Pultrused carbon fibreplate pre-impregnatedin epoxy based resin,protected by a doubleplastic film

WHERE TO USERepairing and reinforcing reinforced concretestructures damaged by time and natural causes.Anti-seismic strengthening of structures built onearthquake zones.

Some application examples Repair and upgrade of beams for flexural

strengthening.

Repair of structures damaged by fire.

Repair of structures damaged by earthquakes.

Restore bi-dimensional structures such as plates,slabs, small vaults and tanks with high bendingradius.

Reinforce viaduct slabs after an increase of staticand/or dynamic loads.

Reinforce industrial and/or commercial structuresas a consequence of an increase of static loadsbrought on by equipment, machinery, etc.

Reinforce car park decks in residential andindustrial buildings.

Reinforce structures subject to vibration.

Anti-seismic strengthening of vaulted structureswithout having to increase the seismic masses andwithout danger of liquid percolation towards theinternal surface of an archway.

Reinforcement of load bearing elements inbuildings that have been restructured forarchitectural reasons or change of use.

TECHNICAL CHARACTERISTICSCarboplate is a range of pultrused carbon fibreplates, with high resistance and flexibility, for platingprestressed reinforced concrete and steel structures.

Carboplate can replace conventional steel sheetsthat are used for plating.

Carboplate is available in different widths (50, 100 and 150 mm) and with three modules ofelasticity (170, 200 and 250 GPa).

Carboplate E 170 Carboplate E 200 Carboplate E 250

Because of its composition and manufacturingprocedure, which ensures constant properties to allparts of the material, Carboplate has the followingproperties:

high tensile strength; light weight; reduced thickness; excellent endurance strength.

ADVANTAGESUnlike work based on conventional methods, theCarboplate range of products, thanks to their

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extreme light weight, can be used withoutthe need of special machinery orequipment and in a very short time, oftenwithout downtime of the structure.

Unlike the plating method using metalplates (bton plaqu method), Carboplatedoes not need temporary reinforcementsduring placing and removes all risks ofcorrosion of the applied reinforcement.

Unlike the plating method usingimpregnated fabric on the job-site,Carboplate can be applied quickly and thefull success of the operation depends lesson the operators ability.

Because of its degree of flexibility,Carboplate can be used to line cylindricalstructures (basins, storage bins, holdingtanks, etc.) with a bending radius greaterthan 3 m.

RECOMMENDATIONS Before bonding, make sure that the

concrete substrate has a tensile strength > 1.5 MPa.

Do not use Carboplate on un-curedconcrete.

On particularly porous surfaces or onconcrete placed in environments with ahigh R.H. (underpasses, basements,etc.), it is recommended to applyMapeWrap Primer 1 to prime thesesurfaces before bonding the Carboplate(refer to the relevant technical data sheetfor the preparation and application of theproduct). The following application ofAdesilex PG1 or Adesilex PG2 must becarried out while MapeWrap Primer 1 isstill fresh.

APPLICATION PROCEDUREPreparing the concrete substrateThe surface on which Carboplate has tobe bonded must be perfectly clean, dry,mechanically strong and smooth (theroughness must not be higher than 1 mm).

All traces of form-release agents,varnishes, paints and cement laitance mustbe removed from the substrate bysandblasting.

If the concrete has deteriorated in depth,remove the damaged parts manually ormechanically or by hidro-scarifyingpneumatic bush hammering.

Remove all traces of rust from metalreinforcement rods and protect withMapefer, a two-component corrosion-inhibiting cement mortar or Mapefer 1K,one-component, corrosion-inhibitingcement mortar (follow application methodsdescribed in the relevant technical datasheet).

Repair the concrete surfaces with productsfrom the Mapegrout range.

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Wait at least 3 weeks before applyingCarboplate.

If reinforcement must be carried outimmediately, use epoxy mortars such asAdesilex PG1 or Adesilex PG2 to repairthe deteriorated concrete.

Products to use for bondingIn temperatures between +5C and +20C,use Adesilex PG1.

Adesilex PG2 should be used intemperatures higher than +20C because ithas a longer pot life.

Preparing Adesilex PG1 andAdesilex PG2Mix together the two components thatmake up Adesilex PG1 and Adesilex PG2.

Pour Part B into Part A and mix with a drillfitted with a stirrer until the mix is perfectlysmooth and even (the same colour greythroughout).

The components are already in correctproportions. Do not use partial quantities.

Bonding the Carboplate Carboplate is supplied in rolls that must

be cut on site according to the desiredlength with an electric saw fitted with adiamond blade.

During its manufacturing, the sides ofCarboplate are protected by a plasticsheet. This material protects the platefrom dirt while cutting.

Before bonding, this sheet must beremoved from the Carboplate, that willbe placed in contact with the chosenepoxy adhesive.

Prime the surface that needs to bereinforced with MapeWrap Primer 1(particularly porous surfaces or onconcrete placed in environments with ahigh R.H.).

Apply a uniform 1-1.5 mm thick layer ofAdesilex PG1 or Adesilex PG2 (inrelation to the temperature) with a flattrowel over the Carboplate on the sidewhere the protective sheet has beenremoved.

Apply a layer of Adesilex PG1 orAdesilex PG2 also on the substrate (thatmust be clean and dry) that will receivethe plate. If the surface has been primedwith MapeWrap Primer 1, theapplication of the adhesive layer must becarried out while the primer is still fresh.

Install the Carboplate applying aconstant pressure over the wholesurface. Use a stiff rubber roller andremove the excess resin with a trowelpaying attention not to move the plate.

A view of the bridgeduring reparation work

Fixing Carboplate inespecially createdareas on the substrate

A bridge-deckreinforced withCarboplate

For plating curved structures, it isnecessary to use clamps or supports tohold the plates in place until the resin hascompletely hardened (usually 24 hoursbefore removing the temporary supports).

If more layers of Carboplate arenecessary, remove the second plasticfilm from the already installed plate once Adesilex PG1 or Adesilex PG2 has set,before installing the next plate.

The surface plated with Carboplate can beprotected with Mapelastic, Elastocolor orwith a fire resistant paint. The protectioncoat can be applied 24 hours after theinstallation of the plates.

PRECAUTIONS TO TAKE DURINGAND AFTER APPLICATION During application the temperature must

not be below +5C and the structure

must be protected from rain and dustbrought by wind.

Maintain the treated surfaces at atemperature higher than +5C after workhas been carried.

Protect the surface from rain for at least24 hours. If the minimum temperaturedoes not go below +15C, or for at least3 days if the temperature should belower.

SAFETY INSTRUCTIONS FOR PREPARATION ANDINSTALLATIONIt is absolutely essential that users wearwaterproof rubber gloves, protectivegoggles and clothing while preparing andinstalling the carbo-plate and epoxysystems (Adesilex PG1 or Adesilex PG2).Avoid contact with the eyes and skin.

Carboplate coveredwith Mapegrout BM

Applying the epoxyprimer

The repaired bridge-deck

TECHNICAL DATA (typical values)

PRODUCT IDENTITY

Matrix: epoxy resin

Reinforcement: high resistance carbon fibres

Colour: black

PRODUCT PROPERTIES

Carboplate Carboplate Carboplate

E 170 E 200 E 250

Density (g/cm3): 1.61 1.56 1.61

Fibre content (%): 68 68 65

Thickness (mm): 1.4 1.4 1.4

Width (mm): 50 100 150 50 100 150 50 100 150

Resistant section (mm2): 70 140 210 70 140 210 70 140 210

Weight (g/m): 113 225 338 109 218 328 113 225 338

FINAL PERFORMANCES

Tensile strength (MPa): 3,100 3,300 2,500

Modulus of elasticity (GPa): 170 200 250

Ultimate elongation (%): 2 1.4 0.9

Shearing strength (MPa): 77 70 79

Coefficient of expansion (m/m/C): 0.6 x 10-6 0.8 x 106 0.4 x 106

In case of contact with the skin, wash withwater and soap. If in contact with the eyes,wash with plenty of water and consult adoctor.

When the product is applied in a closedenvironment, provide good ventilation. Forfurther information carefully read the safetydata sheets of the products.

CleaningDue to the high bonding strength ofAdesilex PG1 and Adesilex PG2 on metal,it is recommended to clean tools withsolvents (ethyl alcohol, toluene etc.) beforethe product drys.

PACKAGINGCarton boxes each containing a 25 m roll.

Carboplate is available in 3 modules ofelasticity (170, 200 and 250 GPa), each one in 3 widths (50, 100 and 150 mm): Carboplate E 170/50/1.4 Carboplate E 170/100/1.4 Carboplate E 170/150/1.4 Carboplate E 200/50/1.4 Carboplate E 200/100/1.4 Carboplate E 200/150/1.4 Carboplate E 250/50/1.4 Carboplate E 250/100/1.4 Carboplate E 250/150/1.4

CONSUMPTION OF ADHESIVEThe consumption of Adesilex PG1 or Adesilex PG2 depends on the width of theCarboplate plates; approximately;following: 50 mm plate: 160-200 g/m; 100 mm plate: 320-400 g/m; 150 mm plate: 480-600 g/m.

STORAGEStore in a sheltered dry place.

WARNINGAlthough the technical details andrecommendations contained in thisproduct report correspond to the best ofour knowledge and experience, all theabove information must, in every case, betaken as merely indicative and subject toconfirmation after long-term practicalapplications: for this reason, anyone whointends to use the product must ensurebeforehand that it is suitable for theenvisaged application: in every case, theuser alone is fully responsible for anyconsequences deriving from the use of the product.

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All relevant references for the product are available

upon request and from www.mapei.com