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RLA Penapatch Panel LW: A Technical Overview
RLA Penapatch Panel LW is a polymer-modified, lightweight cementitious mortar engineered for dependable adhesion and negligible shrinkage on concrete and masonry. It enables single-application high builds up to 50 mm vertically and 100 mm in overhead/soffit areas, eliminating the need for formwork and reducing labour. At 35 mm thickness, it achieves a 4-hour fire rating (AS 1530.4), supporting specification on internal panel junctions and plate covers. With fast drying, a smooth steel-trowel finish, and compatibility with protective/decorative coatings, Penapatch Panel LW helps crews close out patching scopes quickly and confidently.
Core Features & Specifications
- High-build capability: up to 50 mm vertical and 100 mm overhead in one application—no formwork.
- 4-hour fire rating to AS 1530.4 at 35 mm—confidence for tilt-up plate cover.
- Low shrinkage formulation for long-term dimensional stability.
- Strong adhesion to concrete/masonry; polymer-modified for durable bonds.
- Reliable working time at 20 °C: initial set ~3 h, final set ~5 h.
- Lightweight wet density ~900 kg/m³; ~15 L yield per 10 kg bag.
- Coverage guide: ~1.85 kg/m² per mm thickness.
- Application temperature range: 5–35 °C.
- Finishes to a smooth, paintable surface; compatible with protective and decorative coatings.
The RLA Penapatch Panel LW Advantage
- Faster close-out: high-build, one-pass repair reduces time on elevated platforms and scaffolds.
- Less rework: shrinkage-compensated design minimises edge curling and map cracking.
- Spec confidence: AS 1530.4 fire performance at defined thickness supports compliance.
- Smooth aesthetic: steel-trowel finish reduces skim/filler needs before coating.
- Simple mixing: add water only (approx. 3.1–3.6 L per 10 kg) for consistent, workable mortar.
Proactive Troubleshooting
Scenario: Applying to dusty or laitance-affected concrete
Potential Outcome: Reduced bond strength and potential delamination.
Adheseal Best Practice: Mechanically prepare (scabble or water blast) to sound substrate and remove contaminants; saw-cut repair boundary to ≥5 mm depth to avoid feather-edging. Pre-soak substrate and remove standing water prior to application.
Scenario: Work in hot, windy, or direct sun conditions
Potential Outcome: Premature drying, reduced workability, and increased shrinkage risk.
Adheseal Best Practice: Use chilled mix water, work below 35 °C, and cure promptly—apply a curing agent over exposed repairs to control moisture loss.
Applications in Practice: Trade Scenarios
For Builders (On-site Applicator): Covering Tilt-Slab Joiner Plates
The Professional's Challenge
Achieve a compliant, fire-rated cover over steel plates without formwork, maintain build thickness, and deliver a smooth, paint-ready surface fast.
The Adheseal Solution: Engineered Certainty in Practice
Prepare and pre-soak the panel, remove free water, then place Penapatch Panel LW to ≥35 mm for 4-hour fire performance. Compact well, steel-trowel the face, and cure appropriately. Expect initial set ~3 h, final ~5 h at 20 °C before subsequent coatings per conditions.
Best Practice Note
Saw-cut a perimeter to ≥5 mm depth; for porous panels, pre-treat with a suitable surface conditioner to prevent flash drying and maintain workability.
For Remedial Contractors (Specifier/Engineer Focus): Overhead/Soft Soffit Repairs
The Professional's Challenge
Repair spalls and defects overhead with controlled build, low rebound, and minimal weight—without installing formwork.
The Adheseal Solution: Engineered Certainty in Practice
Mix 10 kg with ~3.1–3.6 L water to a cohesive, non-sag mortar. Place in lifts up to 100 mm overhead, compact thoroughly around exposed rebar (cleaned and primed as required), then finish with a steel trowel for a smooth face ready for coatings.
Best Practice Note
In warm/windy conditions, implement curing immediately after finishing to prevent premature moisture loss and shrinkage-related surface defects.
Frequently Asked Questions
What thickness is required to achieve the 4-hour fire rating?
Apply 35 mm thickness to achieve a 4-hour fire rating tested to AS 1530.4. Ensure the substrate is prepared and the repair is compacted and cured correctly to meet performance expectations.
Can I use Penapatch Panel LW for structural or trafficable repairs?
No. It is a non-structural repair mortar and is not designed for pedestrian or vehicle traffic. Use appropriate structural/trafficable repair systems where required.
What is the mix water for a 10 kg bag?
Typically ~3.1–3.6 L per 10 kg bag. Add powder to water while mixing to achieve a smooth, cohesive mortar. Avoid excess water to maintain build and final strength.
What are the placement limits?
Minimum thickness is 5 mm. Maximum single application is 50 mm vertical and 100 mm overhead/soffits. Occasional localized areas <5 mm are acceptable but should be avoided on large areas.
When can I coat over the repair?
After adequate curing and drying for the specific coating system. The product is compatible with RLA protective coatings and conventional decorative coatings. Always follow coating manufacturer over-plaster/over-render times.
Applications & Benefits
| Application / Use Case | Key Benefit | Primary Trades |
|---|---|---|
| Covering metal joiner plates on tilt-up/precast panels | 4-hour fire rating at 35 mm; smooth, paint-ready finish | Builders, Remedial Contractors |
| High-build vertical patching on concrete/masonry | Up to 50 mm in one pass; low shrinkage; strong adhesion | Builders, Concreters |
| Overhead/soffit spall repairs | Lightweight mix supports up to 100 mm overhead without formwork | Remedial Contractors |
| Pre-paint/render fairing | Steel-trowel to smooth face; compatible with protective/decorative coatings | Builders, Painters |
Applying RLA Penapatch Panel LW: Enhanced Protocols & Best Practices
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Substrate Preparation
Mechanically prepare to a sound surface; saw-cut repair edges and achieve ≥5 mm minimum depth. Pre-soak, then remove all free water.
Concrete/Masonry
Scabble/water-blast to remove laitance and contaminants; SSD before placement.
Exposed Steel
Clean to bright metal; prime with a zinc-rich primer and allow to dry fully.
Timing: Do preparation immediately prior to mixing to control dust and moisture state.Pro Tip: On hot/dry substrates, condition surface to reduce suction and improve open time. -
Mixing
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).
Standard Conditions (≈20 °C)
Use room-temperature water. Mix until lump-free; do not over-water.
Hot/Cold Conditions
Use chilled water above 30–35 °C ambient; warm water below 5–10 °C to maintain workability.
Timing: Plan to place within the working time; do not re-temper partially set material.Pro Tip: Batch only what you can place and finish before initial set (~3 h at 20 °C). -
Placement & Finishing
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.
Vertical Repairs
Place in one lift up to 50 mm where practical; avoid feather-edges over large areas.
Overhead/Soffits
Build up to 100 mm with thorough compaction to manage sag; support may be unnecessary due to lightweight, cohesive mix.
Timing: Initial set ~3 h; final set ~5 h at 20 °C before light handling.Pro Tip: Do not overwork the surface; over-trowelling can draw water to the face and weaken the skin. -
Curing & Overcoating
Protect from rapid drying (sun/wind) and rain/water for ≥24 h. Implement appropriate curing, then overcoat with compatible systems after adequate drying.
Warm/Exposed Conditions
Apply a curing aid immediately after finishing to control moisture loss and minimise shrinkage.
Coating Readiness
Confirm dryness and follow the coating manufacturer’s over-plaster/over-render recoat times.
Timing: New concrete substrates must be ≥21 days old before application.Pro Tip: Maintain protection from traffic until fully cured; this product is not designed for trafficable surfaces.
Limitations & Safety
Product Limitations
Not for structural repair or pedestrian/vehicle traffic surfaces.
Do not apply below 5 °C (falling) or above 35 °C. Avoid hot, windy placement without curing measures.
Avoid excess mix water—reduces build and final strength, extends drying time.
Protect from water/rain for ≥24 h. Substrate movement may reflect through the repair.
New concrete must be ≥21 days cured before application.
Safety & Handling Requirements
Personal Protective Equipment
Wear safety glasses, gloves, and suitable clothing. Avoid skin/eye contact with cementitious powder and wet mortar.
Ventilation Requirements
Use in well-ventilated areas. Avoid inhalation of dust during mixing; wear a P2 respirator where dust exposure is possible.
Fire & Handling Precautions
Non-flammable product. Store sealed, dry, and out of direct sun. Keep off cold floors to avoid 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 attention.
Skin:
Wash with soap and water. Remove contaminated clothing and launder before reuse.
Inhaled:
Move to fresh air and rest. Seek medical advice if symptoms persist.
Swallowed:
Rinse mouth. Do not induce vomiting. Seek medical attention.
Seek medical attention immediately in all cases of serious exposure.
RLA Penapatch Panel LW Application Guide
Concrete & Masonry
Surface Preparation
Remove oil, grease, dust, paint, and laitance by scabbling or water-blasting. Saw-cut the perimeter and break out weak concrete to achieve a ≥5 mm minimum depth. Pre-soak with clean water and remove free water prior to application.
Primer Requirements
Primer recommended for highly porous substrates
On porous or hot/dry surfaces, use a suitable surface conditioner to reduce flash drying, then pre-soak with water. Ensure no standing water remains.
Surface Conditioner/Curing Aid (as specified)Tilt-Up & Precast Panels (Joiner Plates)
Surface Preparation
Mechanically abrade around plates, remove contaminants, and pre-soak the concrete. Compact mortar around edges and trowel to a smooth finish. Build to ≥35 mm where a 4-hour fire rating is required.
Primer Requirements
No primer typically required on sound, pre-soaked concrete
Ensure the concrete is saturated-surface-dry (SSD) with no free water. Use surface conditioner only if necessary to manage rapid suction.
—Exposed Steel/Rebar
Surface Preparation
Grit-blast or mechanically clean to bright metal, removing corrosion and loose scale. Replace damaged bars as required.
Primer Requirements
Primer required on cleaned steel
Prime cleaned steel/rebar with an appropriate zinc-rich primer and allow to dry completely before applying mortar.
Zinc-rich anticorrosive primer
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