Home
My Wrekin
Access cover being installed

Unipak preparation, mixing, application and storage instructions

Unipak preparation, mixing, application and storage

Unipak mortar is a two-part polyester resin mortar for rapid bedding and fixing of highways ironwork, duct frames and precast concrete units. It is particularly suited for use in critical and heavily trafficked highway locations. It exceeds the requirements of the Design Manual for Roads and Bridges - CD 534 (formerly HA104/09) and complies with the observations of WRc Research Report Street Ironwork - Cost Effective Management CP373.

Preparation

The substrate should be dry, sound, clean and free from contaminants, debris and dust which may interfere with the adhesion between the mortar and substrate.

Mixing

Remove resin tin and bag of filler/activator from tub. Empty contents of the tin into the tub and slowly add the filler/activator while mixing thoroughly with a slow speed drill and paddle. Always mix in the ratio of one full bag with one full tin. Two or more packs may be mixed at the same time, but only mix enough material which can be applied within 5-10min. Do NOT post mix, vary from 1:1 ratio, wet-up after mixing or re-use once opened.

Application

Do not apply in wet conditions. Apply the mortar in beds, each of 5-50mm thickness, within 5 minutes of mixing to allow time for adjustment. If used, interleave mortar beds between UniForm adjustment units.

The final bedding layer should be typically 10-15mm thicker than required to allow for access cover frame levelling adjustments. Place the frame onto the mortar bed and tamp to the required level. Any mortar disturbed during fitment should be re-fixed into position with any extruded mortar removed from the chamber side of the installation.

Apply a final UniPak bed of 10-15mm thickness on top of the frame flange, making sure that it intimately mixes with the mortar that surrounds the frame and extrudes through it. Allow the bedding to set firm, then perform the hammer test. Hit the mortar with a hammer, and if an indent is left, the material needs more time to cure.

Once fully cured, backfill and apply a suitable wearing course or pavement, using materials conforming to the New Roads & Streetworks Act 1991 Code of Practice. If UniForm wedges aren’t used UniPak mortar can receive traffic after 1 hour - if UniForm wedges are used then the installation can be trafficked immediately, subject to the backfill and wearing course cure periods.

Uniform Wedges should be used to affect frame levelling in circumstances where elevated temperatures preclude conventional frame tamping from occurring. All works should be carried out in line with advice and Codes of Practice described in DoT HD27, Highways England CD 534 (formerly HA104/9), DMRB, MCHW SERIES 500, NRA MCDRW Vol.1 section 507.1.

Restrictions

Speed of set and strength development will be affected by site and substrate temperature. Warm conditions will accelerate setting and cold conditions will slow setting. Protect freshly placed material from freezing until set. In adverse weather conditions, UniPak mortar should not be used if the temperature is 3°C on a falling temperature or below 3°C on a rising thermometer.

Storage

Store in unopened manufacturer's container in cool dry conditions. Filler/powder: Store in dry places at temperatures between 5°C and 25°C. Avoid frost. Resin/liquid: Flammable/combustible. Keep away from oxidisers, heat and flames. Store in tightly closed, original containers in dry, cool and well ventilated places.

Related pages

Related products

Stock code Description My Wrekin
PC/UNIFORM/151076 Uniform chamber adjustment unit 760mm x 100mm x 15mm
PC/UNIFORM/251076 Uniform chamber adjustment unit 760mm x 100mm x 25mm
PC/UNIWEDGE/755012 Uniform support wedge 120mm x 50mm x 75mm
YPCR/U12.5 12.5Kg Unipak® rapid curing polyester resin mortar
YPCR/U25 25Kg Unipak® rapid curing polyester resin mortar
YPCR/U6.5 6.5Kg Unipak® rapid curing polyester resin mortar