Concrete Repair Mortar – CR100
High-Performance Mortar for Surface Concrete Repairs
Concrete surface deterioration and damage are common issues in concrete construction and cement surfaces. These problems may arise due to various reasons such as detachment of concrete when separating from molds, reinforcement corrosion leading to surface damage, poor-quality concrete, improper curing methods, or surface impacts. Therefore, a repair mortar is needed, which not only matches the composition of concrete but also provides excellent bonding and proper particle distribution. The CR100 Cement-based Repair Mortar, with its unique formulation and special structure, is ideal for restoring both internal and external concrete surfaces.
This repair mortar is designed using cement, fine aggregates, polypropylene fibers, and copolymer resins. After mixing with water, it becomes easy to apply. The product adheres firmly to various concrete and cement surfaces and offers high durability. It resists cracking from shrinkage after curing and reduces the costs of concrete surface waterproofing.
Mechanism of Action
The concrete repair mortar features a finely graded composition, including micronized silica, which ensures excellent trowelability and spreading. The high proportion of cement and copolymer resins provides superior bonding to substrates. The mortar is highly resistant to the penetration of liquids and corrosive materials, making it an excellent option for surface repair and waterproofing. Additionally, the presence of polypropylene fibers enhances the mechanical strength of the repair mortar and strengthens its structure.
Key Properties of Concrete Repair Mortar
- Does not cause corrosion of steel reinforcements
- Ready-to-use mortar, no need for additional cement or aggregates
- Achieves early mechanical strength
- Excellent moldability and flowability
- Reduces waterproofing costs for concrete surfaces
- High mechanical strength
- Thermal expansion coefficient matches that of concrete and cement surfaces
- No cracking or shrinkage after setting
- Extremely resistant to freeze-thaw cycles
- Compatible with hardened concrete
- Outstanding adhesion to substrates
- Improves the waterproofing performance of structures
- Flexibility and good elasticity
- Creates a smooth, high-quality surface due to its soft and uniform texture
- Bridges surface cracks
- High resistance to environmental destructive factors
- Can be applied by spraying or troweling
- Available in various colors
- Easy to mix and apply with water
Applications
- Repairing surface damage before decorative finishes or painting
- Ideal for repairing substrate surface damage before applying waterproofing materials
- Suitable for filling cracks and joints between concrete elements
- Can be used for repairing both interior and exterior building surfaces
- Suitable for concrete floor repairs
- Can be applied as a primer for surfaces that need protective coatings
- Can be used to prepare surfaces before waterproofing or flooring installation
- Effective for filling non-structural cracks and gaps
- Useful for correcting uneven surfaces caused by formwork errors
- Can fill holes left from bolts or dowels in concrete
- Suitable for grouting in water-related structures
- Ideal for creating an exposed finish on concrete surfaces
- Repairs spalls and surface defects in pre-cast structures
- Suitable for repairing various concrete surfaces including water tanks, sewage systems, concrete columns, marine facilities, and water transmission channels
Physical and Chemical Properties
- Physical State: Powder
- Color: Gray
- Specific Gravity: 1.5 ± 5% gr/cm³
- Standards: ASTM C1583, BS EN 12636
- Chloride Ion: None
- Solubility: In water
Consumption Rate
The consumption rate of the concrete repair mortar depends on the surface conditions and the extent of the damage. Typically, about 1.5 kg of the product is required to cover one square meter at a thickness of 1 mm.
Application Method
- Ensure that the surface is free from loose particles, grease, and contaminants.
- Roughen the surface before applying the mortar.
- If the reinforcement bars are exposed, clean them of rust and scale using a brush or sandblasting.
- Apply a primer layer if necessary to enhance bonding.
- Mix 3.5 to 4.5 liters of water with each 20 kg bag of mortar.
- Gradually add the powder to water while mixing continuously until a uniform mixture is obtained.
- Apply the mixture using a trowel, spatula, or spray.
Important Notes
- Always mix enough powder to be used within 30 minutes.
- Ensure the mortar is compacted behind the reinforcement bars.
- Maximum allowed thickness for the mortar is 50 mm for horizontal and vertical surfaces, and 40 mm for overhead applications.
- To improve bonding and enhance properties, add 2 kg of bonding agent per 20 kg bag of mortar.
- When applying multiple layers, wait for 3 hours for the initial set before applying the next layer.
Safety Precautions
- The product is not harmful to the environment.
- In case of ingestion, seek medical attention immediately.
- Always wear gloves, goggles, and a mask during application.
- In case of skin or eye contact, rinse immediately with water.
Storage
- Shelf Life: One year in original packaging
- Storage Conditions: Keep away from freezing, excessive heat, and direct sunlight
- Ideal Storage Temperature: 10°C to 30°C
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