Directions For Using Elephant Armor® DOT Industrial Grade Mortar or Asphalt Repair Mortar

 

Assess the Damage

Evaluate the extent and nature of the damage to determine the appropriate repair approach. Identify areas of contamination, degraded concrete, or other surface issues that need to be addressed.

 

Safety Precautions

Prioritize safety by wearing appropriate personal protective equipment (PPE) such as gloves, safety goggles, and a mask to protect yourself from dust, chemicals, and potential hazards. Consult the Safety Data Sheet before use.

Download Elephant Armor® SDS

 

Surface Preparation

Surfaces to be treated with Elephant Armor® Mortars must be clean, sound and free from contaminants that can act as a bond breaker (such as oil, grease, dirt, curing compounds, acids, etc.)  It is the applicator’s responsibility to ensure a proper bond. It is mandatory to chemically or mechanically remove any and all curing compounds or contaminants that are present.

 

The surface may require pre-treatment with GST International Degreaser Pro or Pro-Grade Cleaner, followed by power-washing to clean the contaminated surface.

 

Mechanical preparation options:

1.Fastest method for vertical and overhead preparation:

Pressure washing, hydro blasting or sand blast to remove the cream of the concrete, paints or other contaminants. If pressure washing, hydro blasting or sand blasting do not remove contaminates, go to step #2.

 

2. Fastest method for horizontal preparation: Mechanical grind the concrete surface using metal bonded tooling (16 grit or 35 grit) using walk behind grinders with vacuum systems. Hand held grinders with shrouds, vacuum and metal coarse wheel.

 

Rinse and Dry

After cleaning, rinse the surface with clean water to remove any residue from the cleaning solution. Use Pro-Grade Cleaner to neutralize the surface if harsh stringents or acids have been used. Allow the surface to dry completely before proceeding to the next step. Ensure proper ventilation or use drying equipment if necessary.

 

Ecobeton®-USA Vetrofluid® Application (optional step)

In cases where the area to be repaired is severely degraded, an application of Ecobeton®-USA Vetrofluid® should be applied to restore the stability and integrity of the substrate. Allow at least 72 hours for the Vetrofluid® to cure prior to continuing the Elephant Armor® repair.  More about Ecobeton-USA® Vetrofluid®

 

Prime the Area to be Repaired 
The surface is now ready to be primed using one of the following methods:

 

1. EA Primer Slurry Bond Coat:

The EA Primer/Slurry bond coat serves to enhance the bond strength between the damaged substrate and the Elephant Armor® repair material. The slurry coat, when mixed with 1 part Elephant Armor® Mortar to 1 part EA Primer, provides for easy application on the damaged substrate using a roller or stiff masonry brush. If there is any exposed steel or rebar, apply a rust inhibitor first.  Pay special attention to the corners, sides and any exposed rebar.  Elephant Armor® Primer can also be used in a NEAT application. This application conforms to the structural bonding requirements of ASTM C 1059-13, Type II.

 

Important! It is crucial that the slurry coat does not fully dry before placing the Elephant Armor®. The wet and tacky nature of the slurry coat helps retain moisture in the substrate, preventing premature drying and ensuring a favorable environment for the bond to develop. More information on EA Primer Slurry Bond Coat®

 

2. Saturated Surface Dry (SSD):  

SSD is a common practice in the concrete repair industry and may also be used with Elephant Armor®, however there are certain considerations that should be kept in mind. The repair area must be clean and free of all dust, debris, oil and organic stains. Dampen the repair area and place the Elephant Armor® using the appropriate tools and finishing techniques specific to the job. It is important that there is no standing water or pooling on the repair area prior to placement of the Elephant Armor®. See more information on SSD

 

Mixing

Mix the dry contents prior to adding water. Add approximately 5.5 - 6.5 US quarts (5.2 - 6.2 liters) of water (depending on desired slump). It is mandatory to thoroughly mix with a dual shaft power mixer. (example: ColloMix Xo 55 Duo)  

 

Due to our unique product design, this type of mixer is required to ensure sufficient shear capacity needed to properly provide a homogeneous mix.  Do not use a drywall paddle blade.  While mixing, ensure there is no unhydrated Elephant Armor® on the sides or bottom of the bucket, as this will alter the water/cement ratio. Continue mixing until the mixture is lump free and has achieved the desired consistency (slump) for your application. When mixing our ten pound buckets or a small amount of Elephant Armor® Mortar, a ½” drill or larger, using an egg beater, mortar or Jiffy Bit can be used. Actual mixing time will depend on mixer speed, shear capacity, and desired consistency or flow required.

 

Application of Elephant Armor® Mortars

You are now ready to apply the Elephant Armor® repair material. Apply the repair material to the damaged areas, using GST Textured Rollers and GST Squeegee Trowels. Elephant Armor® Mortars can also be sprayed on to repair vertical surfaces.  Follow the our guidelines for mixing ratios, application techniques, and curing times.

 

Application:

• Elephant Armor® Mortars are best placed with a textured roller and squeegee trowel (available at your GST International dealer) or traditional placement tools.

• ¼” and ½” gauges are available to be attached to the textured rollers for a more even finish.

• Do not over-trowel. Wait for initial set before applying final trowelling or a smooth roller finish. Initial set has begun as soon as the ‘bleed water’ begins to dissipate. Set times will vary with weather conditions.

• Elephant Armor® Mortars can be finished with trowels, brooms, decorative rollers or stamping mats.     

• Elephant Armor® Mortars accept integral powder or liquid colors, acid stain and water based or acrylic stains.

• Elephant Armor® Delay added to the mixing water will allow additional working time.
  (Please refer to package instructions)    

• When placing Elephant Armor® Mortars, all repairs should be water-cured for approximately one hour after the mortar has achieved final set.

 

Curing

After completing the repair, provide appropriate curing conditions. Water curing is recommended after final set and the Elephant Armor® has lightened in color. Spray water on the repaired surface 2 or 3 times during a period of approximately 1 hour. Damp cloths may also be placed over the repair area for the same amount of time.

 

Additional Protection

After the Elephant Armor® repair has fully cured, (24 hrs.) it is advisable to apply a light coat of Ecobeton®-USA Vetrofluid®. This additional application of Vetrofluid® helps further to enhance the longevity of the repair, providing an extra layer of protection and bond strength between the Elephant Armor® and the damaged substrate.

 

Clean-Up

Clean-up Elephant Armor® with water, however Elephant Armor® Mortars are fast curing; have additional water on hand to clean the mixer blades and other tools as they are used.

 

Important

GST International has created this instructional guideline for making concrete repairs with Elephant Armor® Mortars using proven techniques and industry best practices. The success of any concrete repair depends on proper implementation, surface preparation, and adherence to industry best practices.  Since GST International cannot ensure these practices are carried out, we can not be held liable nor accept any responsibility for work done by others.

 

Precautions / Limitations:

• Use required Safety Equipment and Best Practices.     

• A feathered edge is not acceptable.    

• Do not add more water than recommended.     

• Do not over work or over trowel the spall repair or overlay.     

• Follow ACI Hot Weather Concreting 305R-99 procedures.

• Do not apply Elephant Armor® Mortars to frozen surfaces, at temperatures below 40° F (4° C).

• Elephant Armor®Primer is not a substitute for water in any proportion with standard mixes of Elephant Armor® mortars.

• Consult the Safety Data Sheet in all cases before use. Download SDS

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