MC-Nafufill FM
Flowable Polymer-Modified Micro-Concrete for Large-Volume Structural Repair — Poured or Pumped Application for Column Jacketing, Pier Strengthening, and Full-Section Concrete Replacement at 40 to 150 mm Depth
Authorized Project Distributor — MC-Bauchemie India | Space Arc Engineering, Ghaziabad
Product Overview
MC-Nafufill FM is a factory-blended, polymer-modified flowable micro-concrete from MC-Bauchemie designed for the large-volume end of the structural concrete repair spectrum — where the repair volume, geometry, or access constraints make hand-applied trowel mortar impractical and a poured or pumped flowing repair material is required. The distinction from the trowel-applied MC-RocTec 30 and MC-RocTec 45 structural repair mortars lies in the aggregate grading and flow characteristics: MC-Nafufill FM uses a maximum aggregate size of 8 to 10 mm (versus 3 to 5 mm for fine-grain repair mortars), providing a coarser grading that approximates micro-concrete rather than mortar — enabling application in 40 to 150 mm layer depths that would be uneconomical with fine-grain repair mortar; the flowing consistency at the recommended water addition allows the mixed MC-Nafufill FM to be poured from above or pumped through a grout pump into a formwork-enclosed repair void without vibration (self-compacting at fluid consistency) or with minimal vibration, ensuring complete void filling even in congested rebar zones. The EN 1504-3 Class R4 classification (compressive strength above 55 MPa, tensile adhesion above 2.0 MPa, low carbonation and chloride permeability) represents the highest structural repair mortar performance class — appropriate for the large-section structural repair applications where MC-Nafufill FM is specified: column and pier jacketing (adding a reinforced concrete jacket around a corroded or overloaded existing column), full-section beam repair (replacing delaminated or corroded concrete section in a beam web or flange with formwork), and piled abutment cap repair (restoring concrete section loss in bridge abutment cap beams with high design load). Space Arc Engineering supplies MC-Nafufill FM for structural repair contractors, bridge rehabilitation specialists, and infrastructure maintenance agencies in Ghaziabad, Delhi NCR, Noida, and Uttar Pradesh.
Applications
- Reinforced concrete column jacketing and section enlargement — construction of a reinforced concrete jacket around an existing deficient or corroded column to restore and increase the structural load-carrying capacity; column jacketing using MC-Nafufill FM involves: exposing and cleaning the existing column surface; installing additional reinforcement around the column perimeter connected to the existing column by drilled and bonded dowel bars; erecting formwork around the new reinforcement to define the jacket dimensions; pouring or pumping MC-Nafufill FM into the annular space between the existing column surface and the formwork face; the flowing consistency of MC-Nafufill FM allows complete filling of the jacket void including the space behind the reinforcement without vibration, ensuring full encapsulation of the new reinforcement and full contact between the jacket concrete and the existing column surface for composite structural action
- Bridge pier and column repair with formwork — structural repair of large-volume concrete section loss in bridge piers, abutment stems, and retaining wall faces where the repair area is too large (greater than 0.1 square metres) or too deep (greater than 50 mm) for economical trowel application of hand-applied repair mortar; MC-Nafufill FM poured into formwork secured to the prepared pier or column face provides a high-volume, high-quality repair that matches the structural performance of the original concrete (Class R4 classification), restores the design structural cross-section and reinforcement cover, and is economically efficient on large repair areas compared to trowel mortar
- Structural concrete full-section replacement in industrial structures — replacement of full sections of reinforced concrete that have been removed by breaking out due to: severe corrosion-induced delamination across the full cross-section depth; localised fire damage requiring removal of heat-damaged concrete; structural damage from impact requiring removal and section reconstruction; in industrial settings, MC-Nafufill FM is the practical material for restoring large removed sections of column, beam, or slab because it can be poured or pumped into the formwork in a single operation, achieving the required section geometry and density without the multiple thin-layer trowel applications that a hand-applied mortar would require for the same volume
- Precast beam-to-column joint filling and in-situ structural connection grouting — filling of the precast beam-to-column connection pockets in precast concrete frame structures where the structural connection is made by pouring in-situ concrete into the joint pocket around the precast beam bearing and reinforcement starter bars; MC-Nafufill FM flowable micro-concrete is appropriate for filling these connection pockets (typically 100 to 250 mm deep and 150 to 300 mm in plan) where the flowing consistency ensures complete void filling around the reinforcement and bearing hardware inside the joint pocket without requiring access for vibration
Key Advantages
- EN 1504-3 Class R4 — highest structural repair mortar classification — compressive strength above 55 MPa, tensile adhesion above 2.0 MPa, the highest performance class in the EN 1504-3 structural repair product classification; Class R4 is required by structural engineers for repair of primary structural members (columns, beams, transfer structures) in high-consequence buildings and infrastructure where the repaired section must perform at the same or higher structural level as the original design concrete; MC-Nafufill FM Class R4 classification provides the structural engineer with the confidence to design the repaired section for full design load without structural downgrading
- Self-compacting at fluid consistency — complete void filling without vibration in congested reinforcement zones — at the recommended water content for fluid consistency (within manufacturer-specified water range), MC-Nafufill FM fills formwork voids by self-weight, completely encapsulating reinforcement and filling corner voids without external vibration; vibration-free filling is important for column jacketing and joint pocket filling where access for a vibrator is physically impossible between the new reinforcement and the existing concrete substrate; the absence of vibration also eliminates the risk of vibration-induced plastic settlement that can cause surface voids in tall formwork pours
- Factory-blended consistent quality versus site-mixed concrete — the factory-blended polymer-modified formulation eliminates the variability of site-mixed concrete repairs where water additions, cement content errors, and inadequate mixing are common sources of below-specification repair quality; every batch of MC-Nafufill FM produced to the specified water content achieves the same strength, flow, and polymer modification regardless of site batching skill; this batch-to-batch consistency is important for structural repair works where the structural engineer requires documented material test results to verify the repair concrete meets the design specification
Technical Data
| Type | Flowable polymer-modified micro-concrete — factory-blended single-component, gauged with water on site to fluid consistency |
| EN 1504-3 Classification | Class R4 — Highest Structural Repair (compressive strength above 55 MPa, tensile adhesion above 2.0 MPa) |
| Maximum Aggregate Size | 8 to 10 mm — micro-concrete grading for poured application in 40 to 150 mm depth repairs |
| Compressive Strength at 28 days | Greater than 55 to 65 MPa — EN 12390-3 cube test method |
| Tensile Adhesion to Concrete | Greater than 2.0 MPa (substrate failure) — EN 1542 pull-off test on properly prepared substrate |
| Consistency at Fluid Mix | Self-compacting to slightly vibrated — slump flow 200 to 300 mm at recommended water content |
| Layer Thickness | 40 to 150 mm per pour with formwork — multiple pours for thicker sections |
| Application Method | Poured from above or pumped through grout pump into formwork-enclosed repair void |
Get a Quote
+91 9999155255 | info@space-arc.com | Space Arc Engineering, Sahibabad, Ghaziabad
Frequently Asked Questions
A structural consultant in Delhi has been appointed to oversee the rehabilitation of 6 reinforced concrete columns in a 1985-era multi-storey commercial building in Connaught Place — the columns are 450 x 450 mm in section, each 3.5 metres floor-to-floor, and show extensive concrete cover loss from carbonation-induced corrosion with section reduction of 40 to 60 mm on all four faces and visible corroded main bars (25 mm diameter); the structural assessment recommends column jacketing to restore and increase the column load capacity — the jacket design calls for a 75 mm concrete jacket all around the existing column, with 4 x 16 mm corner bars and 10 mm closed stirrups at 150 mm centres tied to the existing column by 12 mm dowel bars drilled and epoxy-anchored at 250 mm grid spacing — how should MC-Nafufill FM be used for this jacketing, and what is the material quantity for 6 columns?
Column jacketing of 6 columns in a Connaught Place commercial building using MC-Nafufill FM is a typical urban structural rehabilitation project. Here is the complete procedure and material quantity. Preparatory work before jacketing — column surface preparation: chip all loose, carbonated, and delaminated concrete from the existing 450 x 450 mm column surface to reach sound concrete (phenolphthalein test on exposed concrete — remove to a depth where the concrete turns pink indicating pH above 9); typical removal depth: 40 to 60 mm on the most-affected faces; clean all exposed main bars (25 mm diameter) to bright metal by power wire brush or needle gun and apply MC-Dur 900 corrosion protection primer in two coats; drill and anchor 12 mm dowel bars at 250 mm grid on each column face using MC-Nafufill KS or suitable epoxy anchor grout in 100 mm deep holes; install the new 16 mm corner bars and 10 mm stirrups as per the structural drawing, tied to the dowel bars; check minimum cover to new stirrups from the jacket face — minimum 25 to 30 mm clear cover to stirrups; erect 18 mm ply formwork around the full column perimeter to the full 3.5 metre floor height — the formwork must resist the hydrostatic pressure of the fluid MC-Nafufill FM at 3.5 metres head (approximately 52 kN per square metre at the base) — use steel formwork or heavily braced ply; install a 75 to 100 mm inlet funnel at the top of the formwork on one face and a vent opening on the opposite face at the top; seal the base of the formwork to the floor slab to prevent grout leakage. MC-Nafufill FM mixing and pouring procedure: mix MC-Nafufill FM in a mechanical drum or paddle mixer — add water first (minimum water content per data sheet — do not exceed maximum water to maintain Class R4 strength), add powder while mixing, mix for minimum 4 minutes to achieve uniform lump-free consistency; check slump flow immediately after mixing — target 220 to 280 mm spread for self-compacting jacket fill; pour continuously from the top of the formwork through the inlet funnel — maintain a continuous pour without stops as stopping allows the previously poured material to begin stiffening and creates a cold joint within the jacket; pour rate: approximately 1 to 2 metres of column height per 20 to 30 minutes to control formwork pressure build-up and allow any trapped air to escape; monitor the vent opening — when MC-Nafufill FM appears at the vent, the jacket void is completely filled; continue pouring until the material at the vent is at the same level as the pour level, confirming full jacket filling; strike the formwork at 24 hours — apply wet curing for 72 hours after formwork removal. Material quantity for 6 columns: each jacket volume per column: original column perimeter (4 x 0.45 metres = 1.8 metres perimeter) x jacket thickness 75 mm = effective jacket area; approximate jacket volume per column (outer jacketed column 600 x 600 mm minus original column 450 x 450 mm cross-section, multiplied by 3.5 metres height): (0.60 x 0.60 – 0.45 x 0.45) x 3.5 = (0.36 – 0.2025) x 3.5 = 0.1575 x 3.5 = 0.551 cubic metres per column; for 6 columns: 0.551 x 6 = 3.31 cubic metres of MC-Nafufill FM; MC-Nafufill FM consumption: approximately 2,100 to 2,200 kg per cubic metre (micro-concrete density) = 3.31 x 2,150 = 7,115 kg = 285 bags of 25 kg; add 10 percent waste and over-pour allowance = 315 bags of 25 kg MC-Nafufill FM; additional materials per column: MC-Dur 900 corrosion primer for exposed bars (estimate 4 square metres bar surface per column x 0.15 kg per square metre x 2 coats = 1.2 kg per column, 7.2 kg for 6 columns); MC-Contact bonding slurry: 4 x 0.45 metres x 3.5 metres = 6.3 square metres per column x 0.3 kg per square metre = 1.9 kg per column, 11.4 kg for 6 columns. Space Arc Engineering supplies MC-Nafufill FM and the complete structural column jacketing system (MC-Dur 900, MC-Contact, anchor grout) for urban building rehabilitation projects in Delhi, Ghaziabad, Noida, and Uttar Pradesh — contact +91 9999155255 for site inspection and material supply.
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Space Arc Engineering is an Authorized Project Distributor for MC-Bauchemie India serving Delhi NCR, Ghaziabad, Noida and Uttar Pradesh.
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