Large-scale structural injection using high-performance fluid mortars in an urban environment. 

Large-scale structural injection using high-performance fluid mortars in an urban environment. 

Introduction 

Large urban projects involving reinforced concrete structures require technical solutions that can ensure strength, durability and long-term performance.  

As part of the refurbishment works on the underground car parks at Plaza de España in Madrid, a large-scale intervention was carried out involving the supply and application of more than 2,000,000 kg of fluid mortar.  

The main objective was to consolidate structural elements using a structural injection and filling system with high-performance mortars that could overcome the technical, logistical and sustainability challenges of a construction site located in the heart of the city. 

Project description 

The intervention focused on the reinforcement and filling of structural elements across several underground parking levels.  

PROPAM® GROUT 140 and PROPAM® GROUT 180 cement-based mortars were used for this purpose, being poured and pumped into critical areas such as columns, footings, diaphragm walls, and precast elements.  

The project was executed in phases to allow for progressive and coordinated implementation alongside other renovation works.  

The self-compacting properties and excellent workability of the products were key to achieving effective structural consolidation in a restricted-access urban environment. 

Reasons for the intervention 

• Reinforce any deteriorated structural elements or those requiring increased load-bearing capacity.  

• Fill voids and honeycombs in areas with high structural demands.  

• Use a certified, high-performance system to ensure the durability of structures.  

• Meet execution deadlines in a dense urban area with heavy traffic and logistical constraints. 

Project challenges 

• Coordinate the supply of more than 2 million kg of product without any on-site interruptions.  

• Application in restricted and geometrically complex areas.  

• Maintain strict control of temperature, flowability and curing times.  

• Compatibility with existing structures and other construction systems is also ensured.  

• Commitment to sustainability: all materials used bear the Susterra label, our range with sustainability attributes.

Applied solution 

Structural filling and reinforcement of large-volume elements: 

🔹 PROPAM® GROUT 140 
A non-shrink, fluid mortar with high compressive strength and excellent long-term performance. Ideal for anchoring, base plate filling and column and footing reinforcement. 

🔹 PROPAM® GROUT 180 

High early-strength mortar specially designed for projects requiring rapid commissioning. Its formulation allows for fluid, safe and homogeneous application, even under demanding conditions.  

Both products comply with EN 1504-6 and belong to the Susterra range, which focuses on providing more sustainable and environmentally responsible construction solutions. 

The added value of the PROPAM® system 

• A certified technical system in accordance with EN 1504 for structural reinforcement.  

• Over 2 million kg have been supplied to date, ensuring continuity and efficiency on-site.  

• High flowability and workability, making it ideal for large surfaces and hard-to-reach areas.  

• Reduction in execution times without compromising the final quality.  

• A reliable and durable solution offering excellent mechanical performance and dimensional stability.