Reinforcing castings with Limepor COCCIOFORTE

It increases the strength of vaults without adding excessive weight and is well received by heritage authorities: it is Limepor COCCIOFORTE, KIMIA’s structural reinforcement system with a cocciopesto effect for the construction of collaborating layers. The system, composed of a mix of aggregates blended with a two-component organic binder, makes it possible to consolidate arches and vaults, overcoming the limitations of traditional reinforced overlays.

The weaknesses of traditional reinforced overlays

Arches and vaults are among the architectural elements most exposed to deterioration caused by seismic events and structural settlements. There are various consolidation techniques for these types of structures, but one of the most common is the reinforced overlay, used to stiffen the floor system or to evenly redistribute loads across the surface to be strengthened. The consolidation intervention using this technique consists of connecting the existing vault to an extradosal counter-vault in order to create a new structure that works in collaboration with the one below.

Traditional reinforced overlays, however, are not without weaknesses and are often rejected by site supervisors and heritage authorities, especially when interventions concern buildings of historical value. The main critical issues are:

• the high mass added to the structure;
• the impact on thermo-hygrometric balance;
• the need to carry out additional drilling, beyond perimeter holes, to grout in the metal anchoring bars;
• the impossibility of use on painted substrates, which may be damaged by the salts contained in the water used to mix the mortar.

The advantages of using Limepor COCCIOFORTE

To overcome the issues highlighted above, as an alternative to the conventional mortars used for constructing reinforced collaborating overlays, KIMIA has developed Limepor COCCIOFORTE, a unique reinforcement system composed of aggregates rooted in ancient tradition, mixed with eco-compatible organic binders. This solution fully meets the requirements of adaptability and mechanical and hygrometric compatibility with existing structures, and offers a range of advantages summarized in five key points.

1 – Applicability on decorated intrados surfaces

This feature addresses the last of the previously mentioned issues. Unlike reinforced overlays, Limepor COCCIOFORTE does not use mortars that release water, thus eliminating the risk that any salts present may chemically or mechanically interact with painted surfaces.

2 – Speed of execution

Limepor COCCIOFORTE only requires mixing with a standard site concrete mixer and is very easy to apply. The layer simply needs to be connected to the perimeter walls. Over the rest of the covered surface, the composite action can rely on the adhesion of the organic binder to the substrate. Moreover, Limepor COCCIOFORTE provides compressive, flexural, and tensile strength, making it unnecessary to install metal meshes or grout anchoring connectors.

3 – Rapid commissioning

Limepor COCCIOFORTE achieves its final mechanical properties in just 7 days, unlike traditional mortars, which typically require 28 days to reach full performance.

4 – Reversibility

The system does not compromise the integrity of the vault, unlike reinforced overlays that require dense anchoring. It can also be easily removed through thermal treatment.

5 – Performance and compatibility

Its high mechanical properties allow for thin application layers and therefore a limited increase in loads. It also features a low elastic modulus combined with excellent compressive and flexural strength. Finally, it ensures perfect aesthetic integration with historic and monumental structures thanks to the two available finishes: “cocciopesto” and “ivory.”

The compatibility and reversibility ensured by Limepor COCCIOFORTE make it an ideal system for strengthening vaulted elements in churches and historic buildings. Notable examples include the Church of San Domenico in L’Aquila, severely damaged by the 2009 earthquake, the Norman Castle in Ginosa, in the province of Taranto, and the Refectory of the Sacred Convent of Assisi (for the latter, see the video below).

Do you have a project where Limepor COCCIOFORTE could be used? Contact us for technical support.