Support mortar is a premium, cement-based composite material designed specifically for the installation of road and railway bridge supports. Thanks to the use of advanced performance additives, the final surface is exceptionally smooth and even. It effectively addresses the common issues of traditional mortars, such as unevenness, cracking, and flaking. This product offers self-leveling properties, high early strength, long-term durability, no shrinkage, excellent wear resistance, and easy handling during construction.
Key Features of Support Mortar:
1. Excellent fluidity allows it to flow freely without vibration or pressure, making the construction process faster and more efficient.
2. It achieves very high compressive strength within just 2 hours—ranging from 20 to 40 MPa depending on the temperature—and maintains high flexural strength over time.
3. The mortar has a slight expansion property that helps prevent cracking, ensuring long-lasting structural integrity.
4. It performs well in a wide range of temperatures, from -5°C to -35°C, without requiring additional insulation or cooling measures. It maintains both workability and strength development under extreme conditions.
5. Ideal for repairing damaged areas, filling tracks, and grouting support structures, especially for high-speed railway bridges and track systems. It can also be used for leveling concrete beams or repairing pier surfaces.
6. Complies with the temporary technical specifications for precast concrete beams and basin rubber bearings used in passenger dedicated lines.
Construction Method for Support Mortar:
1. Before applying the mortar, the support pad surface should be chiseled to remove debris and ensure a clean base. The area should be thoroughly saturated with water, but there should be no standing water when starting the application.
2. Place the support in position, insert a small steel wedge underneath, and adjust the support to the desired elevation. Leave a 20-30 mm gap between the bottom of the support and the support pad.
3. After confirming the center position and elevation of the support, install the grouting formwork. Ensure tight sealing between the formwork and the cushion surface to prevent any leakage during gravity grouting. Calculate the required volume of slurry beforehand and fill it carefully to avoid gaps or shortages in the middle.
4. The water-to-material ratio should be between 0.135 and 0.15 (by weight). Start by adding water to the mixing tank, then gradually add the dry mix while stirring with an electric mixer. Continue mixing for 2–3 minutes after all the powder is added to ensure a uniform consistency. The mixed slurry must be used within 10 minutes.
5. Once the grout reaches the required strength, remove the formwork and steel wedge. Check for any leakage, refill any gaps if necessary, tighten the anchor bolts, and finally install the beam support base plate.
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