MasterCast® 141

Guidelines and Recommendations for use

To be read in conjunction with the MasterCast 141 technical datasheet

MasterCast® 141
Guidelines and Recommendations for use
Concrete repair using MasterCast 141
Concrete repair and renovation If chlorides are present, deterioration may
It is generally accepted that concrete is best occur in adjacent areas, due to chloride
repaired with concrete or cement mortar. To action, although at the time of repair no
meet this requirement for a cementitious repair defect is apparent. Protection of adjacent
system, BASF have developed the following areas helps to limit any further decay.
method which incorporates the use of
MasterCast 141, as a simple, versatile and 2. Preparation
cost effective system for the renovation of i. Carry out preparation of the defective area
concrete. thoroughly and in accordance with current
good practice.
The method is especially suitable where due to ii. Mechanically clean reinforcing steel to
logistical or economic considerations, the use of remove all corrosion products. Wash
MasterEmaco pre-bagged repair products is not reinforcing steel with clean water (to remove
appropriate. soluble salt contamination) and allow to dry.
iii. Avoid feather edging around patch repairs
SBR based concrete repair method by saw cutting to 5 mm.
Most repairs can be executed using the
following method, which is based on established 3. Priming
good practice and the use of MasterCast 141. i. Brush apply a primer coat of 1½:1 cement :
This repair method will give durability similar to MasterCast 141 by weight over freshly
that of the surrounding concrete fabric. cleaned and dry reinforcing steel. Allow
primer to dry for 16 to (not exceeding) 36
The method is outlined below: hours.
1. Diagnosis ii. Pre-wet the prepared concrete substrate (so
i. Ascertain the cause of failure. that concrete is saturated but surface is free
Ensure that the new repair is carried out in of water).
such a manner that the original cause of iii. Re-prime reinforcement and concrete with
failure is eliminated - this will make certain primer as 3.1 above.
that, in the future, a similar failure does not
4. Repair
re-occur in the repair or alongside it.
i. Whilst the primer is still wet, carefullyapply
ii. Determine whether chlorides are present.
and compact a mix comprising of 50kg OP
MasterCast 141 repairs are generally
cement, 150kg well graded BS 882 C&M
recognised as being one of the most
(previously Zone 2) sand and 10 litres of
effective ways of limiting further problems
MasterCast 141, adding water as required
caused by high percentage of chlorides in
to give sufficient workability. Yield is 0.1 cu.
concrete.
metre.
ii. REPAIR MORTARS SHALL NOT BE
APPLIED TO DRY MasterCast 141
PRIMER. APPLY INTO WET OR TACKY
PRIMER ONLY.
MasterCast® 141
Guidelines and Recommendations for use
Comments: The method is often applied to leaking lift pits or
i. On vertical patches, coats can be applied up wells, basements, inspection pits and other
to 25mm thick, provided slumping does not underground structures. It is also used to
occur. This depends on the repair size and waterproof liquid storage tanks, bund walls,
geometry. On larger flat areas, coats should swimming pools, water towers and sea (or other
not exceed 6mm in thickness, though immersed) structures.
several coats can be applied in quick
succession, each coat setting firm before Leaking basements and pits
The walls may be dry or damp, but free of
the next is applied (usually between 15-30
running water. In this case the remedial
minutes, dependent on ambient conditions).
tanking is relatively straightforward.
Finish off the final surface. Alternatively -
Alternatively, water may be leaking under
scratch the first coat after application, allow
pressure, in which case special measures
to dry overnight and then apply a second
have to be taken.
coat.
Liquid retaining and submerged structures
5. Watchpoints: Internally applied tanking is equally successful
i. Do not mix more mortar than in preventing penetration of liquid into the
can be used within 30 minutes. structure and, particularly, in stopping leakage
ii. If shuttering is required, this should be from concrete liquid retaining tanks. When
prepared and fitted ahead. The shutter is aggressive chemicals are involved, an
then removed and MasterBrace ADH 1414 appropriate protective coating from the
epoxy bonding agent is applied (instead of MasterProtect range may be applied over the
MasterCast 141 slurry). The shutter is system.
replaced and the repair is completed
without delay. Leaking basements and pits
iii. Do not provide less than 10mm absolute 1. Initial inspection
minimum thickness of repair mortar over Clear away all water and closely inspect the
reinforcement. structure to determine that the existing walls
and floors are sound. Any cracks must be
6. Curing static (otherwise watertight movement joints
Moisture cure for 24 hours only and then will have to be formed). Any defects must be
allow to dry out slowly. All the above rectified prior to commencing waterproofing
work is to comply with the and the substrate must be sound. Check that
recommendations detailed in the the structural floor and walls are capable of
MasterCast 141 technical data sheet. taking the hydrostatic load that will result once
waterproofing is completed (the water level
Internal waterproof tanking with
may well rise once leakage is stopped).
MasterCast 141 modified mortars
MasterCast 141 modified mortar is ideal
for waterproofing new build or existing
structures subject to water pressure
(pressures up to 20 metre head of water or
more can be handled by this method).
MasterCast® 141
Guidelines and Recommendations for use
2. Preparation Apply 13mm screed to horizontal surfaces, or
Prepare the surface to be waterproofed. two coats of render on vertical surfaces (to
Remove any laitance from the concrete achieve 13mm total thickness), to tank the area
and weak or delaminating brickwork. completely. When the screed has dried
Brush down and clean off. This sufficiently to take foot traffic, apply fillets of the
preparation is often carried out by use of same mortar at floor/wall junctions and internal
scabblers or chipping hammers. wall angles.
At the junction between floors and walls
Notes:
or other upstands, apply a 25 – 50 mm
Mortar mixes for screeds, renders and fillets are to
triangular fillet using the MasterCast 141
be 3:1, BS 882 C&M sand (previously Zone 2) OP
vertical render mortar mix. Allow to dry
cement, + 10 litres MasterCast 141 per 50kg
for 24 hours.
cement. (For render, BS 1199 Table 1 sand can
be used). Add water as required for workability.
3. Water leakage under pressure
If leaking is under pressure, cut into the For high water pressure, increase MasterCast 141
structure to relieve the pressure at use to 15 litres per 50kg cement. (In this case sand
points of severe leakage and pipe water must not be too wet or the desired workability may
away to a drain or pump. (Pipes are set be unattainable).
in and any remaining leaks are plugged
5. Movement
using the techniques described
Form watertight joints where further movement is
overleaf). expected. Form rebates at joints and waterproof
leaving an approximately 25 x 25mm rebate. Apply
4. Waterproofing MasterSeal PG 470 onto the primed joint and
i. Thoroughly pre-wet any dry surfaces, waterproof over, as illustrated.
making sure that they are saturated (but Typical movement joint
surface free of water).
ii. Mix a MasterCast 141 slurry of 1 part
MasterCast 141 to 1½ to 2 parts of
cement by volume. Mix to a smooth,
creamy paste.
iii. Brush apply two full coats of this slurry,
to a total thickness of approximately
1mm, allowing the preceding coat to dry
Alternatively, covering the joint with MasterSeal 930,
(usually overnight) prior to applying the
joint strip, maybe appropriate. Consult your BASF
second at right angles to the first.
representative for further advice
iv. When the slurry coats have dried, apply
a third coat (at right angles to the
second) and immediately render or
screed onto it.
MasterCast® 141
Guidelines and Recommendations for use
6. Removal of pressure-relieving pipes: Fixing brick slips, tiles, copings, kerbstones
When the waterproofing has cured, etc. using MasterCast 141
remove pipes (if placed), plug holes and
MasterCast 141 modified mortar is ideal for
make good the waterproofing.
waterproof and chemical-resistant bonding and
Liquid retaining and submerged bedding of slip bricks, tiles, glass blocks,
structures Similar techniques to those mosaics, kerbstones and precast units.
outlined in Sections 1, 2, 4 and 5 above are
Fixing method - brick slips and tiles Prepare
used to provide a MasterCast 141
the substrate to receive the mortar - see
waterproof lining.
MasterCast 141 technical data sheet. It is
Plugging leaks imperative that a good mechanical key to a
Leaks and holes drilled to relieve water sound, strong and stable substrate is achieved
pressure are sealed permanently using when fixing slip bricks and unsupported tiles.
MasterSeal 590 applied as recommended. To The thickness of the mortar bed should normally
plug leaks under pressure, chase out the area be 6mm, but in special circumstances this can be
of the leak until water flow is free; insert a increased upto a maximum of 12mm.
length of plastic hose leading to a suitable
1. Thoroughly clean the substrate and saturate
drain or pump sump. Seal around the plastic
with clean water. Remove all free water
hose using MasterSeal 590 plugging
(leaving surface damp only). Thoroughly
compound as above: applied with a gloved
dampen the back of the brick or tile to reduce
hand. When set hard, clean the cavity and
suction.
apply a slurry of 1½ to 2 parts OP Cement to
approximately 1 part of MasterCast 141.
2. Provide rigid temporary support for any
Repair the hole around the pipe with a
unsupported bottom courses and brace
MasterCast 141 mortar and allow to cure.
where necessary. Bottom courses should
When the surrounding MasterCast 141 be permanently supported over at least 75%
mortar waterproofing is complete, withdraw of their length.
the pipe and plug the hole with plugging
3. Apply a MasterCast 141 bonding slurry to the
compound as above, using a gloved thumb to
back of the tile and to the substrate whilst still
hold it in place until set (approximately 1
damp.
minute). Fill the remainder of the hole with
mortar and when firm, complete the 4. Before the bonding slurry starts to dry, butter
MasterCast 141 waterproofing ensuring that the back of the tile or brick with mortar to
the slurry coats overlap the slurry coats of the give the desired thickness and firmly press
surrounding waterproofing. home to ensure complete contact. Strike off
Similar techniques are used for plugging surplus mortar. Do not disturb until set.
leaks that do not need to be piped. Cure and protect as recommended.

5. Similar mortar may be used for pointing joints -

but not until at least 24 hours have elapsed.
MasterCast® 141
Guidelines and Recommendations for use
Notes: Floor screeds and toppings using
Adequate slip and compression joints must MasterCast 141
be provided, together with vertical joints Applied to properly prepared sound substrates,
where appropriate at centres not exceeding suitably designed mixes modified with MasterCast
4 metres. As a general rule, brick slips 141 produce thin (6mm-25mm) floor toppings
should not be less than 20mm or more than which exhibit improved impact and wear
35mm thick. Tiles and concrete claddings resistance together with added resistance to many
should not exceed 35kg/m² maximum chemicals. These floors are economical, dustproof
weight. Hard, dense and/or smooth and durable.
materials should have moulded lugs or Similar mixes can be used as unbonded screeds
keys on the back surface. of 35mm- 60mm thick.

All the above work is to be carried out as Laying of MasterCast 141 screeds and toppings.
generally recommended in the MasterCast
141 technical data sheet and relevant local 1. Inspect the substrate for defects and where
standards. necessary repair with MasterCast 141 mortar -
refer to Guidelines and recommendations for
concrete repair.
Recommended mix
Rapid hardening Portland cement: 50kg
2. Thoroughly prepare the substrate. The floor
BS 882 M&F (previously Zone 3) 150kg
topping is only as good as the substrate onto
sharp washed sand:
MasterCast 141: 15 litres which it is laid. The substrate must be load-
Add water as necessary: approx. 3 litres bearing and stable throughout the life of the
wearing topping and preparation must be
For thicknesses less than 6mm (for light tiles adequate - refer to Guidelines and
only, and not less than 4mm), BS 882 F recommendations for preparation of substrates
(previously Zone 4) sand can be used. If over for further guidance.
6mm bed is unavoidable (but not more than
12mm), BS 882 C&M /previously Zone 2) The vast majority of floor failures are due to
sand is recommended. For heavier tiles and poor preparation and the need for good
slip bricks, applied to a dense background, preparation cannot be over-stressed.
reduce the sand content to 125kg.
3. The minimum thickness of MasterCast 141
MasterCast 141 modified mortars are also screeds is 6mm. Do not feather edge. Cut
ideal for bedding kerbstones or precast rebates for thickening at threshold joints and at
units following the same principles as free edges. It is recommended that these
outlined above. rebates give double the screed depth and width
overall.
MasterCast® 141
Guidelines and Recommendations for use
Typical edge detail Mix designs
1. Medium duty floor screeds and toppings

Normal thickness 12mm (min. 6mm, max. 25mm)

Mix by weight:
OP Cement 50kg
Zone 2 sand (BS 882 Grade C&M) 150kg
MasterCast 141 10 litres
4. Thoroughly clean off the substrate and Add water as required approx. 5-7 litres
saturate with clean water. Remove all Yield approx. 0.1m³
free water (leaving the surface damp
Note:
only).
Reduce sand content to 125kg for thicknesses
5. Fix screed battens to level. under 10mm.

6. Work a MasterCast 141 bonding slurry into 2. Heavy duty floor topping
the floor, using a stiff brush to give a Recommended thickness 20- 25mm
thickness of 1 to 2mm. Mix by weight:
Ensure that coverage is complete and that
the slurry is still wet when the flooring is OP Cement 50kg
Zone 2 sand (BS 882 Grade C&M) 75kg
placed onto it. Do not apply slurry too far
6mm single size clean granite aggregate 75kg
ahead of the floor laying. Re-apply slurry if
MasterCast 141 10 litres
the earlier application dries. Add water as required approx. 5-7 litres
Yield approx. 0.1m³
7. Mix and place the MasterCast 141
modified mix in accordance with the 3. General notes:
technical data sheet recommendations.
Increase the MasterCast 141 content to 15 litres if
Finish as the work proceeds - i.e.,
watertightness or enhanced properties are
immediately after placing. required. (Do not use wet aggregates or the
desired workability may be unattainable).
8. Moisture cure for a minimum of 1 day
before allowing to dry out slowly. Protect MasterCast 141 can also be used to advantage
and do not traffic until sufficiently hard. in textured and architectural floor finishes etc.,
the rate of addition normally being 10 litres per
50kg of cement and the mix design being
dependent on aggregates being used and the
finish desired.
MasterCast® 141
Guidelines and Recommendations for use
Preparation of substrates using 2. Reduction to accommodate the application
MasterCast 141 Some repairs necessitate reduction of the
Preparation of substrates prior to repair existing substrate to accommodate the
minimum thickness of the application. This is
The performance of MasterCast 141 repairs,
frequently the case, for example, when slabs or
whether patches, renders, screeds, toppings
pavements are being resurfaced.
or slurry only, is dependent on the surface to
Reduction can be carried out by planers, by
which they are applied being suitable to
sharp scabblers or by blasting with very high
receive them and so to develop the full
pressure water, grit or sand. As above, care
potential of the MasterCast 141 mixes used.
must be taken to remove material from the
Depending on the nature of the repair,
substrate surface without causing damage to
preparation may involve one or more of the
underlying layers below.
following processes:

1. Removal of defective substrate and After reduction, the thickness achieved should
exposure of corroded steel. be as constant as possible - avoid high points
2. Reduction to accommodate the application. and depressions. If a change of thickness is
3. Preparation of the surface - this is unavoidable, it must be very gradual.
necessary in practically every case (unless However, free edges of floors should have a
already clean and suitable). thickening - refer to the Guidelines and
recommendations for preparation of
substrates.
1. Removal of defective substrate
and exposure of corroded steel Test the reduced surface for soundness -
Identify the decayed or damaged area. Mark probe to ensure that there are no soft or
clearly. Saw cut the perimeter of the area to weak areas.
be treated or cut neatly, keeping the sides of
the areas as square as possible. Defective 3. Preparation of the substrate surface
material must be removed carefully using This applies to untreated surfaces and to
suitable reducing plant, needle guns or sharp treated surfaces (as 1 and 2 above) that are
tools and chipping hammers. The force not sufficiently regular and/or not adequately
applied must not be such as will damage textured. Texturing can be achieved by
sound material beneath; for this reason jack scabbling or light grit blasting.
hammers must never be used.
The lightly textured but firm surface must be
If unsound material or corroded brushed clean of all loose debris, dust and
reinforcement is found to extend beyond standing water. An air lance using oil-free
the premarked area, extend the cutting as compressed air or an industrial vacuum aid
necessary, treating the edges as above. If thorough cleaning.
corroded, ensure that the back of the
reinforcement is exposed to a depth of
20mm. Test the substrate exposed for
soundness.
MasterCast® 141
Guidelines and Recommendations for use
The surface must be thoroughly wetted has been corroded away and the reduction might
down and kept damp for at least 1 hour; free impair the strength of the structure, the missing
water is then removed, just prior to cross- sectional area must be reinstated. This is
application of the MasterCast 141 slurry. usually achieved by lapping in or anchoring
additional reinforcement. When in doubt, an
Watchpoint
Engineer’s advice must be sought. Critical cross
If a surface is contaminated, e.g.: by oil, all
sectional areas are usually those of main bars
the contaminant and any contaminated
and shear reinforcement in areas of high shear. A
substrate must be removed prior to
10% reduction in cross-sectional area is usually
preparation of the substrate. Light oil or
accepted as the maximum permissible, but each
grease deposits should be removed with a
and every case must be considered on its merits.
degreasing solution. Heavy oil deposits
should be removed by hot compressed air. If
Watchpoint
purpose designed equipment is not available,
Always ensure that concrete repair extends to
a propane gas torch may be used to heat the
the limits of corrosion and for a nominal distance
concrete and dry out the deep seated oil.
beyond (say 25mm). This may mean cutting
Care must be taken when using this method
beyond the edges of the decayed concrete or
to heat the concrete slowly. Keeping the torch
behind the reinforcing bars to expose corrosion.
trained on one spot to effect a rapid heat
Before cutting structural concrete away,
build up will cause the concrete to spall
consider structural stability.
violently

Temporary structural support and / or

The need for adequate preparation
removal of load
There is no substitute for good substrate
The structural significance and safety of each
preparation prior to application of MasterCast
repair process should be considered and, if
141 mixes.
necessary suitable propping must be provided
If a reduced standard of substrate preparation
during repair.
is undertaken, the user cannot expect to
achieve the full potential of the MasterCast Properties of MasterCast 141 and modified
141 repair. Poor substrate preparation can be mortar
the cause of future failure of a repair. MasterCast 141, styrene butadiene co-
polymer latex rubber:
Cleaning corroded reinforcement
Reinforcement should have all the corrosion Typical values
removed by use of powered tools, abrasive
pH 10.5
blasting, water jetting or wire brushing, as
Specific gravity 1.01
appropriate. For basic repairs, clean the steel
Freeze-thaw Withstands at least 5 freeze
removing all corrosion and leaving clean. stability thaw cycles, but inside storage
Where chlorides are present in significant above 0°C is recommended
amounts, all rust must be removed by grit Particle size 0.17 micron*
blasting. After cleaning reinforcement, it is Stabilisation Non-ionic
advisable to finally wash and dry (to remove
final traces of soluble salts). If excessive steel
MasterCast® 141
Guidelines and Recommendations for use
Butadiene content 40% by weight of the SBR Tensile strength
polymer BS 6319 Part 7 but at pulling rate 1.5mm/min.
Antioxidant Yes (Curing condition modified as above).
Bactericide Yes
Antifoam Yes Adhesion method 1
Minimum film Approximately 1°C A half dumb-bell of steel or cured mortar was
forming placed in a tensile mould as above, primed and
temperature the test mortar compacted against it. Pulling
Shelf life 12 months, but from above rate: 1.5mm/min.
(interior storage) 0°C to 25°C agitate before use
after prolonged storage Adhesion method 2
*A cubic mm of dried film is made up from more than Slant Shear BS 6319 Part 4.
125,000,000,000 particles
Water vapour permeability
BS 4016/BS 3177 11mm thick test pieces.
Tests on performance properties of
MasterCast 141 modified mortars Water penetration
30 metres per head of water was applied to one
Mix formulation for test:
face of a mortar disc 85mm diameter, 15mm
All mixes were prepared with 3 parts BS 882
thick. The volume of water passed in a given
Zone 2 sand and 1 part Ordinary Portland
time was then measured.
cement. The level of MasterCast 141 was
varied. Comment:
Test results are tabulated overleaf. These results
The minimum quantity of water was used to illustrate that the incorporation of MasterCast
achieve a reasonable consistency in accordance 141 in cement mortar significantly improves
with normal good working practice. Typically adhesion, tensile and flexural strengths, both at
water:cement ratio was 0.5 for unmodified normal working temperatures and under extreme
mortar, 0.28-0.34 for modified mortars. conditions of use. Very good resistance to a wide
range of chemicals is also demonstrated. It is
Unless stated otherwise, results were obtained
apparent that MasterCast 141 enables highly
after ageing specimens for 28 days. Curing
water resistant mortars to be designed with low
conditions were:
w:c ratios and low water penetration
1 day wet, 27 dry for ”DRY” and normally 1 wet, characteristics.
20 dry, 7 wet for ”WET” (abbreviated on next
page to 1W27D, 1W20D7W).

Test methods
Air content
BS 4551: 13:2 or 13:3.

Compression tests
BS1881: Part 116: (Curing condition
modified as above).
Flexural strength
BS 4551: (Curing condition modified as above).
MasterCast® 141
Guidelines and Recommendations for use
Test results MasterCast 141 modified mortars
MasterCast 141 ltr/50kg cement 0 10 12.5 15 20
Values in N/mm²
Adhesion to concrete: 1W27D DRY 0.07 2.0 - 2.1 3.4
Test method 1 1W20D7W WET 0.3 1.0 - 0.9 1.4
1W20D63W WET 0 1.4 - 1.8 2.1
Adhesion to steel: DRY 0 2.0 - - 1.6
WET 0 - - - 1.3
Slant shear adhesion (mortar/SBR mortar using 141
bonding slurry) Test method 2: - 31 - - -
Tensile Strength: DRY 3.0 - - - 4.3
WET 1.8 - - - 3.9
Compressive Strength: DRY 56.0 50 - - -
Flexural Strength: DRY 7.1 - 13.2 - 10.6
WET 5.8 - - - 9.6
Effect of chemicals on Flexural Strength after 6
months immersion:
Untreated DRY 7.2 - 13.2 - -
10% Potassium Hydroxide DRY 6.1 - 12.3 - -
10% Magnesium Sulphate DRY 4.3 - 13.3 - -
5% Lactic Acid DRY 5.9 - 8.0 - -
10% Sucrose DRY 5.9 - 9.2 - -
5% Hydrochloric Acid DRY 0 - 2.2 - -
20% Ammonium Nitrate DRY 2.6 - 4.8 - -
Petroleum Spirit DRY 7.7 - 7.5 - -
Effect of extremes of temperature
Flexural Strength:
Untreated 7.1 - - - 10.6
After 60 freeze/thaw cycles in 10% brine at -18°C 0 - - - 10.4
After 1 year at 70°C 5.2 - - - 14.3
Adhesion to concrete:
Untreated 0.1 - - - 3.4
After 6 months at 70°C 0 - - - 2.6
Co-efficient x 106
Thermal expansion (linear): - 20°C to + 20°C 12.7 - - 12.8 -
+ 20°C to + 60°C 12.8 - - 12.9 -
Shrinkage during drying:
w/c ratio 0.40 0.34 - 0.34 0.30
% shrinkage 0.07 0.02 - 0.01 0.01
g / m² / 24 hrs
Water vapour permeability: 46.9 38.1 - 3.9 1.9
Water penetration: kg / m² / 24 hrs
with MasterCast 141 in mortar 100 35 - 0 0
with MasterCast 141 / cement sealing coats 0 - - - -
on unmodified mortars
 MasterCast® 141
Guidelines and Recommendations for use

BASF_CC-UAE/MCast_141Guide_09_95/v1/03_14/v2/02_19
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STATEMENT OF our best scientific and practical knowledge. As the information herein is of a general nature, no assumption can be
RESPONSIBILITY made as to a product's suitability for a particular use or application and no warranty as to its accuracy, reliability or
completeness either expressed or implied is given other than those required by law. The user is responsible for
checking the suitability of products for their intended use.

Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF either
NOTE orally or in writing may be followed, modified or rejected by the owner, engineer or contractor since they, and not
BASF, are responsible for carrying out procedures appropriate to a specific application.

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P.O. Box 37127, Dubai, UAE to certified management system and
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