have incoming or salient angles smaller
than 135º without a cove shape or encounters, which will has a radius not smaller than 3 cm.

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3.4.2. Application of the waterproofing membrane
MAXURETHANE® FLEX is a two-component liquid product, solvent free and 100% solids
based on moisture curing special polyurethane resins, that provides a high performance,
waterproofing flexible membrane designed for long-term protection and waterproofing of concrete,
cement-based mortars, bricks, tiles, etc.
Application procedure: MAXURETHANE  FLEX is supplied in pre-weighed sets. The

hardener, component B, is fully poured into the resin, component A. To make sure the proper full
reaction between the two components, scrape the sides and bottom of both packaging to ensure
complete mixing.
The mixture can be done manually or better using a low speed drill (300 - 400 r.p.m.
maximum), until achieving a homogeneous product in colour and appearance. Avoid producing too
much air while mixing the product. Pot life for application is only 20 - 30 minutes at 20ºC, apply
immediately after mixing. The proposed system has a total consumption from about 0,6-0,8 kg/m2
(see Figure 12):
Primer (0,25-0,50 kg/m2) + 1st coat (0,3-0,4 kg/m2) + 2nd coat (0,3-0,4 kg/m2)
Primer: Apply the MAXEPOX® PRIMER solvent-free epoxy primer for polyurethane-based
waterproofing materials with a recommended load from about 0,25 to 0,50 kg/m2 using a roller,
brush, etc. Allow primer to dry before applying the MAXURETHANE® FLEX, check the
technical data table for the open-time period. Thus, the open-time of 10 kg at 20 ºC is 5 hours.
If primer hardens, another coat of primer must be applied prior to be coated.
1st coat application: Apply a first coat of MAXURETHANE® FLEX with coverage from 0,3 to
0,4 kg/m2 using a roller, brush, etc. Allow the first coat to dry between 6 or 12 hours,
depending on the environment and ventilations conditions and then, apply the second or
successive coats.
2nd coat application: Apply a second or successive coats of MAXURETHANE® FLEX in

perpendicular direction to the last one, using the same coverage, i.e. from 0,3 to 0,4 kg/m2.
The dry total thickness for the application (primer and two coats) is about 0,6 – 0,7 mm. On
vertical surfaces, apply in three or four coats to achieve the same consumption, i.e. 0,6 -0,8
kg/m2.
Application conditions: Do not apply neither below 5 ºC or when such temperatures are
expected to drop within the 24 hours. Do not apply on frozen surfaces. Do not apply
MAXURETHANE® FLEX above 85% of relative humidity. Surface and ambient temperature must be
at least 3 ºC higher than dew point. Measure the relative humidity and dew point for applications
carried out in proximities of marine environment. Do not apply if rainfall, dew, condensation or water
contact is expected within the first 24 hours after application.
Curing: Observe at least a minimum curing period of 24 hours (20 ºC and 50% R.H.). Lower
temperatures and bigger relative humidity can increase the curing time.

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Work description
Unit Description
2
m Waterproofing of walls, floor and ceiling with flexible and waterproofing polyurethane-based membrane.
®
Apply two coats of the MAXURETHANE FLEX flexible and polyurethane-based waterproof membrane by
2
brush, roller or air-less gun with a recommended coverage of 0,3-0,4 kg/m per coat, which ensures complete
waterproofing even in the most severe conditions. Patch all holes and cracks before waterproofing. Clean and
®
prepare and primer the surface with MAXEPOX PRIMER, prior to the application of the waterproofing
membrane. On vertical surfaces, apply in three or four coats to achieve the same consumption, i.e. 0,6-0,8
2
kg/m .
SECOND COAT:
®
MAXURETHANE FLEX (0,3-0,4
2
kg/m )
FIRST COAT:
® 2
MAXURETHANE FLEX (0,3-0,4 kg/m )
PRIMER:
® 2
MAXEPOX PRIMER (025,-0,30 kg/m )
CONCRETE SURFACE:
(Solid, free of dust and dry)
1. Concrete surfaces (wall, floor and ceiling) must be solid, free of dust and dry.
®
2. Apply one coat of MAXEPOX PRIMER by brush, roller or air-less gun with a recommended coverage of 0,25-
2 ®
0,30 kg/m . Allow the primer to dry before applying MAXURETHANE FLEX i.e. open-time of 10 kg at 20 ºC
is 5 hours.
®
3. Apply a first coat of MAXURETHANE FLEX by brush, roller or air-less gun with a recommended coverage of
2
0,3-0,4 kg/m .
®
4. Apply the second coat of MAXURETHANE FLEX by brush, roller or air-less gun with a recommended
2
coverage of 0,3-0,4 kg/m . Before applying this second coat, observe a drying time of at least 10-12 h.
2
On vertical surfaces, apply in three or four coats to achieve the same consumption, i.e. 0,6 - 0,8 kg/m .
Figure 12.- Application of the MAXURETHANE® FLEX waterproofing membrane for anaerobic tanks
4. PROPOSED MATERIALS
4.1. ELASTOMERIC SEALANTS AND WATER-SWELLING MATERIALS
MAXJOINT® W-SEAL is an elastic and water swelling profile provided with pre-formed
hydrophilic resins that increase the volume up to four times when it is into direct contact with water. It
is a suitable product for sealing of joints and cracks in concrete and masonry. Because of the fact that
this profile has great water swelling capability it could be used in order to fill voids and joint
unevenness by pressing against the concrete surface. In this way, the water passing is avoided and a
watertight sealing is provided.
MAXFLEX® 900 is a two-component polysulphide-based joint sealant. Product cures chemically

at ambient temperature, providing a joint sealant with low elasticity modulus, especially recommended
for sealing of both horizontal and vertical joints wherein high chemical resistance is required.

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MAXFLEX® XJS is a sealing system consisted of a thermoplastic elastomeric strip (TPE) with
two lateral fleece edges, which is fixed to the surface using an epoxy-based adhesive, MAXEPOX®
JOINT, or a flexible cement-based mortar, MAXSEAL® FLEX, over expansion joints or cracks
subjected to extreme movements or exposed to chemicals. It assures a watertight joint while allowing
the movement of the treated element, for both interior and exterior applications.
MAXEPOX® JOINT is a two-component, solvent-free, epoxy-based mortar, specially designed

to provide a waterproof pointing with high mechanical and chemical resistance on ceramic tiles with
low or none porosity, over horizontal and vertical surfaces. Also it can be used as bonding mortar of
elastic band over concrete and mortar, as well as over non-absorbent substrates such as metal,
polyester, etc and wherein a fast putting into service is required.
4.2. CONCRETE REPAIR MORTARS AND SYSTEMS
MAXREST® PASSIVE is a one-component liquid product, ready to use as an oxide converter

and protection of re-enforcing bars and other steel and iron surfaces against corrosion. Once applied
neutralizes the corrosion process, reacting quickly with the rust and transforms iron oxide into a stable
passive coat giving full protection against corrosion, salts, acid and alkali attack.
MAXREST® is a one-component structural repair mortar, made of special cements, additives

and selected aggregates, which provide a thixotrophic product with quick setting that does not shrink. It
firmly adheres to the surface, which it is applied on, and restores concrete to its original condition. It is a
suitable product for repair and restoration of concrete structures, façades, cracks, fissures and
honeycombs and for restoration of damages lines and shapes of concrete elements.
MAXRITE® -S is a normal setting, single component polymer-modified mortar, made up of

special cements, selected aggregates and special resins, especially designed for the application over
large surfaces. Its formulation allows it to be applied by dry or wet-process spraying, as well as
manually by trowel, over substrates such as concrete, concrete blocks, mortars, stone, etc.
MAXEPOX® CEM is a three-component mortar composed of water-based epoxy-modified

resin and cements, which has been specially designed for repair, levelling and protection of concrete
surfaces, on vertical or horizontal, in coats up to 5 mm thickness. It is a suitable system for dampen
substrates preparation prior to the application of epoxy or polyurethane-based top-coatings.
4.3. WATERPROOFING MATERIALS AND SYSTEMS
MAXEPOX® PRIMER is a two-component, solvent-free, low viscosity, transparent epoxy primer

to be used prior to application of MAXURETHANE® FLEX, acting as an excellent bonding agent and a
vapour barrier on concrete, mortars and porous substrates when subject to permanent water
immersion: channels, reservoirs, fountains, etc
MAXURETHANE® FLEX is a one-component liquid product ready to use, based on moisture

curing of special polyurethane resins, which provide a high performance waterproofing elastic
membrane designed for long-term protection and waterproofing of concrete, cement-based mortars,
blocks, bricks, tiles, etc.

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4.4. SURFACES FINISHING
Only in case MAXURETHANE® FLEX may be exposed to U.V. exposure it must be cover with a
U.V. resistant coloured polyurethane membrane such as MAXURETHANE® 2C
MAXURETHANE® 2C is a two-component transparent product based on air-cured synthetic

aliphatic polyurethane resins. It is specially formulated for protecting surfaces from the sun radiation
and aggressive chemical attack and abrasion, in industrial floors, reservoirs and food industry.
5. SPECIFICATION LIST
Treatment of out-standing points
1. Passing pipes
Work description
Unit Description
m Tight sealing of passing metal pipes in walls or concrete slabs. Make a groove around the pipe with a 3 cm width
®
and 10 cm in depth. Fasten to pipes the suitable MAXJOINT W-SEAL water-expansion profile (for example; H-2005)
® ®
tiring wire or using MAXFLEX 100 HM polyurethane-based sealant-adhesive. Fill the groove with MAXREST non-
®
shrinkage and quick setting structural repair mortar (or MAXPLUG if water is present) finished in a concave shape.
Clean and damp the surface, prior to the application of the repair mortar. Waterproof the area with two coats of
®
MAXURETHANE FLEX including a glass-fibre veil with at least 10 cm on the surface and around the passing pipe.
m Tight sealing of passing PVC/plastic/small size pipes in walls or concrete slabs. Make a groove around the pipe
®
with a 3 cm width and of 5 cm in thickness. Fill the groove with MAXJOINT ELASTIC cement—based, moisture
tolerant elastic mortar-sealant, finished in a concave shape. Wire brush thoroughly, remove dust and contaminant and
®
dampen (prime) the surface with water, prior to the application of MAXJOINT ELASTIC. Waterproof the area with two
®
coats of MAXURETHANE FLEX including a glass-fibre veil with at least 10 cm on the surface and around the
passing pipe.
2. Concave corners
Work description
Unit Description
m Sealing of wall-slab encounters. Open a 30 x 30 mm groove along the wall-slab joint. Fill the groove with
®
MAXREST non-shrinkage and quick setting structural repair mortar, finished in a concave shape. Clean and dampen
®
the surface, prior to the application of the MAXREST repair mortar. Waterproof the area with two coats of
®
MAXURETHANE FLEX including a glass-fibre veil with at least 10 cm on the surface and along the concave corner
or encounter.
4. Anchoring of elements
Work description
Unit Description
Anchoring of elements. Drill holes in sound concrete to accept the head of bolts. Place anchor bolts in the hole and
®
pour a MAXGRIP quick-setting, non-shrink, cement-based anchoring mortar in the hole
5. Cold joints and non-active-fissures / cracks

Work description
Unit Description
m Repair of cold joints or non-active cracks. Make a groove of 2 cm in depth with a thickness from 1 to 2 cm along the
®
joint/cracks and fill it with MAXREST structural mortar without shrinking, and then level the surface. Clean and
dampen the surface, prior to the application of the repair mortar. Waterproof the area with two coats of
®
MAXURETHANE FLEX including a fibre glass mesh with at least 10 cm on the surface along the joint/cracks.
6. Active-fissures / cracks
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Work description
Unit Description
m Sealing of active cracks with polyurethane-based elastomeric sealant. Make a groove of 2 cm in depth with a
thickness from 1 to 2 cm along the cracks and primer the surfaces of the joint edges with PRIMER 1 and then seal it
®
with MAXFLEX 100 LM polyurethane-based elastomeric sealant. Wire brushes thoroughly, remove dust and
contaminant, clean and dry the surface, prior to the application of the elastic sealant. Waterproof the area with two
®
coats of MAXURETHANE FLEX including a fibre glass mesh with at least 10 cm on the surface along the
joint/cracks.
7. Form tie wire holes

Work description
Unit Description
Tight sealing of form tie wire holes, voids and other damages. Provide an oversized cut out with a depth of 3 cm
®
around the passing pipe and patch the area with MAXREST non-shrinkage and quick setting structural repair mortar.
Clean and damp the surface, prior to the application of the mortar. Waterproof the area with two coats of
®
MAXURETHANE FLEX including a fibre glass mesh with at least 10 cm around of form tie wire hole surface.
Treatment and sealing of expansion joints
Work description
Unit Description
m Sealing of expansion joints with polysulphide-based elastomeric sealant. Repair the joints edges with
®
MAXREST non-shrinkage and quick setting structural repair mortar. Clean and damp the surface, prior to the
application of the repair mortar. Apply masking tape where required before priming. Prime the surfaces of the joint
®
edges with PRIMER 900 using a paint brush before applying MAXFLEX 900 polysulphide-based elastomeric
®
sealant. Clean and dry the surface, prior to the application of the elastic sealant. Place MAXCEL into the joint gap
with a diameter 25% bigger than width of joint and minimum thickness of 10 mm.
Work description
Unit Description
®
m Sealing of big gap/expansion joints with TPE elastomeric band. Repair the joints edges with MAXREST
non-shrinkage and quick setting structural repair mortar. Clean and damp the surface, prior to the application of
the repair mortar. Apply the base coat material on the substrate in order to provide the strip with proper
®
bonding. Approximate consumption for MAXEPOX JOINT is about from 0,8 to 1,0 kg/linear meter. Place the
®
MAXFLEX XJS strips with the white fabric strip facing down. Apply the topcoat of adhesive “wet on wet”.
®
Connections of MAXFLEX XJS strips are done using an appropriate adhesive for TPE.
Structural repair and levelling of concrete

Work description
Unit Description
2
m Cleaning the whole surface by water spraying at high pressure from 150 to 200 bars
2. Treatment of steel reinforcements

Work description
Unit Description
2
m Treating of the steel reinforcements with oxide-converters. Remove the concrete surrounding the rebar’s and
undercut under rebar’s at least 2 cm. Clear the rust and scale using a metal wire brush and cover the rebar’s with
®
MAXREST PASSIVE one-component anti-corrosion and protective water-based liquid for neutralizing oxides and
2
provide a protective barrier, applying two coats with a total consumption of 0,13 kg/m

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R-IT-06/04
Page 26 / 27
3. Structural repair of concrete elements

Work description
Unit Description
2 ®
m Repair of concrete elements with structural mortars. Repair the cleared areas with MAXREST non-shrinkage
and quick setting structural repair mortar. Clean and dampen the substrate to a saturated, surface dry condition,
®
prior to the application of MAXREST repair mortar. Apply a bond coat by brush and then, apply the mortar with a
trowel or wing pallet until get the original form with float finish.
4. Levelling and resurfacing of concrete surfaces

Work description
Unit Description
2
m Levelling and resurfacing of concrete element surfaces with epoxy/cement-based cosmetic mortar (up to 5
®
mm thick) prior to application of epoxy or polyurethane coatings. Repair the cleared areas with the MAXEPOX
CEM levelling and repair mortar for cosmetic restoration of mortars and architectural concrete up to 5 mm (1,95
2
kg/m ·mm). Clean and damp the surface, prior to the application of the repair mortar. Apply the mortar with a trowel
or wing pallet until get the original form with float finish.
Treatment and waterproofing of concrete surfaces
Work description
Unit Description
2
m Waterproofing of walls, floor and ceiling with flexible and waterproofing polyurethane-based membrane.
®
Apply to coats of the MAXURETHANE FLEX flexible and polyurethane-based waterproof membrane by brush,
2
roller or air-less gun with a recommended coverage of 0,3-0,4 kg/m per coat, which ensures complete
waterproofing even in the most severe conditions. Patch all holes and cracks before waterproofing. Clean and
®
prepare and primer the surface with MAXEPOX PRIMER, prior to the application of the waterproofing membrane.
2
On vertical surfaces, apply in three or four coats to achieve the same consumption, i.e. 0,6-0,8 kg/m .
Finishing of surfaces
Work description
Unit Description
2
m Protective finishing with a polyurethane-based coating. Observe at least about 24 hours of curing time for
®
the MAXURETHANE FLEX polyurethane waterproofing membrane. Appling of two coats of the
® 2
MAXURETHANE 2C protective coating with a recommended coverage from 0,2 to 0,25 L/m , allowing a
drying time between coats of 24 hours, depending on the environment and ventilations conditions.

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R-IT-06/04
Page 27 / 27
6. TECHNICAL DRAWING
TECHNICAL DRAWING #1
Waterproofing and protective system for anaerobic tanks
Preparation of the substrate

1.- Repair with MAXREST® and levelling with MAXEPOX® CEM
2.- Primer MAXEPOX® PRIMER: 0,25-0,50 kg/m2
Waterproofing of the surfaces*

3.- 1st coat of MAXURETHANE® FLEX: 0,3-0,4 kg/m2
4.- 2nd coat of MAXURETHANE® FLEX: 0,3-0,4 kg/m2
Protection of the waterproofed surfaces

5.- 1st coat of MAXURETHANE® 2C: 0,20 - 0,25 L/m2
6.- 2nd coat of MAXURETHANE® 2C: 0,20 - 0,25 L/m2
2
* On vertical surfaces, apply in three or four coats to achieve the same total consumption, i.e. 0,6 - 0,8 kg/m .

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Method of Waterproofing With MAXURETHANE FLEX W

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RECOMENDACIÓN TÉCNICA / TECH.

WATERPROOFING AND PROTECTIVE R-IT-06/04

DRIZORO S.A. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

DRIZORO S.AU. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

2. DESCRIPTION OF THE SYSTEM

3. PHASES OF THE WORK

DRIZORO S.AU. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

The aim of present document is describe a suitable polyurethane-based waterproof coating

2. DESCRIPTION OF THE SYSTEM

- Treatment and clearing of the surface to be coated.

- Sealants and other materials for joints:

DRIZORO S.AU. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

JOB PROPOSED SYSTEM

1. a) MAXJOINT ELASTIC + MAXURETHANE FLEX with DRIZORO VEIL

3. PHASES OF THE WORK

3.1 TREATMENT OF OUT-STANDING POINTS

JOB PROPOSED SYSTEM

Treatment of outstanding points: 1. a) MAXJOINT ELASTIC + MAXURETHANE FLEX with FG veil

DRIZORO S.AU. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

3.1.1. Passing pipes

DRIZORO S.AU. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

Option a) Small size pipes or plastic pipes:

Option b) Big size pipes or metal pipe

Figure 1.- Tight sealing of passing pipes

1.- Opening of a groove along the corner and patching with

Figure 2.- Detail of treatment of concave corners

3.1.3. Anchoring of small elements

3.1.4. Cold joints and non active fissure/cracks

DRIZORO S.AU. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

1.- Opening of a groove along the corner and

3.1.5. Active cracks (subjected to movements)

DRIZORO S.AU. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

1.- Polyurethane-based sealant.

3.1.6. Form tie wire holes, voids and other damages

DRIZORO S.AU. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

3.2. TREATMENT OF EXPANSION JOINTS

Table III.- Products for treatment of expansion joints

JOB PROPOSED SYSTEM

DRIZORO S.AU. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

1.- Polyurethane foam joint backing rod

DRIZORO S.AU. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

1.- Base coat of MAXEPOX® JOINT

2.- Elastic band: MAXFLEX® XJS

3.- Top coat of MAXEPOX® JOINT

Figure 7a.- MAXFLEX XJS over big gaps

1.- Base coat of MAXEPOX® JOINT

2.- Elastic band: MAXFLEX® XJS

3.- Top coat of MAXEPOX® JOINT

Figure 7b.- MAXFLEX XJS over corners

Figure 7.- Elastic sealing system for big gaps/expansion joints

DRIZORO S.AU. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

3.3 STRUCTURAL REPAIR AND LEVELLING OF CONCRETE SURFACES

Table IV.- Products for repair jobs

JOB PROPOSED SYSTEM

3.3.1. Preparation of the substrate

- Removal of any damaged protective, maintenance or superficial coatings, as well as any

DRIZORO S.AU. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

3.3.2. Treatment of the steel reinforcements

3.3.3. Structural repair of concrete elements

DRIZORO S.AU. C/Primavera, 50-52. 28850 Torrejón de Ardoz-Madrid (SPAIN)

Table V.- Structural repair mortars

- MAXREST® is a non-shrink, thixotrophic, quick setting, and structural repair mortar. It is

- MAXRITE® -S is a one-component, non-shrink, and thixotrophic, long-setting, polymer-

- MAXRITE® - F is a one component thixotrophic shrinkage-compensated mortar, with