When spalling concrete or damaged masonry threaten structural integrity, a quick patch is not enough. You need a lasting rebuild. Penapatch HB80 delivers the high-strength, high-build repair that restores concrete and masonry to its full capacity, ensuring long-term durability and protection against re-deterioration. It's about getting the repair right, the first time.
Penapatch HB80 was engineered for demanding structural concrete and masonry remediation. It provides a rigid, shrinkage-compensated mortar that builds thick sections in a single pass. This ensures critical repairs on vertical, overhead, and horizontal surfaces are not just filled, but genuinely rebuilt. Its formulation guards against ongoing degradation from chlorides, carbon dioxide, and abrasion, which is critical for infrastructure with a long service life expectation.
Mixing requires a mechanical forced-action mixer with a high-shear spiral paddle, ensuring a consistent, lump-free mortar. Precisely control the water ratio to 3.6 litres per 20 kg bag; excess water reduces final strength and build. For general concrete and masonry, prime surfaces with RLA Rendergrip A. For damp or immersed conditions, use RLA Epilox Binder. If corroded steel reinforcement is present, clean to a bright condition and prime immediately with RLA Zinc Rich Primer before applying Penapatch HB80. Apply the mixed material by trowel or gloved hand, thoroughly compacting it into the primed substrate and around any exposed rebar. Maintain application temperatures between 5°C and 35°C. Proper curing with a suitable compound like RLA Curecon A is essential for optimal performance.
Penapatch HB80 often functions as a critical structural component within multi-layered systems. For retaining wall waterproofing, for example, it can be applied as the primary repair material after an initial coat of a waterproofing membrane like Everflex VBS Bitumen Primer and an appropriate two-part epoxy primer. The repair mortar then receives a final application of waterproofing, ensuring a robust, sealed, and structurally sound system. This placement highlights its role as a core structural element, rather than a surface finish.
Yes, Penapatch HB80 is designed for high-build applications, allowing repairs up to 180mm horizontally and 100mm vertically in a single pass without formwork. This capability reduces labour and speeds up project timelines.
Apply Penapatch HB80 at a minimum depth of 5mm for large repair areas. It is not intended for general skim coating, though very localised areas under 5mm may be acceptable.
This mortar achieves a 28-day compressive strength of 68 MPa and exhibits low permeability. This robust performance helps protect against chloride attack and carbonation, extending the service life of the repaired structure.
Yes, concrete and masonry substrates must be primed with RLA RENDERGRIP A to ensure a tenacious bond. For damp or immersed conditions, use RLA EPILOX BINDER, and prime exposed steel reinforcement with RLA ZINC RICH PRIMER.
| Application | Key benefit | Primary trades |
|---|---|---|
| Structural concrete panel repair | Achieves 68 MPa compressive strength by 28 days (AS 1478.2-2005), restoring full structural integrity to damaged elements. | Concrete repairers, structural engineers, civil contractors |
| High build vertical, overhead, and horizontal repairs | Allows single-application builds up to 100mm vertically without formwork, and up to 180mm horizontally, significantly reducing labour and project time. | Civil contractors, builders, concrete restorers |
| Repair of spalled concrete due to rebar corrosion | Low permeability and shrinkage compensation protect against chloride attack and carbonation, extending the service life and preventing future damage to reinforcement. | Infrastructure maintenance, asset managers, building restorers |
| Reinstatement of concrete in high-wear areas | Demonstrates high abrasion resistance with a wear index of 120 (ASTM CS01-1984), offering enhanced durability compared to standard concrete. | Industrial flooring contractors, civil construction, maintenance teams |
Remove contaminants and weak material. Break out to a minimum 5 mm depth and create a mechanical key by scabbling or high-pressure water blasting. Clean and prime steel reinforcement as required.
Prepare to sound substrate; for highly porous surfaces, pre-soak then remove excess water prior to priming.
Grit blast to bright metal and prime immediately with RLA Zinc Rich Primer.
Apply the correct primer and place HB80 while the primer is tacky.
Use RLA Rendergrip A. If it dries before placement, re-apply and wait to tacky.
Use RLA Epilox Binder and place while tacky (not dry).
Add 3.6 L water per 20 kg bag into a clean pail. Slowly add powder while mixing with a forced-action/high-shear mixer for 3–5 minutes to a smooth, cohesive mortar.
Do not hand mix; do not use free-fall mixers; do not exceed water dose; do not mix part bags.
Place using a trowel or gloved hand. Thoroughly compact into the primed substrate and around reinforcement. Finish with a steel trowel; avoid over-working.
Vertical: 5–100 mm (up to 160 mm in small pockets with formwork). Horizontal: 10–180 mm.
Wet-spray with suitable pump/nozzle; pre-mix to specified water dose.
Cure according to good concrete practice using RLA Curecon A. HB80 may be overcoated with RLA protective/decorative coatings without removing the curing compound.
Clean tools with water immediately after use. Cured material must be removed mechanically.
Signal Word: Danger
Wear safety shoes, overalls, gloves (polyvinyl chloride recommended for intermittent contact), chemical goggles, and a respirator (organic vapour/particulate if inhalation risk exists).
Use only outdoors or in well-ventilated areas. Ensure ventilation is adequate to maintain air concentrations below exposure standards. Avoid generating and inhaling dusts.
Store locked up in a cool, dry, well-ventilated place, out of direct sunlight. Keep away from foodstuffs and incompatible materials. Keep containers tightly closed when not in use. Dispose of contents and container in accordance with local, regional, national, and international regulations.
Correct substrate preparation and priming are critical for the long-term performance of any structural repair.
Surface prep: Remove all oil, grease, dust, plaster, paint, and other bond-inhibiting contaminants. Remove all cracked or weakened material, ensuring a minimum repair depth of 5mm. Use scabbing or high-pressure water blasting to remove laitance and create a mechanical key.
Primer: Required. Prime all concrete and masonry with RLA RENDERGRIP A Bonding Agent and Primer. Allow the primer to reach a tacky consistency before application. For very porous substrates, pre-soak with water and remove excess water before applying RLA RENDERGRIP A.
Surface prep: As for standard concrete and masonry.
Primer: Required. Prime with RLA EPILOX BINDER. Apply the binder and ensure it remains tacky, not dry, before applying Penapatch HB80.
Surface prep: Remove all loose scale, corrosion, and rust deposits. Clean steel to a bright condition, ideally by grit blasting.
Primer: Required. Immediately after cleaning, treat all exposed steel and rebar with RLA ZINC RICH PRIMER. Exercise care to avoid contact of the primer with the host concrete.
| Property | Value |
|---|---|
| Colour | Grey Powder |
| Fresh Wet Density | 2240 kg/m³ |
| Yield per 20kg Bag | 10.5 litres |
| Bags per Cubic Metre | 95 |
| Application Temperature Range | Min 5ºC - Max 35ºC |
| Coverage | 2.2 Kg/m²/mm |
| Water per 20kg Bag | 3.6 litres |
| Flexural Strength 1 Day | 5.5 MPa (AS 1012-11-2000) |
| Flexural Strength 7 Days | 9 MPa (AS 1012-11-2000) |
| Flexural Strength 28 Days | 10 MPa (AS 1012-11-2000) |
| Compressive Strength 1 Day | 24 MPa (AS 1478.2-2005) |
| Compressive Strength 7 Days | 52 MPa (AS 1478.2-2005) |
| Compressive Strength 28 Days | 68 MPa (AS 1478.2-2005) |
| Initial Set Time | 1.5 hours (at 20°C) |
| Final Set Time | 2.5 hours (at 20°C) |
| Young's Modulus | approximately 26 GPa |
| Co-efficient of Thermal Expansion | 7-10 x 10⁻⁶/ºC |
| Drying Shrinkage 7 Days | < 100 micro-strain |
| Drying Shrinkage 28 Days | < 350 micro-strain |
| Drying Shrinkage 56 Days | < 450 micro-strain |
| Abrasion Resistance Wear Index 28 Days | 120 (ASTM CS01-1984) |
| Horizontal Application Thickness Min | 10mm |
| Horizontal Application Thickness Max | 180mm |
| Vertical Application Thickness Min | 5mm |
| Vertical Application Thickness Max | 100mm |
Here are some common examples on where RLA Penapatch HB80 Mortar used by our customers.
