Repair Mortar

Key Features & Benefits

Superior Bond Strength: Chemically and mechanically bonds tenaciously to sound concrete, steel, and masonry substrates, ensuring long-lasting repairs.

High Early & Ultimate Strength: Achieves rapid load-bearing capability and exceptional long-term compressive and flexural strength.

Excellent Durability: Resists water penetration, chloride ion ingress, carbonation, and freeze-thaw cycles, protecting the substrate and reinforcement.

Low Shrinkage: Minimizes cracking risk during curing, ensuring monolithic performance with the existing structure.

Non-Sag Properties: Ideal for vertical and overhead applications without slumping.

Excellent Workability: Smooth, plastic consistency for easy mixing, pumping (optional), troweling, or spraying.

Corrosion Protection: Creates a high-alkaline environment, passivating steel reinforcement.

Breathable: Allows moisture vapor transmission from the substrate.

Crack-Bridging Ability: Accommodates minor substrate movement.

Technical Parameters

Primary Application Scenarios

 Structural Repair Mortar is versatile and suitable for a wide range of repair and restoration projects:

Concrete Spall & Damage Repair: Repairing deteriorated concrete caused by corrosion, impact, weathering, or fire damage on bridges, parking structures, buildings, dams, piers, and industrial floors.

Structural Strengthening: Restoring load-bearing capacity to columns, beams, slabs, walls, and other structural elements.

Edge & Corner Repair: Precision repair of damaged edges, corners, and arrises on precast elements, beams, and parapets.

Crack Repair (Wide Cracks): Filling and structurally repairing static cracks wider than approximately 0.5mm (0.02").

Seismic Retrofit & Jacketing: Bonded overlay for strengthening columns and walls in seismic upgrade projects.

Abrasion & Erosion Repair: Repairing surfaces damaged by high traffic, flowing water, or abrasive materials in spillways, tunnels, and industrial settings.

Anchorage Grouting: Bedding anchor bolts, base plates, and machinery where high strength and bond are critical.

Precast Concrete Repair: Repairing imperfections or damage in precast concrete elements before or after installation.

Marine & Waterfront Structures: Repairing wharves, jetties, and sea walls exposed to harsh marine environments (ensure compatibility with specific exposure class).

Surface Preparation & Application

Substrate Preparation: CRITICAL. Remove all unsound concrete, contaminants (oil, grease, dirt, laitance), rust, and loose particles. Achieve a clean, sound, rough, porous substrate (typically SSPC-SP 13 / NACE No. 6 or ICRI Concrete Surface Profile CSP 3-5). Exposed rebar must be cleaned to bright metal (SSPC-SP 11) and primed with a suitable corrosion-inhibiting primer.

Pre-wetting: Saturate the substrate surface with clean water (no standing water) immediately before application.

Mixing: Add clean, potable water gradually to the powder (follow specific bag instructions for exact water ratio, typically ~13-16% by weight). Mix mechanically (low-speed drill & paddle) for 3-5 minutes until a smooth, lump-free consistency is achieved. Avoid over-mixing or adding excess water. Use mixed material within pot life.

Application: Apply by trowel, spray (requires compatible equipment), or pour depending on project needs. Compact thoroughly, especially in deep sections or around rebar. For thicknesses > 25mm (1"), apply in multiple layers. Feather edges smoothly.

Finishing & Curing: Finish surface as required (smooth, textured). Immediately after finishing, cure continuously for at least 3-7 days using curing compound, wet burlap, or plastic sheeting to prevent plastic shrinkage cracking and ensure proper hydration. Protect from rain, freezing, excessive heat, and rapid drying.

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