Spalling concrete is rarely a cosmetic problem. Once the cover cracks and water reaches the reinforcement, the steel rusts, expands and pushes off more concrete, an accelerating cycle that only stops when the section is properly repaired.
Our repair system treats the cause as well as the damage: cut back to sound concrete, clean and protect the steel, then rebuild with a shrinkage-compensated mortar that bonds to the parent concrete and matches its behaviour.
Supplied to contractors and builders, or supplied and applied by our own teams with a written warranty.
| Type | Polymer-modified cementitious repair mortar / flowable micro-concrete |
|---|---|
| Compressive strength | Typically 20–30 MPa at 7 days, 45–60 MPa at 28 days |
| Bond strength | Greater than 2.0 MPa to prepared concrete |
| Layer thickness | 5 – 50 mm per layer (micro-concrete up to 100 mm formed) |
| Working time | Approximately 30 minutes at 30 °C |
| Shrinkage | Compensated, nil to slight positive expansion |
| Chloride content | Nil |
Typical values for guidance. Actual figures vary by grade and manufacturer. The data sheet for the exact product supplied on your project is provided with delivery.
25 kg bags. Rebar primer and bonding agent supplied as part of the repair system.
The sequence our teams follow, and the sequence we recommend to contractors buying the material from us.
Break out all loose and drummy concrete to sound material, squaring the edges to about 10 mm depth. Never feather-edge.
Expose corroded bars fully around their circumference, remove rust to bright metal, and replace any bar that has lost significant section.
Apply rebar corrosion-inhibiting primer to the steel, then an SBR bond coat to the concrete.
Press firmly into place in layers, compacting well against the substrate. Finish to the original profile.
Cure with damp hessian or curing compound for at least 3 days before coating or waterproofing.
Chemical treatment that converts iron oxide into a stable organo-metallic barrier and primes the steel for coating.
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Styrene butadiene rubber latex for bonding slurries, polymer-modified repair mortars, screeds and waterproof plaster.
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Cementitious and epoxy non-shrink grouts for machine bases, anchor bolts, column base plates and structural gaps.
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Capillary crystalline and acrylic-cementitious coatings for basements, water tanks, retaining walls and wet areas.
View Details →Tell us the area, the structure and the problem. We will recommend the right system, quote it in writing and, if you want, apply it ourselves.
