Uses

• Repairing honeycombed concrete.
• General structural concrete repairs.
• Repairing broken structural concrete elements.
• Vertical, horizontal and overhead concrete repairs.
• Patch repair of concrete floor slabs.
• Concrete repairs in areas exposed to dynamic loads.
• Filling voids deeper than 5 mm.
• Vertical repairs up to 20 mm thick in a single layer.
• Overhead repairs up to 30 mm thick in a single layer.
• Horizontal and patch repairs up to 50 mm thick in a single layer.

Advantages

• High-strength structural repair mortar.
• Single-component product requiring only clean water.
• Polymer-modified and fiber-reinforced formulation.
• Non-shrink properties for dimensional stability.
• Thixotropic consistency suitable for vertical and overhead application.
• High build-up without sagging.
• High physical and mechanical performance.
• Compatible with the host concrete.
• Extremely low permeability.
• Helps protect reinforcement against corrosion and contaminant ingress.
• Suitable for internal and external applications.
• Classified as R3 according to BS EN 1504-3.

Standards Compliance

• Complies with BS EN 1504-3, class R3.
• Compressive strength tested according to ASTM C109.
• Flexural strength tested according to ASTM C348.
• VOC content tested according to ASTM D2369.

Substrate Preparation

The substrate must be sound, clean and free from dust, oil, grease, laitance, weak concrete and other contaminants.

Cut back all damaged concrete until sound concrete is exposed, with a minimum repair depth of approximately 10 mm. Saw-cut the perimeter of the repair to a minimum depth of 10 mm and avoid feather edges.

Remove concrete from around exposed reinforcement to provide approximately 25 mm clearance. Grit-blast corroded reinforcement until rust and scale are removed.

Where reinforcement has suffered significant loss of cross-section, consult the structural engineer regarding replacement or strengthening.

Clean the repair area thoroughly using a suitable brush and oil-free compressed air. Any shuttering must be watertight, rigid and adequately supported.

Priming

1. Apply one or two coats of a suitable corrosion-inhibiting primer to cleaned reinforcement within 2-4 hours of grit blasting.
2. Thoroughly pre-soak the concrete repair area with clean water.
3. Remove all standing and excess water.
4. Apply one coat of WHITE SAND PRIME RC acrylic primer and bonding agent.
5. Allow PRIME RC to become tacky before applying REP S 100.

Mixing

1. Place approximately 4 litres of clean water in a suitable mixing container for each 25 kg bag.
2. Slowly add REP S 100 powder while mixing continuously.
3. Use a grout mixer or slow-speed drill fitted with a high-shear mixing paddle.
4. Mix for at least three minutes until homogeneous and uniform.
5. Do not divide the packs or attempt partial mixing.
6. During hot weather, keep the powder in a cool place and use chilled mixing water.
7. Maintain the mixed-material temperature below 30°C.

Placement and Finishing

1. Apply REP S 100 using a suitable trowel or by hand while wearing protective gloves.
2. Press the mortar firmly onto the substrate and around reinforcement.
3. Compact the material thoroughly to remove trapped air and voids.
4. For thick vertical and overhead repairs, apply the mortar gradually in firmly pressed patches or layers.
5. Ensure full adhesion between the substrate and subsequent layers.
6. Initially level the surface using a wooden or plastic float.
7. Complete the final finish using a steel float.

Curing

Cure REP S 100 by continuous water curing and covering the repair with polyethylene sheets.

Alternatively, apply a suitable WHITE SAND-CURE curing compound to reduce water evaporation from exposed surfaces.

Cleaning

Clean tools and equipment immediately after use and before the initial cure using clean water. Hardened material must be removed mechanically.

Storage and Shelf Life

REP S 100 has a shelf life of 12 months when stored in its original sealed packaging in a dry, shaded place under suitable warehouse conditions at a temperature below 35°C.

Packaging

• 25 kg paper bags.
• 50 kg paper bags.

Health and Safety

• Wear suitable protective gloves and safety goggles during mixing and application.
• Avoid unnecessary contact with the skin and eyes.
• In case of skin contact, wash immediately with soap and clean water.
• In case of eye contact, rinse immediately with plenty of clean, cold water.
• Seek medical advice if irritation continues.
• The product is non-flammable and is not classified as hazardous under current legislation.
• Do not dispose of the material in water or soil. Follow applicable local disposal regulations.

Quality and Technical Support

WHITE SAND products are developed and manufactured under a quality-oriented product-development process and an independently certified quality management system.

WHITE SAND provides technical assistance regarding concrete assessment, repair preparation, reinforcement treatment, placement and curing.