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Use RLA Penapatch HB80 for: High-build structural repairs on vertical, overhead, and horizontal surfaces, concrete cancer treatment, and patching damaged panels where high strength is critical.
Stop letting complex, multi-stage repairs slow you down. RLA Penapatch HB80 is a high-performance structural repair mortar engineered to solve the biggest challenges in concrete restoration. Its standout feature is the ability to be applied up to 80mm thick on vertical and overhead surfaces in a single pass, completely eliminating the need for time-consuming formwork. Fused with exceptional compressive strength that surpasses parent concrete and inbuilt protection against chloride attack, Penapatch HB80 isn't just a patch; it's a permanent, high-strength solution designed for Australian conditions.
Product Details:
Primer Information: Achieving a tenacious, permanent bond is critical, and correct priming is key. For standard porous concrete and masonry, prime with RLA RENDERGRIP A and allow it to become tacky before application. For areas subject to dampness or permanent water immersion, the substrate must be primed with the two-part RLA EPILOX BINDER. For treating concrete cancer, all exposed steel reinforcement must be cleaned to bright metal and immediately coated with RLA ZINC RICH PRIMER to prevent further corrosion.
Strength Development & Cure Time: RLA Penapatch HB80 gains strength rapidly, reaching an impressive 24 MPa in just 24 hours, allowing for a swift return to service. It achieves its final, formidable compressive strength of 68 MPa after 28 days. While it has an initial set time of 1.5 hours, the surface must be protected from rain and water contact for a minimum of 24 hours. For best results and to ensure full design strength, apply a curing compound like RLA CURECON A.
Coverage Rate: A 20kg bag of RLA Penapatch HB80 yields approximately 10.5 litres of mortar. In practical terms, this means one bag will cover about 1 square metre at a 10.5mm thickness. To calculate for your job, use the rate of 2.2 kg of powder per square metre, per millimetre of repair depth.
Application Temperature Range: Engineered for reliable performance across Australia, Penapatch HB80 can be applied in temperatures from 5°C to 35°C. For work in colder southern states, mixing with warm water will improve workability. In the heat of northern summers, using chilled water is recommended to manage the setting time.
Application Thickness: This mortar’s versatility shines in its application range. For vertical surfaces, apply from a minimum of 5mm up to a massive 80mm in a single application, with the ability to fill smaller pockets up to 160mm deep. For horizontal surfaces like floors and slabs, apply from a minimum of 10mm up to 180mm thick.
Shrinkage Compensation: RLA Penapatch HB80 is dimensionally stable. It is a shrinkage-compensated mortar, meaning it won't pull away from the edges of the repair during curing. This prevents the formation of micro-cracks, ensuring a monolithic, seamless repair with long-term integrity and zero bond failure.
Key Features of RLA Penapatch HB80 & What They Mean For You
- Single-Application High Build: Apply up to 80mm thick on vertical surfaces without slumping. This means you can ditch the formwork, saving hours of labour and material costs on every structural repair job.
- Exceptional Compressive Strength (68 MPa): Your repairs will be stronger than the surrounding concrete. This delivers ultimate confidence in structural applications and significantly reduces the risk of future failures and costly call-backs.
- Low Permeability Formula: The dense polymer-modified structure creates a barrier against water and chlorides. This actively protects embedded steel from corrosion, making it the ideal choice for treating concrete cancer and for use in coastal or corrosive environments.
- Shrinkage Compensated for Long-Term Stability: It locks into place without shrinking or cracking. This ensures a permanent, seamless bond to the host concrete that won’t fail over time.
- Pre-bagged & Easy to Use: Eliminates on-site mixing errors and ensures consistent performance every time. Just add the specified amount of water and mix, for a perfect, workable mortar.
Why Choose RLA Penapatch HB80:
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Problem: "Vertical and overhead concrete repairs are slow and require expensive formwork."
Solution with RLA Penapatch HB80: Its unique high-build, non-slump chemistry allows for up to 80mm application in one go, eliminating formwork entirely. You'll complete jobs faster, with less labour and higher profit margins. -
Problem: "Worried that a patch repair will become a future weak point in the structure."
Solution with RLA Penapatch HB80: Engineered to a final compressive strength of 68 MPa, it delivers a repair that is demonstrably stronger and more durable than the original concrete, ensuring structural integrity and client satisfaction. -
Problem: "Need to repair spalled concrete and treat 'concrete cancer' for good."
Solution with RLA Penapatch HB80: When used with RLA ZINC RICH PRIMER, its low-permeability matrix provides tenacious adhesion and actively blocks the moisture and chlorides that cause rebar corrosion, extending the life of the asset.
When to Choose RLA Penapatch HB80 Over Other Options:
- Choose RLA Penapatch HB80 over "standard sand/cement mortars" when: your repair is structural and requires guaranteed high strength, low shrinkage, and long-term durability. Standard mortars cannot match its compressive strength, bond, or protective properties.
- Choose RLA Penapatch HB80 over "epoxy mortars" when: you need a breathable repair that is easier to work with and clean up. Penapatch HB80 provides immense strength while allowing vapour transmission and requires only water for mixing and cleaning.
- RLA Penapatch HB80 is particularly effective for: Repairing damaged precast panels, columns, and beams; reinstating concrete cover in spalled areas; and high-build vertical and overhead repairs where speed and eliminating formwork are critical.
- Consider other Adheseal solutions when: you need to repair actively leaking cracks or require an anchor grout. For these applications, explore the wider Adheseal range of specialised products.
Trade-Specific Applications & Pro Tips for RLA Penapatch HB80:
For Civil Construction and Concrete Repair Specialists:
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Application Focus: Structural Repair of Spalled Concrete on Columns & Beams
- Micro-Guide: 1. Break out all loose and drummy concrete to a sound substrate, ensuring a minimum 5mm depth. 2. Clean exposed rebar to bright metal and coat with RLA ZINC RICH PRIMER. 3. Prime the concrete substrate with RLA RENDERGRIP A. 4. While the primer is tacky, firmly press Penapatch HB80 into the repair void, compacting it thoroughly around the rebar. 5. Build out to the desired profile and finish with a steel trowel.
- Performance Benefits: Achieves a repair with higher strength than the parent concrete, while its low permeability protects the steel from future corrosion, ensuring long-term structural integrity.
- Pro Tip: For very large-scale repairs, Penapatch HB80 can be applied via a wet spray process. Consult an Adheseal expert for guidance on suitable equipment.
- Common Pitfall to Avoid: Not preparing the steel reinforcement correctly. Any remaining rust or scale will compromise the repair and lead to future failure. Grit blasting to a bright condition is essential.
For Builders and Waterproofers:
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Application Focus: Patching Damaged Concrete Panels & Wall-Floor Junctions
- Micro-Guide: 1. Saw-cut the perimeter of the repair area to avoid feather-edging. 2. Ensure the substrate is clean, sound, and free of contaminants. 3. For damp areas or below-grade repairs that will be waterproofed, prime with RLA EPILOX BINDER. 4. Apply Penapatch HB80, ensuring it is well-compacted. 5. Finish flush with the surrounding surface.
- Material Compatibility Notes: Fully compatible with the RLA range of decorative and protective coatings, including waterproofing membranes, which can be applied directly over the repair once cured.
- Performance Benefits: Creates a stable, non-shrinking, high-strength base for subsequent coatings and finishes. Its low permeability provides an added layer of protection against moisture ingress.
- Pro Tip: If the RENDERGRIP A primer dries completely before you apply the mortar, you MUST re-apply it. Applying mortar to dried primer will result in a poor bond.
- Common Pitfall to Avoid: Adding excess water to the mix. This will cause the mortar to slump, reduce its build capability, and severely compromise its final compressive strength. Always use the specified 3.6L per 20kg bag.
How to use RLA Penapatch HB80
- Essential Tools & Setup: You'll need a mechanical forced-action mixer (a high-power drill with a high-shear spiral paddle is ideal), a clean mixing pail, measuring jug, and steel trowels. Do NOT use a free-fall cement mixer.
- Surface Preparation – The Key to Success: The substrate must be solid, clean, and free of all oil, grease, paint, and laitance. Break out any unsound concrete. A clean, profiled surface with a mechanical key ensures the best bond.
- Trade-Specific Pro Tips for Optimal Results: In hot, windy conditions, apply RLA CURECON A curing compound immediately after final trowelling to prevent premature drying and surface cracking. For deep repairs, ensure the mortar is thoroughly compacted into all corners and behind rebar to avoid leaving voids.
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Troubleshooting Common On-Site Issues:
- Issue: "The mortar is slumping on a vertical surface." Solution: This is likely due to either too much water in the mix, or the RENDERGRIP A primer being too wet on application. Re-check your water measurement and ensure the primer is tacky, not wet.
- Issue: "The final surface is cracking." Solution: This can be caused by applying the mortar too thin (less than 5mm), overworking the surface during finishing, or failing to cure it correctly in hot or windy conditions.
Storage, Shelf Life, and Handling
- Optimal Storage Conditions: Store bags in a cool, dry place, elevated off cold concrete floors and protected from direct sunlight. This is critical to prevent moisture contamination and ensure product performance.
- Shelf Life and Batch Information: RLA Penapatch HB80 has a shelf life of 12 months from the date of manufacture when stored correctly in unopened bags. Always use the oldest stock first.
- Handling & Disposal: This is a cementitious product. Avoid inhaling dust and contact with skin and eyes. Dispose of cured material responsibly in accordance with local council regulations.
Certifications and Compliance
- Tested to Australian Standards: RLA Penapatch HB80 is rigorously tested to ensure it meets or exceeds key Australian Standards for performance, including AS 1478.2-2005 for Compressive Strength and AS 1012.11-2000 for Flexural Strength.
- ASTM C501-84 Compliant: Performance data for abrasion resistance is tested against this international standard, giving you a clear benchmark of its exceptional durability for high-traffic horizontal repairs.
- Australian Made: Proudly manufactured in Australia to handle the toughest local conditions, ensuring quality, consistency, and local support.
Frequently Asked Questions About RLA Penapatch HB80
Q: Do I really need to use the specified RLA primers? Can't I just wet the surface?
A: Yes, priming is mandatory. Simply wetting the surface will not provide the tenacious bond required for a structural repair and can lead to failure. RLA RENDERGRIP A (or EPILOX BINDER for wet areas) creates the necessary chemical and mechanical key for Penapatch HB80 to achieve its full design strength and longevity.
Q: How do I properly repair concrete with exposed, rusty rebar?
A: First, break away all concrete from around the rebar. Clean all rust and scale off the steel until it is a bright metal finish (grit blasting is best). Immediately coat the clean steel with RLA ZINC RICH PRIMER to prevent flash rusting. Then, prime the surrounding concrete with RENDERGRIP A before applying Penapatch HB80, ensuring the mortar is compacted fully around the primed steel.
Q: What happens if I add more than 3.6 litres of water to the mix?
A: Adding excess water is a critical error. It will significantly reduce the mortar's non-slump properties, making high-build applications difficult. More importantly, it will severely compromise the final compressive and flexural strength of the cured material, potentially turning a structural repair into a weak point. Always use a measuring jug for accuracy.
Q: Can I use Penapatch HB80 for a thin cosmetic skim coat?
A: No, Penapatch HB80 is not designed for feather-edging or skim coating. It must be applied to a minimum thickness of 5mm on vertical surfaces and 10mm on horizontal surfaces. Applying it thinner than the specified minimum can lead to premature drying, cracking, and poor adhesion.
Q: How soon can I paint or apply a waterproofing membrane over the repair?
A: You must allow the repair to cure properly. RLA Penapatch HB80 can be over-coated with the RLA range of decorative and protective coatings. Even if a curing compound like RLA CURECON A is used, it does not need to be removed before applying a compatible RLA coating. Always refer to the coating's technical data sheet for its specific requirements regarding substrate moisture content.
Applications Where RLA Penapatch HB80 Excels:
- Concrete Cancer Repair: Its high strength and low permeability make it the perfect material for breaking out spalled concrete and reinstating cover over newly protected steel reinforcement.
- Vertical & Overhead Structural Patching: Repairing damaged columns, beams, soffits, and precast panels without the delay and cost of installing formwork.
- High-Traffic Horizontal Repairs: Patching damaged industrial floors, walkways, stairs, and kerbs where high abrasion resistance and high strength are critical for long service life.
- Civil Infrastructure Maintenance: Ideal for repairs to bridges, culverts, tunnels, and other concrete infrastructure where durability and performance are non-negotiable.
Top Benefits of Using RLA Penapatch HB80 on Your Projects:
- Massive Labour & Time Savings: The ability to apply thick sections in a single pass without formwork dramatically speeds up project completion, putting money back in your pocket.
- Structurally Superior Repairs: Deliver work that is stronger and more durable than the original concrete, enhancing your professional reputation and eliminating call-backs.
- Long-Term Asset Protection: Its dense, polymer-modified structure actively prevents the causes of concrete degradation, extending the life of the structure you're working on.
- Consistency and Reliability: As a pre-bagged, Australian-made product, you get consistent, reliable, high-quality results every time you open a bag.
Step-by-Step Application Guide for RLA Penapatch HB80:
- Preparation is Paramount: Break out any loose, cracked, or unsound concrete. Saw-cut the edges of the repair area to avoid feathering. The substrate must be clean, solid, and free of all contaminants. For exposed rebar, clean to bright metal.
- Priming: Apply the correct primer for the job. For exposed steel, coat with RLA ZINC RICH PRIMER. For the concrete substrate, apply RLA RENDERGRIP A (or RLA EPILOX BINDER for wet areas). Allow the primer to become tacky to the touch before proceeding.
- Mixing: In a clean pail, add 3.6 litres of clean water. Slowly add the 20kg bag of Penapatch HB80 powder while mixing with a mechanical mixer and high-shear paddle. Mix for 3-5 minutes until a smooth, lump-free mortar is achieved. Do not add more water or mix partial bags.
- Application Technique: Using a trowel or gloved hand, press the mixed mortar firmly into the primed repair area. Ensure it is thoroughly compacted against all surfaces and behind any rebar to eliminate voids. Build out to the required thickness (up to 80mm vertically).
- Tooling for a Professional Finish: Smooth the surface with a steel trowel to match the surrounding profile. Do not overwork the surface, as this can bring excess water to the face and weaken it.
- Curing Process: Curing is essential. In warm, dry, or windy conditions, apply a suitable curing compound like RLA CURECON A immediately after the final trowel. Protect the repair from rain and running water for at least 24 hours.
- Clean-Up: Clean all tools and equipment with water immediately after use. Cured RLA Penapatch HB80 can only be removed mechanically.
RLA Penapatch HB80 limitations:
- Do not apply at thicknesses below 5mm except in very localised areas.
- Product should not be applied when ambient temperature is below 5°C or above 35°C.
- Excess water will weaken strength and cause slumping—use only 3.6L per 20kg bag.
- Substrate movement may cause reflective cracking in applied repair mortar.
- Must not be exposed to water or rain for at least 24 hours post-application.
Safety precautions when using RLA Penapatch HB80:
- Personal Protective Equipment: Safety gloves, eye protection, dust mask (P2), and protective clothing
- Ventilation: Ensure adequate airflow during mixing and application, especially indoors
- Handling: Avoid skin and eye contact; do not breathe dust during mixing
- Dispose of hardened product as construction waste in accordance with local regulations
RLA Penapatch HB80 Adhesion Profile – Compatible Substrates:
- Concrete (Cured): Excellent adhesion. Ensure concrete is at least 21-28 days old, structurally sound, and free of laitance, curing compounds, or other contaminants. Must be primed with RLA RENDERGRIP A. For very porous concrete, pre-soak with water then remove excess before priming.
- Masonry (Brick & Blockwork): Bonds tenaciously to sound masonry. Ensure surfaces are clean and dust-free. Prime with RLA RENDERGRIP A to ensure a consistent, high-strength bond.
- Steel Reinforcement: Does not bond directly to corroded steel. Steel must be cleaned to a bright metal condition and immediately primed with RLA ZINC RICH PRIMER to ensure corrosion protection and proper adhesion of the repair system.
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