Polymer-modified repair mortars

Sika MonoTop-352NFG is the general-purpose, fibre-reinforced, polymer-modified structural repair mortar in the MonoTop range — EN 1504-3 Class R3, tested ~30 MPa @28d. Applied up to 75 mm per layer on vertical and overhead surfaces with a built-in corrosion inhibitor; no bonding primer is required on a well-prepared, roughened substrate.

Sika MonoTop-612N is the high-build EN 1504-3 Class R4 structural repair mortar in the MonoTop range — tested ~70 MPa @28d — for deep spall reinstatement in a single layer up to 100 mm on vertical and overhead surfaces. It has no integral corrosion inhibitor and is intended for use with external Sika FerroGard inhibitors / anodes where rebar protection is required.

Sika MonoTop-412NFG is an EN 1504-3 Class R4 structural repair mortar (not a fine / cosmetic mortar) with a built-in corrosion inhibitor — tested ~50 MPa @28d — applied up to 50 mm per layer on vertical and overhead surfaces. For a 0–3 mm cosmetic fairing coat, Sika MonoTop FC is the correct separate product.

ARDEX BR 340 is a MICROTEC fibre-reinforced, polymer-modified structural repair mortar — EN 1504 R3, tested 30–40 MPa @28d — applied 10–80 mm on vertical, horizontal and overhead surfaces with an active corrosion inhibitor. It is low-resistivity (compatible with ARDEX BRX 60 LO galvanic anodes). Prime the substrate with ARDEX WR Prime (wet-on-wet) and rebar with BR 10 ZP — not ARDEX P 51 (a flooring primer).

ARDEX BR 345 is the high-resistivity (>15,000 Ω·cm) variant of the BR structural repair mortar — EN 1504 R3, tested 30–45 MPa @28d, AS/NZS 4020 potable-water compliant — applied 10–80 mm on vertical, horizontal and overhead surfaces with an active corrosion inhibitor. Because of its high resistivity it must NOT be used with ARDEX BRX 60 LO galvanic anodes. Prime with ARDEX WR Prime + BR 10 ZP on rebar.

Fosroc Renderoc HB is a general-purpose hand-applied, polymer-modified structural repair mortar distributed by Parchem — tested 28 MPa @28d (AS 1478.2) — applied up to 80 mm vertical / 50 mm overhead per layer. It is reported to Australian Standards only (no EN 1504-3 class — specify HB40 where an R3 classification is required). Prime the substrate with Nitobond HAR and rebar with Nitoprime Zincrich.

Fosroc Renderoc HB40 is the EN 1504-3 Class R3 member of the Renderoc high-build range — tested 38 MPa @28d (EN 12190), with pull-off bond 1.8 MPa (no primer) or 2.5 MPa with Nitobond HAR — applied up to 40 mm per layer. It is compatible with Galvashield galvanic anodes. Specify HB40 where an R3 classification is required.

Fosroc Renderoc FC is the fine cosmetic fairing coat of the Renderoc range — a 0–3 mm featherable polymer mortar for blowholes, bug-holes and surface profiling over a completed, sound structural repair. Working life ~20 min. It is not a structural repair mortar and must not be used to reinstate concrete cover.

Mapei Mapegrout T40 is a thixotropic, fibre-reinforced, polymer-modified EN 1504-3 Class R3 structural repair mortar — tested >40 MPa @28d, AS/NZS 4020 potable-water compliant — applied ~30–35 mm per layer on vertical and overhead surfaces. Adhesion (>2 MPa, EN 1542) is achieved on a roughened, saturated (SSD) substrate with no bond coat; treat exposed rebar with Mapefer.

Mapei Mapegrout T60 is an EN 1504-3 Class R4, sulphate-resistant, fibre-reinforced repair mortar with integral organic corrosion inhibitors — tested 60 MPa @28d — applied up to 100 mm vertical (multi-coat) or 20 mm overhead. Bond >2 MPa (EN 1542) on a roughened, saturated (SSD) substrate; treat exposed rebar with Mapefer.

Fosroc Renderoc G is a geopolymer acid / chemical-resistant repair and lining mortar (fumed silica + slag + fly ash) for aggressive exposure — sewers, acid bunds and processing plants — not a default polymer-modified spall mortar. Tested 35 MPa @28d; retains 26 MPa after 8 weeks in 20% sulphuric acid. Certified to Australian Standards only (no EN class).