Structural Repair Mortar is a high-strength, fine-filled cementitious mortar, formulated specifically for the repair of damaged concrete where structural repair is required. Repair mortars are specifically designed to restore or replace the original profile and function of damaged concrete. They help repair concrete defects, improve appearance, restore structural integrity, increase durability and extend the longevity of the structure. To ensure a successful repair, it is important to use the right tools and techniques.
A soft-bristled brush should be used to remove pieces of mortar on the face of the brick before they harden and to sweep loose mortar from finished joints. This will prevent the mortar from staining. If you accidentally smear mortar on the brick, you'll have to come back later and use a chemical cleaner. Additionally, it is important to apply color-matched polyurethane putty where stucco, wood and other materials meet brick in order to prevent water from entering and damaging your bricks. When it comes to repairing concrete defects, there are several types of repair mortars available.
Fine aggregates in microconcrete produce a concrete that is suitable for large heavily reinforced repairs and for pouring into formed sections. A single-component fiber-polymer modified concrete repair mortar with a lightweight formula is suitable for extra tall construction, large area reinstallations or small patch repairs. Patented repair mortar for concrete, showing fine aggregate particles (white) and cement matrix (dark brown) with PFA (white spheres); PPT, x150, 1 mm wide. Filling cracks or gaps with a specialized concrete repair mortar requires careful consideration of the type of repair needed. The repair mortar used may differ between each of the required repairs.
Concrete petrography can also be used to evaluate rehabilitation strategies, repairs and repair methods, assessing the depth at which solid concrete starts. However, as can be seen from the literature, as well as in our own experience, there is still room for progress in the development of the repair mortar. One problem with patch repairs is that the new grout will promote the formation of a strong cathode, and this can lead to “incipient anodes” at the edges of the repair causing rapid corrosion. Conventional patch repairs involve several steps: rupture preparation of the concrete surface including the application of a bonding layer; preparing the surface of any exposed reinforcement through the application of a protective layer or bonding layer; applying a repair mortar that is compacted and cured; and possibly applying a finishing coat. This chapter presents the results of research on the development of geopolymeric repair mortars based on a low-reactivity calcined clay. Low-alkali free-flowing single-component concrete repair mortar with a lightweight formula is suitable for steel reinforcement protection standard. For hand-laid repair touch-ups, one-component concrete-based repair mortar is suitable for all types of structural repairs. Cement-based repair mortars show improved adhesion when the surface of the concrete substrate was pre-wetted.
Structural repairs require a carefully organized rupture and reapplication to ensure that the element has adequate structural capacity for the applied loads that are relevant during the works. Medium-weight concrete repair mortar used in high-performance repair of reinforced concrete columns and beams can also be used.