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RLA Penapatch HB50 is a polymer-modified, fibre-reinforced cementitious repair mortar formulated for high-strength reinstatement of vertical and overhead structural concrete. This shrinkage-compensated matrix allows for high-build application up to 80mm in a single pass, ensuring efficient workflow and permanent bonding without the risk of slumping or debonding.
Engineered with silica fume technology, it provides low permeability against chlorides and carbonation to mitigate the risk of structural failure and project delays.
Frequently Asked Questions
What thickness can I apply in one pass on vertical surfaces?
Typical single-lift range is 5–80 mm on vertical surfaces. In small pockets or with formwork, depths up to ~120 mm are achievable. For thicker sections, build in layers with adequate curing between lifts.
How much water do I add per 20 kg bag?
Use ~3.0 L of clean water per 20 kg bag. Mix to a cohesive, non-slump consistency suitable for vertical or overhead placement. Do not over-water and do not re-temper.
What is the coverage per bag?
Covers approximately 1.85 kg/m²/mm. A 20 kg bag yields about 1.08 m² at 10 mm thickness. Always allow for substrate profile and wastage.
Can I use Penapatch HB50 externally?
Yes. It is suitable for internal and external applications on properly prepared concrete. Protect fresh repairs from rain, sun and wind during early cure.
When can I coat over the repair?
Once the repair has hardened and dried sufficiently. Timing depends on thickness and conditions. Follow the coating manufacturer’s moisture/strength requirements and carry out a moisture check before coating.
What is the recommended temperature range for application?
Apply between 5–35 °C. In hot or windy conditions, cool materials where possible and implement curing to prevent rapid moisture loss.
Applications & Benefits
| Application / Use Case | Key Benefit | Primary Trades |
|---|---|---|
| Spalled concrete repairs around corroded reinforcement | High build with strong bond and low permeability for durability | Remedial contractors, builders |
| Vertical/overhead patching of columns, beams, soffits | Thixotropic, non-slump placement up to 80 mm in a pass | Builders, civil contractors |
| Precast panel edge and corner reinstatement | Shrinkage-compensated, high early/ultimate strength for crisp edges | Precast installers, remedial specialists |
| Durability repairs in chloride-exposed infrastructure | Low permeability to resist chloride ingress and carbonation | Engineers/specifiers, asset maintenance |
Applying RLA Penapatch HB50 High Build Repair Mortar: Enhanced Protocols & Best Practices
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Surface Preparation
Cut back to sound concrete; remove weak/contaminated material. Clean and pre-dampen to SSD. Protect adjacent finishes.
Mechanical key
Scabble, grind or high-pressure water-blast to expose sound aggregate and provide a profile.
Edge detailing
Saw-cut to a minimum depth to avoid feather edges and ensure patch integrity.
Timing: Proceed once the substrate is SSD (no standing water).Pro Tip: Clean reinforcing steel to bright metal and prime if specified. -
Mixing
Add powder to ~3.0 L clean water per 20 kg while mixing with a low-speed drill (≈400–600 rpm) or paddle mixer. Mix to a cohesive, thixotropic paste.
Water control
Adjust within manufacturer tolerance for placement method; do not over-water.
Slurry bonding coat (optional)
For difficult substrates, prepare a thin bonding slurry and apply wet-on-wet before main placement.
Timing: Use mixed material promptly; do not re-temper once setting commences.Pro Tip: Cool mixing water/materials in hot weather to extend working time. -
Placement & Build
Press firmly into the substrate, compact to eliminate voids, and build to the required thickness.
Thickness guidance
Single pass 5–80 mm vertical/overhead; up to ~120 mm in small pockets or with formwork. Layer for deeper sections.
Finishing
Float/sponge finish once material has firmed sufficiently; avoid over-working the surface.
Timing: Allow adequate stiffening between layers; follow standard concrete practice.Pro Tip: Compact around reinforcement to ensure full encapsulation and bond. -
Curing & Overcoating
Protect fresh repairs from rapid drying, rain and temperature extremes. Implement curing suitable to conditions (e.g., curing compound, damp hessian, or shade).
Coating
Overcoat once the repair has hardened and dried to the coating manufacturer’s requirements. Verify moisture and surface condition before coating.
Timing: Cure immediately after finishing; drying time varies with thickness and climate.Pro Tip: In hot/windy Australian conditions, increase curing measures to prevent plastic shrinkage.
Limitations & Safety
Product Limitations
Not for application below 5 °C or above 35 °C, or onto frozen/ice-laden substrates.
Not suitable for feather-edge finishing; maintain minimum thickness and saw-cut edges.
Do not add cement, lime, or admixtures; water-only addition (~3.0 L/20 kg).
Not intended for direct application to timber, metals or plastics without a suitable system/bonding approach.
Safety & Handling Requirements
Personal Protective Equipment
Wear gloves, safety glasses and a P2/P3 dust mask when handling powder and mixing. Use protective clothing to avoid skin contact.
Ventilation Requirements
Ensure good ventilation during mixing and placement, especially indoors or in confined spaces.
Fire & Handling Precautions
Non-flammable. Avoid generating airborne dust. Store sealed in a cool, dry area away from moisture uptake.
Emergency First Aid
Eyes:
Rinse cautiously with water for several minutes. Remove contact lenses if present and easy to do. Continue rinsing and seek medical advice.
Skin:
Wash with soap and water. Remove contaminated clothing and launder before reuse.
Inhaled:
Move to fresh air and rest. Seek medical attention if symptoms persist.
Swallowed:
Rinse mouth; do not induce vomiting. Seek medical attention immediately.
Seek medical attention immediately in all cases of serious exposure.
RLA Penapatch HB50 High Build Repair Mortar Application Guide
Concrete (vertical/overhead)
Surface Preparation
Mechanically remove laitance, weak or contaminated layers; break out to sound substrate. Saw-cut perimeter; avoid feather edges. Pre-dampen to SSD (surface-saturated, no standing water).
Primer Requirements
Primer typically not required on well-prepared SSD concrete
Where substrates are highly absorbent or placement conditions are challenging, a compatible bonding slurry (HB50 mixed to a thin slurry) may be used to promote adhesion. Place wet-on-wet.
Bonding slurry (site-made)Reinforcing Steel (within repair)
Surface Preparation
Clean to bright metal; remove rust/scale. Replace severely corroded sections per engineering advice.
Primer Requirements
Primer optional per project specification
If specified, apply an appropriate steel primer/passivator and allow to cure before placing HB50.
Steel passivating primer (as specified)Horizontal concrete patches
Surface Preparation
Prepare to sound concrete and SSD. Maintain minimum thickness; compact to avoid entrapped air.
Primer Requirements
Primer not required on SSD concrete
Where substrate is very smooth, lightly roughen to create a mechanical key.
—Masonry (cementitious)
Surface Preparation
Remove friable material; roughen and clean. Pre-dampen to SSD prior to placement.
Primer Requirements
Primer recommended where suction is high
Use a cementitious bonding slurry or compatible bonding agent per project spec.
Cementitious bonding slurryDownloads & technical resources
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