Structural repair mortar is a thin-filled, high strength, cementitious mortar specifically formulated for the repair of damaged concrete where structural repair is required. It is most commonly used to repair spalling caused by reinforcement corrosion in concrete structures with chloride ingress. Proprietary products containing cements, cement substitutes, plasticisers, and shrinkage compensating admixtures are supplied pre-mixed. Epoxy concrete repair mortars are specially formulated for use on eroded or cracked concrete floors to provide new strength to the damaged concrete and, in most cases, provide a permanent repair that can withstand heavy use.
QUIKRETE Zip & Mix Repair Mortar is a multi-purpose concrete repair material that can be mixed and used directly from its innovative re-sealable bag. It is ideal for repairing broken edges and corners on concrete steps and curbs, slabs, concrete walls and masonry, and can even be used for overhead applications without the need for forms. 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.
A repair mortar is a patching material composed of cement, fine aggregates, and admixtures. It is used to repair concrete or masonry surfaces and is best suited for shallow repairs (those less than 1.5-2 inches or 38-50 mm). Typical applications include repairing honeycombs, insect holes, tie rod holes or any other small section of concrete. Cement patch repairs are a necessary and effective solution for reinforcing concrete structures that have become defective or spalled.
Filling cracks or voids with a specialised concrete repair mortar, the repair mortar used may differ between each of the required repairs. The results show that the bond strength with the repair product R2 is clearly influenced by the surface treatment. The grout is then poured as shown or, alternatively, can be pumped into the bottom of the repair. Patented repair mortar for concrete contains fine aggregate particles (white) and cement matrix (dark brown) with PFA (white spheres). The fine aggregates in the micro-concrete produce a concrete suitable for large, heavily reinforced repairs and for pouring into formed sections.
The main players in the concrete repair mortar market are Sika AG (Switzerland), Fosroc International Ltd. (Spain) and Fosroc International Ltd. (UK). Photomicrographs show a polymeric repair mortar applied on fire-damaged concrete which was not returned to the uncracked substrate. Medium-weight concrete repair mortar is used in high-performance repairs of reinforced concrete columns and beams.
A lightweight three-component repair mortar is used for stone, mortar, plaster, timber and concrete and suitable for use in vertical and overhead repair work. A single component fibre and polymer modified concrete repair mortar has a lightweight formulation making it suitable for extra high rise construction, large area reinstatements or small patch repairs. Single-component flowable low alkali concrete repair mortar is used for protection of embedded steel reinforcement. For these precursors there is still no definitive answer as to which activators are the most suitable and what their ratio with the precursors should be in order to develop repair mortars that meet all criteria prescribed in the standard for concrete repair mortars. Structural repairs require careful staging and re-application to ensure that the element has adequate structural capacity for applied loads that are relevant during works. Sika's concrete repair materials are specifically designed to meet high strength, speed and low shrinkage requirements.