MALTA RAPIDA

Fast Hardening self levelling Epoxy Mortar

Description

MALTA RAPIDA is a three component product made up of:

  • component A: a mix of liquid epoxy prepolymers;
  • component B: copolymerization amine;
  • component C: special inert material and filler.

After application and hardening, the product provides a good base, especially suitable for further coatings with finishing resins.

The product is prepared by mixing the three components to give rise to a self-leveling fluid mortar, available in various colors, particularly suitable for the realization of resin coatings of industrial flooring cast directly on concrete, without primer.

The main feature of MALTA RAPIDA (fast mortar) is the ability to spread evenly even if applied on uneven concrete surface irregularities, such as on blasted concrete or tiles with wide joints.

MALTA RAPIDA exhibits excellent adhesion on the substrate and a high compressive strength.

MORTAR RAPIDA is especially designed to harden in about 5 hours from laying (at T = + 20 ° C and 50 RH), so as to be able to proceed even with two treatment per day and accelerate the realization of resin floorings.

Usage field

MALTA RAPIDA is used as:

- smooth surface resin coating applied to a thickness of 2 mm for dry processing areas of various industrial sectors with high traffic of forklifts;

- a 1mm thick base layer, with quartz broadcast into the surface, for the subsequent realization of finishes of various nature in:

  • industries of all types, in particular processing plants in a humid environment;
  • in showrooms and shops, on existing natural stone or  tiled surfaces;
  • in homes;
  • in offices.
Packaging

MALTA RAPIDA is available in the following packs:

  • 20 kg (A+B+C) in the SUMMER version;
  • 17.5 kg (A+B+C) in the WINTER version.

MALTA RAPIDA

Fast Hardening self levelling Epoxy Mortar

Substrates preparation

For what concerns resin floorings, the surface should be prepared according to the current dictates of the state of the art the surface must be carefully examined to be sure it is a suitable base and structurally sound:

  • sand and cement screeds: must have been properly cured (for at least 28 days) have a compressive strength greater than 20 MPa and with a residual moisture content of less than 3% (tested in accordance with ASTM Calcium Carbide Test Method D4944) - otherwise consolidate it with diluted NORPHEN SW SOLID and apply a coat of SOLID to protect from moisture.
  • Quartz industrial concrete: apply after the product has cured, with a max moisture content of 3%, after roughening the surface with light blasting or diamond grinding discs diamond, if required, eliminate joints and cracks by "stitching" grouting iron rods in the cast.
  • Stoneware and clinker tiles: should be roughened with a diamond cup wheel or treated with a primer for glossy surfaces like RICRETE 1C.
  • Wood panels: treat the couplings with a strip of RETE DI VETRO (glass fiber mesh) 160 g / m² (of approx. 5 ÷ 7 cm wide) and fix it to the substrate with NORPHEN PU spreading it with a spatula.
Specific preparation

Grouting the Substrate:

in case of existing holes and depressions exceeding 3 mm to be repaired, MALTAFIX must be uses (cement based and fast setting mortar) or a mixture of NORPHEN FONDO SL thickened with 5% EPOXY SILICA;

 

Substrates with a moisture content between 3 and 6%:

• apply a coat of SOLID, on the already roughened surface;

 

Substrate with a moisture content exceeding 6%:

 • apply the cycle Q-PRIMER + Q-RASANTE, on the already roughened surface;

 

Section Joints

Preliminary note: the suggestions on how to treat and manage joints given herein are the result of years of experience and are based on the observation of the typical behavior of concrete: therefore they have no absolute value.

Treatment of hardened quartz concrete floors separation joints prior to applying a MALTA RAPIDA coating over:

a) Quartz industrial floorings with thickness up to 15 cm with a single reinforcement mesh that have been cured for less than 1 year:

  • coat the hidden joints by "stitching" with the insertion of steel rods

or

  • seal the joint with NORPHEN FONDO SL thickened with 5% EPOXY SILICA;
  • coat with MALTA RAPIDA and, after hardening, cut and visibly seal with NORPHEN PU.

b) Floors as in point a) but with a thickness exceeding 18 cm and two reinforcing meshes or with a single mesh + steel fibers (or PE) cured for at least 3 months:

  • seal the joints by filling as above-mentioned and coat with MALTA RAPIDA;

c) the max. area recommended for "stitching" with steel rods should be approx. 500 m2

Product preparation

For thick coatings with smooth surface and 2 mm in processing self-leveling:

  • mix 15 kg of MALTA RAPIDA COMP. C with 5 kg of COMP. A + B SUMMER version;
  • mix 12.5 kg of MALTA RAPIDA COMP. C with 5 kg of COMP. A + B WINTER version;

Laying using a notched steel blade plastering trowel (triangular notch H 5 mm - L 6 mm for standing work and a spiked roller with steel pins.

For thick coatings approx. 1 mm by skimcoating with a flat steel trowel, to be broadcast to excess with quartz sand of various grain size:

  • mix 10 kg of MALTA RAPIDA COMP.C with 5 kg of COMP. A+B in either SUMMER or WINTER version.

Laying: with a flat steel trowel for skim coating followed by quartz broadcasting.

Product application

Working times

MALTA RAPIDA is quite reactive even at low temperatures; as regards application temperatures, the minimum time required for the resin to suitably harden up in order to take any further finishing layer is reported herebelow:

 

Product version

Temperature [°C]

Time [hours]

Winter

+1

24

Winter

+12

5

Summer

+20

5

MALTA RAPIDA

Fast Hardening self levelling Epoxy Mortar

Average Consumption

For a 2.5 mm coating you will need c. 4 kg/m2.

MALTA RAPIDA

Fast Hardening self levelling Epoxy Mortar

Colors

MALTA RAPIDA is supplied in its standard colourless version. A colour version can be required for use as a finish coating.

The cost can vary according to the required colour.

Features

mass per volume, UNI 8310

SUMMER

g/cm³

1.96 ± 0.05

WINTER

1.88±0.05

pot-life, UNI EN ISO 9514

SUMMER

Min

7  (at +15°C)

5  (at +23°C)

WINTER

20  (at +1°C)

5  (at +15°C)

minimum setting time

Days

> 7

application temperature

SUMMER

°C

+15 to +30

WINTER

0 to +15

adhesion to concrete (pull-off test), ASTM D 4541 (support breaking)

Mpa

 

3.5 ± 0.5

 

resistance to UV cycles and condensation, ASTM D 4329

(168 hours exposure)

ΔE

Δ loss

> 35

> 80

bending resistance, UNI EN-196-1

Mpa

35 ± 1

compression resistance, UNI EN-196-1

Mpa

80 ± 2

hardness (Shore D), ASTM D 2240

D

> 65

abrasion resistance, UNI 8298/9

Mg

Aprox. 50

A : B : C Ratio

SUMMER

2 : 1 : 9

WINTER

2 : 1 : 7.5

Note: test data refer to quoted regulations.

MALTA RAPIDA

Fast Hardening self levelling Epoxy Mortar

Warning and informations
  • Measure the temperature of the room where you are going to work in order to be able to choose the correct product version accordingly:

Temperature interval [°C]

MALTA RAPIDA Version

From +0 to +15

WINTER

Over +15

SUMMER

  • Remember that you must keep working on the product; a team of people should be perfectly timed to get the next mix ready just as they finish with the previous one, with no gaps in between.
  • According to room temperature, the product must be kept cool in summer, to prevent an increase in the system reaction time with temperature, and warm in winter, as in the cold weather resins tend to crystallize and become less fluid.
  • Mix components A, B and C in the exact amounts reported on the label: if needed, and in order to use only part of the pack, weigh out the ingredients according to the correct component “Ratio” reported on the pack.
  • Do not apply on:
    1. parquet;
    2. linoleum;
    3. rubber;
    4. any surface likely to expand considerably on the joining gaps.
  • Read the Safety Card
Preservation

Store indoors, at temperatures ranging between +5 and +30°C.