IKO Pacopatch Installation Manual

 

IKO Pacopatch Installation Manual
Issue 1 – Apr 18 | 1
IKO Pacopatch Installation Manual
IKO Pacopatch Road Surface Re-Instatement System
Around Ironworks
IKO Pacopatch Installation Manual
Issue 1 – Apr 18 | 2
Contents
Drivers Manual Summary Page
1. General 3
2. System Components 4
3. Quality Control 5
4. Suitability for Installation 5
5. Traffic Management 5
6. Weather Conditions 5
7. Preparation of Ironwork Rebate 6
8. Installation 1 - Re-Bedding Ironwork 6
9. Installation 2 – In-Filling Rebate and Surface Treatment 7
10. System Installation Checks Carried Out By The Installer 9
11. Aftercare 9
12. Installation Checks on the System 9
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1. General
1.1. The technical installation, composition and system requirements of IKO Pacopatch shall be stated in:
1.1.1. The relevant in-house specifications and codes of practice.
1.1.2. This installation guide.
1.2. Installation of IKO Pacopatch shall be carried out by registered trained installers, under competent supervision, in accordance with the method detailed in section 7.0 of this document.
1.3. A programme of the works shall be agreed with the purchaser / client prior to commencement of the installation. Requirements for the provision of sufficient working area, plant, safety and (if required) testing and protection of the system agreed.
1.4. This document, together with all the necessary Health, Safety and Environment data, relevant COSHH and specific Risk Assessments for the works shall be agreed and submitted to the purchaser / client, and copies held on site.
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2. System Components
(IKO Pacopatch – Typical Build Up)
2.1. IKO Pacopatch Grout (dimensions: 370mm x 185mm x 80mm)
Manufactured in accordance to a BS EN 9001 Quality System. Polymer modified mastic asphalt utilised as the in-fill material, it flows around the brick component of the system, bonding and creating a voidless system.
2.2. Pacopatch Brick: (dimensions: 500mm x 130mm x 45mm)
Mastic asphalt bricks made from a high percentage of recycled material. Forms the bulk of the system providing dimensional stability and acts as a heat sink to the IKO Pacopatch Grout, aiding in cooling. Can be broken down to fit a given shape or size.
2.3. Pre-coated aggregate chippings:
Size and PSV to comply with client requirements.
2.4. Overband:
Optional use for sealing the joint to the ironworks and surrounding road surfacing.
2.5. Quick Dry Bitumen Primer:
Solvent based. Quick-drying. Applied to metal and concrete surfaces.
Pre-coated Chippings embedded in IKO Pacopatch Grout Surface
IKO Pacopatch Brick
IKO Pacopatch Grout
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3. Quality Control
3.1. IKO Pacopatch Grout is tested in accordance with the agreed requirements of the Quality Plan and the relevant in-house test specifications for process control.
3.2. IKO Pacopatch Brick is tested in accordance with the requirements of the Quality Plan.
3.3. Each component received on site shall be logged and stored in such a way as to prevent contamination or deterioration, in accordance with the manufacturer’s instructions.
4. Suitability for Installation
4.1. The system is deemed suitable for installation to bituminous and concrete surfaces that have been prepared in accordance with Section 7.0 of this document.
4.2 Minimum depth of the installation is 100mm
5. Traffic Management
5.1. Traffic Management shall be in accordance with the latest edition of Department of Transport Traffic Signs Manual – Chapter 8 or as agreed between the purchaser / client and the installer.
6. Weather Conditions
6.1. Installation of the system should only be carried out in dry conditions and at a road surface temperature in excess of -5ºC.
6.2. Ambient and road surface temperatures shall be recorded at the start and, if the weather is variable, during the installation process. When possible this shall be recorded on the relevant Site Assessment and Installation Report. If this is not possible then the site supervisor should log the required temperatures.
6.3. The area and surrounding surfaces shall be suitably dry prior to and during the installation of the system. The curing period for the prevailing weather conditions shall be established with the purchaser / client.
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7. Preparation of Ironwork Rebate
7.1. The area into which the system is to be installed shall be clearly defined by the purchaser / client prior to commencement of the on-site work. All failing material must be removed and a minimum clearance of 150mm in all directions from the ironwork flange maintained. The surrounding pavement must be structurally sound.
7.2. The area surrounding the ironwork is saw cut.
7.3. All loose material is removed within the rebate and the ironwork removed.
7.4. Any further loose material is removed from the rebate and the area dried and cleaned further using hot compressed air equipment.
7.5. All surfaces of the trench and rebate are wire brushed to remove all dust, slurry etc. A further application of the hot air equipment may be required to fully dry and clean the joint.
8. Installation 1 – Re-Bedding Ironwork
8.1. Quick Dry primer is applied to all metal and concrete surfaces and allowed to dry. Quicker drying may be facilitated by using warm air.
8.2. Ironwork must be firmly bedded on stable bedding mortar complying with HA 104/09, in accordance with manufacturer’s instructions.
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9. Installation 2 – In-Filling Rebate and Surface Treatment
9.1. Molten IKO Pacopatch Grout is heated to a temperature not exceeding 175ºC (Target 165 +/-10ºC).
9.2. A minimum 25mm thick layer of IKO Pacopatch Grout is applied to the bottom of the rebate.
9.3. IKO Pacopatch Bricks are lightly embedded into the hot IKO Pacopatch Grout ensuring a minimum gap of 10mm in all directions.
9.4. The bricks should be placed in the rebate in such a manner as to ensure the bricks occupy as much of the given space as possible, whilst maintaining the required minimum 10mm gap. Bricks can be broken down smaller to fit a given space as necessary.
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9.5. Once the IKO Pacopatch Bricks are in position, the grout should be allowed to cool for at least 10 mins before flooding the rebate with molten IKO Pacopatch Grout, filing all the voids around the IKO Pacopatch Bricks. A further layer of IKO Pacopatch Grout is then installed up to 20mm below road level. Allow to cool for a further 10 mins.
9.6. If reinstatements are greater than 150mm in depth, multiple layers of bricks can be used. In these situations the layers should be separated by a minimum 10mm layer of IKO Pacopatch Grout. The process is repeated as 9.5 until a level 20mm below road level is achieved.
9.7. The final layer of IKO Pacopatch Grout is applied to bring the level of material to road level and allowed to cool for 5 minutes. Broadcast the pre-coated chippings along the surface of the material and embed by the use of a float or roller. Care should be taken as to not apply the pre-coated chipping too early as they may sink into the grout causing a loss of texture.
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10. System Installation Checks Carried Out By The Installer
10.1. A visual check shall be carried out for uniform surface texture, blemishes and any other discernible faults.
11. Aftercare
11.1. Allow to cool to ambient temperature. During the cooling period no disturbance or trafficking of the system shall be permitted. Assisted cooling during the installation by means of industrial fans or water cooling may be required.
11.2. Before opening to traffic at the end of the cooling period, any excess aggregate shall be removed by sweeping or other suitable method.
12. Installation Checks On The System
12.1. When testing is included in the program of work agreed with the purchaser / client, tests for Skid Resistance Value (SRV) in accordance with TRL Report 176: Appendix E, and Texture Depth to BS EN 13036-1:2002 should be conducted on the finished installation.
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IKO PLC
Appley Lane North
Appley Bridge
Wigan
Lancashire WN6 9AB
www.ikogroup.co.uk
T: 01257 255 711
Sales Support
T: 01257 256 865
F: 01257 256 889
E: sales.uk@iko.com
Technical Services – Grangemill
T: 01257 256 888
E: uk.technical@iko.com
Whilst every care is taken to see that the information given in this literature is correct and up to date it is not intended to form part of any contract or give rise to any collateral liability, which is hereby specifically excluded. Intending purchasers of our materials should therefore verify with the company whether any changes in our specification or application details or otherwise have taken place since this literature was issued.