Method Statement - Ignisliex Malta 4and Mapecoat TUS

METHOD STATEMENT FOR PASSIVE FIRE PROTECTION WITH
CEMENTITIOUS BASED FIBRE REINFORCED MORTAR & LIGHT

REFLECTIVE COATING
This Method Statement is based on our best knowledge and is subject to changes due to
improvements and/or critical issues of the system not acknowledged at present.
Mapei reserves the right to issue a new version of this Method Statement at any time.
Any new version is intended to cancel and replace this Method Statement.
MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

A01 & B01, FIRST FLOOR, SOLUS JAIN HEIGHTS, 1st CROSS,
J.C ROAD, OPP. STOCK EXCHANGE, BANGALORE -560002
TEL NO. +91 80 22221820 +91 80 22221840 ,
E mail : k.brijmohan@mapei.co.in , s.chawla@mapei.co.in
INTRODUCTION
Founded in Milan (ITALY) 1937, Mapei is today’s world leader in the production of adhesives
and chemical products for construction industry. The Group now counts 81 subsidiaries with
70 production facilities in operation over 32 countries and 5 continents. The group turnover
crossed 2.3 billion euro in 2013.
It has 70 production facilities in operation over 32 countries and 5 continents. Mapei’s strong
specialization in the construction market has required high production efficiency. The plants
manufacture mostly high quality chemical products diversified: from powdered adhesives to
liquid and paste products and to polymers, for a global quantity that now exceeds 3 million
tons.
Mapei has always placed great emphasis on research. In fact, the Group invests 12% of its
company’s total work-force and 5% of its turnover in R&D; in particular, 70% of its R&D
efforts are directed to develop eco-sustainable and environmentally friendly products which
meet LEED requirements.
Mapei has got a dedicated underground technology team (UTT) to answer the demand
from the tunneling segment. Products category in this range from
• Additives for Concrete/Shotcrete

Admixtures
Accelerators
Pozzolonas, Fibres
• Injection systems
• TBM products
• Ground Consolidation and Conditioning Systems
• Water-proofing Systems (Membranes and Spray applied)

TEL NO. +91 80 22221820 +91 80 22221840 ,
IGNISILEX MALTA 4: - One-component cementitious-based fibre-reinforced mortar
for passive fire protection in underground constructions.
Ignisilex Malta 4 is a one-component pre-blended cementitious based, fibre-reinforced, high-
resistance mortar especially formulated for fire protection in underground construction. Its
special composition makes it particularly resistant to fire and high temperatures. Ignisilex
Malta 4 is composed of high strength hydraulic binders, synthetic polypropylene fibres,
selected fine grained aggregates and special admixtures developed by MAPEI Research &
Development Laboratories. Ignisilex Malta 4 is suited to protecting both existing and new
concrete structures. It is easily applied by either trowel or by spraying. Ignisilex Malta 4, due
to its insulation properties, prevents concrete from spalling when directly exposed to fire,
lowering the heating rate within the structure. This is mainly due to its content of polypropylene
fibres that create a micro-porosity in the concrete which avoids an excessive increase of
pressure within the material. This is typically due to the evaporation of water at very high
temperatures. In consequence, the application of Ignisilex Malta 4 avoids the mechanical
deterioration of structural concrete, increasing the structural safety. Ingisilex Malta 4 should
be applied in one unique solution (also at the tunnel invert) with the addition of Mapequick AF
70, to the mortar, added directly at the nozzle. For higher thicknesses, it can be applied in two
or more layers. If an ultra-fine render is required, the last cm of thickness can be applied without
the addition of the shotcrete accelerator in order to facilitate the finishing with float.

TEL NO. +91 80 22221820 +91 80 22221840 ,
TEL NO. +91 80 22221820 +91 80 22221840 ,
1. STANDARD: - Fire proofing system of tunnels should be able to withstand a RWS
curve up to 180 minutes.
2. SYSTEM PROPOSED
Ignisilex Malta 4 can be used for passive fire protection of concrete underground structures: -
➢ new structures (shotcrete or ready-mixed concrete); ·
➢ new layers applied in tunnels; ·
➢ existing concrete structures, such as layers in tunnels. I
Ignisilex Malta 4 corresponds to the principles defined in EN 1504-9 (“Products and systems
for protecting and repairing concrete structures: definitions, requirements, quality control and
conformity assessment. General principles for the use of products and systems”) and the
requirements of EN 1504-3 (“Structural and non-structural repairs”) for R1-class non-structural
mortars.
TECHNICAL DATA (TYPICAL VALUES)

PRODUCT IDENTITY
Strength class according to EN 1504-3 R1
Type: CC
Consistency: Powder
Colour: Grey
Apparent specific weight (g/cm3) 0.92
Maximum diameter of aggregate (mm) 1.5
Chloride ion content: - Minimum < 0.05
requirement < 0.05 according to EN 1015-17
(%)
APPLICATION DATA
Colour of Mix: Grey
Mixing ratio: - 100 parts of Ignisilex Malta 4 with 29-31

TEL NO. +91 80 22221820 +91 80 22221840 ,
parts of water
Consistency of the mix: Thixotropic
Density of the mix (Kg/m3) 1800
Workability of mix (at +23C – 50% R.H): Approx. 1 hour
Inflammability: no
FINAL PERFORMANCE DATA (30% MIXING WATER)
Performance characteristic Test method Minimum requirements Product
according to EN 1504-3 performance
for R1 class mortar
Compressive strength EN 12190 > 10 15 (after 28
(Mpa) days)
Bond strength on concrete EN 1542 > 0.8 > 0.8 (after 28
(substrate type MC 0.4) days)
according to EN 1766
(Mpa)
Reaction to fire: EN 13501-1 Euroclass A1
Application Procedure: -
Surface Preparation:
Before application starts it is recommended to increase the roughness of the surface through a smooth
hydro scarification of the surface which:
- For new structures: it removes the form-release agent together with the top surface made of
cement paste
- For old structures: it removes the dirt covering the lining and it is needed to remove loose parts.

TEL NO. +91 80 22221820 +91 80 22221840 ,
Application of Ignisilex Malta 4:- It should be mixed with 29-31% of water by weight to
obtain thixotropic consistency and it remains workable for approximately 1 hour at +20°C. The
mortar can be applied either by trowel or by spraying with no formwork even on vertical
surfaces. Ignisilex Malta 4 is applied by wet spraying technique, adding the liquid setting
accelerator (Mapequick AF 70) in a dosage between 3% and 4% directly in the nozzle. After
applying, we recommend Ignisilex Malta 4 to be carefully cured to prevent the water from
evaporating too quickly, especially in hot weather, causing the surface to crack from plastic
shrinkage. Consumption of Ignisilex Malta 4 is approx. 28-30 Kg/M2 to achieve a thickness of
20mm. Spray water on the surface for the first 24 hours of curing or apply Mapecure 100.
Required compressive strength > 10 Mpa & bond Strength > 0.8 Mpa achieved after 28 days.

TEL NO. +91 80 22221820 +91 80 22221840 ,
TEL NO. +91 80 22221820 +91 80 22221840 ,
Equipment: -
Ignisilex Malta 4 can be applied with suitable spray machine or trowel.

TEL NO. +91 80 22221820 +91 80 22221840 ,
Tested at HAGERBACH facilities Swiss

TEL NO. +91 80 22221820 +91 80 22221840 ,
Application of Mapecoat TU/S: -
Mapecoat TU/S is a water based paint consisting of acrylic resins for the protection of
cementitious substrate of all kinds. Mapecoat TU/S guarantees a high level of protection and
coverage. Mapecoat TU/S guarantees high water vapor transpiration. Mapecoat TU/S can be
applied on slightly damp surfaces but well seasoned and free from shrinkage.
In case of overcoating the next layer should be applied when Mapecoat TU/S is perfectly dry.

TEL NO. +91 80 22221820 +91 80 22221840 ,
TEL NO. +91 80 22221820 +91 80 22221840 ,
MAPECOAT TU/S fulfil the mentioned aims since it is characterized by:
- Low porosity
- Excellent resistance to abrasion, normally caused by washing and cleaning cycles with brushes.
- Low dirt retention
- Easy to be maintained.
- Highly reflective
- Easy to apply, also with mechanized equipment.
TECHNICAL CHARACTERISTICS
TECHNICAL DATA (TYPICAL VALUES)

PRODUCT IDENTITY
Consistency: Fluid paste
Colour: white, orange
Relative density (g/cm3) 1.42
Dry mass residue (%) > 60
Residue dry solid contents in volume (%) >40
Volatile organic substance content (%) <1 (White)
Permeability to water vapor Sd < 1 m
Light reflection (%) >88
Viscosity (mPa-s) 11,000

TEL NO. +91 80 22221820 +91 80 22221840 ,
Surface checklist and preparation
Surface checklist shall be carried out following the procedures below:
- The support must be cleaned by residual dust, for example using compressed air, in
order to improve the adhesion between the product and the surface. If the residual over
the substrate requires a pressurized water washing, it is necessary to wait for a dry
surface prior the application of the coating.
- Each part of the support must be solid and it’s necessary to remove each incoherent part
before spraying the membrane.
- Any external curing agent applied to the sprayed concrete, not compatible with the
coating, shall be thoroughly removed, using a method approved by the Engineer, before
application of the product.
- In case the surface needs to be prepared / smoothened it is possible to approach the
work with two different solutions, epoxy or cement based.
o EPOXY:
▪ Application of a water-based and solvent-free two component Epoxy
mortar MAPECOAT WTG, or
▪ a three component mortar TRIBLOCK FINISH

TEL NO. +91 80 22221820 +91 80 22221840 ,
o CEMENT BASED:
▪ For heavy roughness, grout from either the Mapegrout, Planitop range
of products, Mapefinish or Monofinish should be applied in order to
obtain a regular and solid surface
▪ For smooth roughness, PLANITOP T, a two-component cementitious
grout based on highly-resistant cements, fine graded aggregates, special
additives and synthetic polymers in a water dispersion. PLANITOP T
has a very high adhesion property and is particularly resistant to freeze-
thaw cycles
Application of the product:-
Mapecoat TU/S can be applied by brush, roller, or airless spray. High temperatures and low
levels of humidity reduce the waiting time between each coat, while low temperatures and high
levels of humidity increase the waiting time. Protect the fresh product from rain for at least 12
hours.

TEL NO. +91 80 22221820 +91 80 22221840 ,
RECOMMENDATIONS:-
Do not use Mapecoat TU/S on substrates subject to rising damp. · Do not apply Mapecoat TU/S
when forecast calls for rain (the product may wash off when wet). · Do not dilute Mapecoat
TU/S with solvents. · Do not apply Mapecoat TU/S on crumbling or dusty substrates. · Do not
apply Mapecoat TU/S at temperatures below +5°C or above +40°C. Mapecoat TU/S fulfils all
the main criteria for the EN 1504-9 Standards (“Products and systems for the protection and
repair of concrete structures: definitions, requirements, quality control and conformity
assessment. General principles for the use of products and systems”) and the minimum
requirements for EN 1504-2 Standard
For spraying application of the Mapecoat TU/S it is recommended:
Equipment: Airless pumps such as: WIWA, Larius, Wagner Icebreaker, Graco etc.
Diameter tube: minimum 8 mm, maximum 15 mm

Nozzle: 0.017-0.027”, angle 30°-max. 60°
Pressure: max. 5 bar
Pressure at nozzle: 200-250 bar
Compressor: min 3 m³/min

TEL NO. +91 80 22221820 +91 80 22221840 ,
If necessary, the product can be applied even by hand:

TEL NO. +91 80 22221820 +91 80 22221840 ,
TEL NO. +91 80 22221820 +91 80 22221840 ,
Health & Safety standards
Background: The Manufacturer and Applicator recognizes health of personnel, safety of
operations and environmental protection as the highest corporate priorities, and as a
determinant key to sustainable development. The HSE management system is therefore
integrated into the business as an essential element of management.
Employees of Applicating agency shall:

- Know, understand, and comply with the Health, Safety and Environmental
requirements as applicable to the work they perform.
- Report to their Supervisor any equipment malfunction that may affect the safe operation
of the equipment.
- Advise their immediate Supervisor whenever unsure of the instructions for a task or
where concerned about the safety status of any task.
- Participate in the training courses as scheduled.
- Have a detailed working knowledge of the permit to work procedure applicable to their
own operation or activities.
- Collaborate as necessary with all accident/incident investigations.
Working at Site with MAPECOAT TU/S: anyone working at jobsite shall wear the project
required safety equipment. A copy of the Material Safety Data Sheets (MSDS) for any
chemicals or other products being utilized for these works must be on site and available for
review. Any additional safety or protective equipment stipulated in the MSDS must be worn
and available.
To ensure protection of the environment any protection measures as outlined in the MSDS
must be completed on site to ensure materials don’t damage the environment. Ensure materials
are stored away from waterways and stormwater drainage systems. Also ensure spill kits are
maintained and readily accessible in the vicinity of spray membrane works at all times.

TEL NO. +91 80 22221820 +91 80 22221840 ,

Method Statement - Ignisliex Malta 4and Mapecoat TUS

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METHOD STATEMENT FOR PASSIVE FIRE PROTECTION WITH

CEMENTITIOUS BASED FIBRE REINFORCED MORTAR & LIGHT

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

• Additives for Concrete/Shotcrete

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

Ignisilex Malta 4 is a one-component pre-blended cementitious based, fibre-reinforced, high-

Malta 4 is composed of high strength hydraulic binders, synthetic polypropylene fibres,

temperatures. In consequence, the application of Ignisilex Malta 4 avoids the mechanical

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

TECHNICAL DATA (TYPICAL VALUES)

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

TECHNICAL DATA (TYPICAL VALUES)

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

Application of the product:-

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

For spraying application of the Mapecoat TU/S it is recommended:

Diameter tube: minimum 8 mm, maximum 15 mm

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

Employees of Applicating agency shall:

MAPEI CONSTRUCTION PRODUCTS INDIA PRIVATE LIMITED

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