Repair mortars (polymer-modified)

Technical Properties

• EN 1504-3 R3 certified — meets structural repair requirements for Australian remedial practice
• Overhead and vertical application without sagging — suitable for soffit and column repairs
• Fibre-reinforced matrix resists plastic and drying shrinkage cracking
• Available at Bunnings — stocked nationally for immediate procurement

Limitations

• Requires Sika-approved SBR bond coat or epoxy primer before application — cannot go direct to substrate
• Colour match to weathered concrete is not guaranteed — consult Sika colour-matching service
• Maximum 40 mm per layer — multiple passes required for deep spalls

Technical Properties

• MicroTec micro-fibre technology integrated into the mix — reduced bond coat requirement on sound concrete
• High-build to 50 mm in a single pass — reduces number of layers on medium to large spalls
• EN 1504-3 R3 performance with >2.0 MPa pull-off bond strength
• Stocked by Bldcare, Komerco, and Waterproofing Direct for online ordering

Limitations

• Higher cost per bag than standard polymer-modified grades
• Substrate and ambient temperature minimum 5°C — cold weather delays cure
• Not suitable for feathered edges or thin cosmetic profiling — use Ardex Feather Finish for sections below 5 mm

Technical Properties

• EN 1504-3 R3 structural repair mortar — consistent performance on vertical and horizontal faces
• Stable on vertical faces without formwork in sections up to 40 mm depth
• High compressive strength >35 MPa at 28 days for structural reinstatement
• Chloride-free formulation — suitable for carbonation and chloride-affected structures

Limitations

• Requires Fosroc Nitobond EP or SBR bond coat — do not omit in chloride-affected repairs
• Not formulated low-alkali — do not specify for AAR-affected substrates; use Renderoc LA instead
• Shorter working time at high ambient temperatures — pre-stage placement sequence in summer

Technical Properties

• Bond to existing concrete typically >2.0 MPa pull-off strength when correctly prepared
• Polymer modification improves flexibility and freeze-thaw resistance over plain cement mortar
• Suitable for structural and cosmetic repairs, 5–100 mm depth range

Limitations

• Colour match to existing concrete is not guaranteed without specialist colour service
• Requires minimum CSP 3–4 surface preparation — bond will fail on unprepared surfaces

Technical Properties

• Polymer-modified structural repair mortar from the Tremco CPG Eucocrete concrete repair system
• Suitable for structural spall reinstatement and substrate rebuilding on horizontal and vertical faces
• Compatible with Tremco CPG corrosion protection primers and system components

Limitations

• Tremco distribution network is smaller than Sika or Fosroc — confirm local availability with Tremco CPG Australia before specifying
• Confirm current product name, specification, and EN 1504-3 compliance class with Tremco representative before specifying
• Standard polymer-modified cementitious shrinkage risk — wet curing regime required

Technical Properties

• EN 1504-3 R4 — highest structural classification in the Sika polymer-modified range
• Single-layer application up to 75 mm depth — significantly reduces passes on deep spalls
• Reduced formwork requirement — self-supporting on vertical faces at full thickness
• High early strength — suitable for fast-track programmes on trafficked structures

Limitations

• Highest material cost in the Sika polymer-modified range — specify only where repair depth justifies it
• Rigid formulation — engineer should evaluate joint design at repair perimeter where thermal movement exists
• Trade supply only via Sika distributors — not available at Bunnings

Technical Properties

• Thixotropic rheology suited for vertical and overhead application with low sag — reliable for carpark soffit and beam repairs
• EN 1504-3 R3 structural performance — appropriate for structural spall reinstatement
• Part of the Ardex BR structural repair mortar system — Ardex-warranted when used with Ardex P 51 bonding primer
• Good adhesion with Ardex P 51 bond coat on prepared concrete substrates

Limitations

• Maximum application depth per lift is limited — deep spalls require multiple passes or formwork
• Thixotropic rheology requires hand application — not suited to spray equipment
• Confirm current product code and specification with Ardex Australia before specifying

Technical Properties

• Low-alkali formulation specifically designed for AAR (alkali-aggregate reaction) affected substrates
• EN 1504-3 structural grade — large-area application for extensive spall repairs on AAR-damaged structures
• Reduces risk of further AAR expansion in replacement repair mortar
• Low-shrinkage characteristic suited to large horizontal and vertical area repairs

Limitations

• Niche specification — appropriate only for confirmed or suspected AAR-affected structures; engineer must specify
• Not a direct substitute for Renderoc HB — performance and mix characteristics differ
• Higher cost than standard Renderoc grades; requires Fosroc specialist involvement to specify correctly

Technical Properties

• Bond to existing concrete typically >2.0 MPa pull-off strength when correctly prepared
• Polymer modification improves flexibility and freeze-thaw resistance over plain cement mortar
• Suitable for structural and cosmetic repairs, 5–100 mm depth range

Limitations

• Colour match to existing concrete is not guaranteed without specialist colour service
• Requires minimum CSP 3–4 surface preparation — bond will fail on unprepared surfaces

Technical Properties

• Fine aggregate for cosmetic, thin-section, and profile repairs from 0 to 10 mm depth
• EN 1504-3 R3 structural-grade bond strength even in thin sections
• Can be feathered to near-zero at repair edges — ideal for blending into surrounding concrete
• Normal-setting time provides adequate workable window for trowel finishing

Limitations

• Not suitable for deep structural spalls — maximum 10 mm single layer; use MonoTop-352NFG for deeper sections
• Fine grade requires careful mix water control — excess water causes shrinkage cracking
• Colour matching to aged concrete requires sponge-float technique before cure — applicator skill dependent

Technical Properties

• Polymer-modified feather-edge compound — can be applied to near-zero thickness at repair edges
• Fine aggregate suitable for cosmetic profiling, surface fairing, and thin-section patching to 10 mm
• Part of the Ardex floor levelling system — compatible with Ardex P 51 primer and floor toppings
• Single-component — no specialist mixing equipment required

Limitations

• Not a structural repair mortar — do not specify where EN 1504-3 R3/R4 structural compliance is required
• Cosmetic application only — does not address sub-surface substrate condition
• Not suitable for trafficked surfaces without protective topping

Technical Properties

• Fine cosmetic mortar for blowholes, form-face blemishes, and surface defects in architectural concrete
• Featherable to thin sections at edges — low visible repair line when correctly finished
• EN 1504-3 R2 compliance — meets minimum classification for cosmetic concrete repairs
• Low-shrinkage formulation reduces risk of cosmetic crack re-opening post-repair

Limitations

• EN 1504-3 R2 only — not suitable for structural repairs; use Renderoc HB for structural applications
• Cosmetic quality is heavily applicator-dependent — requires skilled concretor for acceptable finish
• Cannot address underlying substrate condition — cosmetic layer only

Technical Properties

• Bond to existing concrete typically >2.0 MPa pull-off strength when correctly prepared
• Polymer modification improves flexibility and freeze-thaw resistance over plain cement mortar
• Suitable for structural and cosmetic repairs, 5–100 mm depth range

Limitations

• Colour match to existing concrete is not guaranteed without specialist colour service
• Requires minimum CSP 3–4 surface preparation — bond will fail on unprepared surfaces