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Repairing concrete or covering joiner plates on tilt-slab and pre-cast panels often demands precise, high-build solutions. Traditional heavy mortars can require extensive formwork, risk shrinkage, and may lack critical fire ratings. Penapatch Panel LW delivers a lightweight, non-structural alternative, simplifying these complex repairs. It allows high-build applications up to 100mm overhead and 50mm vertically without formwork, while delivering a 4-hour fire rating, making panel repairs both efficient and compliant.
Penapatch Panel LW was formulated to address the specific challenges of non-structural, high-build repairs on vertical and overhead concrete and masonry, particularly within tilt-slab and pre-cast construction. Unlike conventional heavy structural repair mortars that often require extensive formwork and may lack specific fire ratings, this product combines fine fillers, lightweight aggregates, and polymers with cement to create a mortar that allows for single-application builds up to 100mm overhead, eliminating the need for formwork. This delivers a reliable, shrinkage-compensated repair that can be sanded to a smooth, paint-ready finish. Its integral 4-hour fire rating at 35mm thickness also makes it suitable for critical fire-resistant panel applications.
Penapatch Panel LW achieves a 4-hour fire rating to AS1530.4 when applied at just 35mm thick. This ensures compliance for fire-rated panel systems without excessive material build-up. Its lightweight formulation yields 15 litres per 10kg bag, allowing repairs up to 100mm overhead and 50mm on vertical surfaces in a single pass without sag. The 28-day compressive strength of 20 MPa confirms its robustness for non-structural applications, providing lasting durability while its shrinkage-compensated properties maintain dimensional stability over time, resisting reflective cracking in the repair itself.
This mortar requires only the addition of water, mixing to a smooth, soft consistency with a high-shear drill mixer. With an initial set time of 3 hours and a final set of 5 hours at 20°C, it provides a workable window for shaping and finishing. Apply using a trowel or gloved hand, ensuring thorough compaction. For a smooth, paint-ready surface, finish with a steel trowel without overworking. Clean all equipment with water immediately after use. For applications in warm, windy, or exposed conditions, consider using RLA Rendergrip A as a curing agent to prevent premature drying.
In specific concrete repair sequences, Penapatch Panel LW acts as a filler after initial surface preparation and priming. For instance, in systems documented as Megapoxy H → Penapatch LW, a heavy-duty epoxy primer like Megapoxy H Epoxy Resin is applied first to prepare the substrate, followed by Penapatch Panel LW to build up the damaged section. This sequence ensures optimal bond and performance, even in areas that may later be membrane-covered or tiled, provided the application is vertical or overhead.
No, Penapatch Panel LW is specifically a non-structural repair mortar. It is not designed for load-bearing applications or as a structural repair mortar.
Penapatch Panel LW achieves a four-hour fire rating to AS1530.4. This rating applies when the mortar is installed at a minimum thickness of 35mm.
No, this product is not recommended for pedestrian or vehicle traffic. It is designed for vertical and overhead applications on concrete and pre-cast panels, not for floors.
For vertical applications, Penapatch Panel LW can be applied up to 50mm thick. For overhead soffits, it allows builds up to 100mm in a single application.
| Application | Key benefit | Primary trades |
|---|---|---|
| Covering metal joining plates in tilt-up/pre-cast panels | Achieves a 4-hour fire rating (AS1530.4 at 35mm) while creating a smooth, paintable surface. | Pre-cast erectors, commercial builders |
| High-build vertical concrete repairs (up to 50mm) | Allows significant build in one application with good adhesion and minimal sag, eliminating the need for formwork. | Concrete repairers, civil contractors |
| Overhead concrete soffit repairs (up to 100mm) | Achieves high-build repairs in a single pass with negligible shrinkage, reducing labour and material steps. | Specialist repair contractors, renderers |
| General non-structural concrete damage repair | Provides shrinkage-compensated stability and a fast-drying, smooth finish ready for coating or rendering. | Commercial renovators, maintenance teams |
Mechanically prepare to a sound surface; saw-cut repair edges and achieve ≥5 mm minimum depth. Pre-soak, then remove all free water.
Scabble/water-blast to remove laitance and contaminants; SSD before placement.
Clean to bright metal; prime with a zinc-rich primer and allow to dry fully.
Add powder to water while mixing with a spiral paddle to a smooth, soft mortar. Typical water per 10 kg: ~3.1–3.6 L (nominal 3.5 L).
Use room-temperature water. Mix until lump-free; do not over-water.
Use chilled water above 30–35 °C ambient; warm water below 5–10 °C to maintain workability.
Compact mortar into the cavity and around reinforcement. Build to the required thickness (min 5 mm; max 50 mm vertical, 100 mm overhead) and steel-trowel to a smooth finish.
Place in one lift up to 50 mm where practical; avoid feather-edges over large areas.
Build up to 100 mm with thorough compaction to manage sag; support may be unnecessary due to lightweight, cohesive mix.
Protect from rapid drying (sun/wind) and rain/water for ≥24 h. Implement appropriate curing, then overcoat with compatible systems after adequate drying.
Apply a curing aid immediately after finishing to control moisture loss and minimise shrinkage.
Confirm dryness and follow the coating manufacturer’s over-plaster/over-render recoat times.
DANGER: Causes skin irritation. May cause an allergic skin reaction. Causes serious eye damage. May cause respiratory irritation. May cause damage to organs through prolonged or repeated exposure. May cause cancer by inhalation.
Wear protective gloves, protective clothing, safety glasses with side shields or chemical goggles, and face protection. Use a Type P filter respirator of sufficient capacity if dust becomes airborne.
Use only outdoors or in a well-ventilated area. Ensure process controls, enclosure, or isolation of emission sources are used to minimise worker exposure.
Store in original, securely sealed containers in a cool, dry, well-ventilated area. Keep off cold floors and out of direct sunlight. Store away from incompatible materials. Dispose of unused product or contaminated wash water responsibly, consulting local regulations; do not discharge into sewers or waterways.
Proper surface preparation and priming are critical for adhesion and the long-term performance of any cementitious repair mortar.
Surface prep: Surfaces must be free of oil, grease, dust, plaster, paint, and other bond-inhibiting contaminants. Remove all cracked or weakened concrete to create a solid foundation. Scabble or water blast to remove laitance and provide a mechanical key. Saw-cut repair edges to ensure a minimum 5mm depth. New concrete substrates require a minimum of 21 days curing before application.
Primer: Optional. Pre-soak surfaces with clean water; ensure no free-standing water remains before application. For highly porous surfaces, apply RLA RENDERGRIP A before pre-soaking to control flash drying and maintain workability.
Surface prep: Break out concrete to expose all rust-affected steel reinforcement. Remove all loose scale and corrosion deposits. Clean steel to a bright condition, ideally by grit blasting.
Primer: Required. Prime all cleaned steel with RLA ZINC PRIMER. Allow the primer to dry completely before applying Penapatch Panel LW.
| Property | Value |
|---|---|
| Colour | Light Grey Powder |
| Fresh Wet Density | 900 kg/m³ |
| Shelf life | 12 months |
| Packaging | 10kg Poly-lined Bags |
| Application Temperature | 5ºC - 35ºC |
| Coverage | 1.85 kg/m²/mm |
| Water per 10kg bag | 3.1 - 3.6 litres |
| Yield per bag | 15 litres |
| Flexural Strength 1 day | 3.0 MPa (at 20ºC) |
| Flexural Strength 7 days | 5.0 MPa (at 20ºC) |
| Flexural Strength 28 days | 7.1 MPa (at 20ºC) |
| Compressive Strength 1 day | 4.0 MPa (at 20ºC & 50% RH) |
| Compressive Strength 7 days | 18 MPa (at 20ºC & 50% RH) |
| Compressive Strength 28 days | 20 MPa (at 20ºC & 50% RH) |
| Initial Setting Time | 3 hours (at 20°C) |
| Final Setting Time | 5 hours (at 20°C) |
| Young's Modulus | approx. 26 GPa |
| Coefficient of Thermal Expansion | 7-10 x 10⁻⁶ mm/ºC |
| Vertical Application Thickness Minimum | 5mm |
| Vertical Application Thickness Maximum | 50mm |
| Overhead Soffits Thickness Minimum | 5mm |
| Overhead Soffits Thickness Maximum | 100mm |
| Fire Rating | 4 hours to AS1530.4 (at 35mm thickness) |
Here are some common examples on where RLA Penapatch Panel LW used by our customers.
