CONCRETE REPAIR MATERIALS
POLYALK SB: SBR latex-based bonding agent/mortar modifier
- Repair mortar for RCC members enables durable repairs to spalled concrete floors
- Beams, columns, slabs, foundations, etc
- Repair of finished concrete elements
- For repairing surface damage without adversely affecting the structural element
- Renovating concrete staircases, natural stone, or artificial stone
- Improves elasticity, flexibility, and tensile strength
- Easy to use, non-toxic, and plasticising mortar
- Inhibits cracking, improves surface hardening, limits wear and dust production
- Clean the surface on which the bonding coat is to be applied with a water jet
- Apply the bonding coat on the cleaned RCC surface by brush, taking care to avoid pinholes
- Place the next screed or mortar, etc., that is to come over it “wet on wet” application
POLYFILL AR: Elastomeric acrylic crack filler
- Crack filler for plasters, IPS, cement sand screeds, and non-structural cracks
- No need to open the crack – due to the auto-suction property of POLYFILL AR
- No bonding coat or curing is required
- Excellent flexibility and good resistance to UV rays
- The excellent adhesion property
- Sufficiently smooth finish, suitable for further painting application
- One pack easy to use, non-shrink putty
- Do not open the cracks
- Clean the cracks to free them from oil, dust, loose particles, etc
- Moisten the surface with water
- Fill the crack with POLYFILL AR using a spatula or a putty knife
- After filling, allow the surface to dry for at least 24 hrs
- Apply in layers at 24-hour intervals
SUNMIX: Single component ready to use repair polymer modified mortar
- Repair of RCC members, residential, commercial, and industrial structures
- Rehabilitation of heritage structures
- Repair of jetties, bridges, or any other structures in the marine environment
- Repair of structural members subjected to repetitive loading
- All kinds of structural repairs require application by hand or wet spray applications
- Easy to apply, user-friendly
- Requires only the addition of a definite quantity of mixing water
- Dual shrinkage compensating
- Excellent adhesion to concrete with a smooth finish
- Low permeability
- Excellent resistance to environmental elements
- Low rebond saves material cost during spray application
- In a clean drum, mix SUNMIX mechanically using a forced-action pan mixer
- For a normal application, use from 13-15% water to-powder ratio
- Mixing time depends upon the type of mixer used
- 2 to 3 minutes is the average time until the mortar is homogeneous and lump-free
- Use immediately
- Add water if necessary to get desired consistency.
- Mix for a further 1 to 2 minutes.
- Do not add excess water under any circumstances
- However, a little extra water may be required in hot climates.
POLYCRETE: Microconcrete
- Suitable for repairs of structural slabs, columns, and beams
- Repair of structures in distress, leaky water tanks, machine foundations, etc
- It can be used for grouting, lining, etc
- Emergency repairs
- In the fresh state: cohesive, flowing, and self-levelling
- In the hardened state: non-shrink, good bond, compact and dense
- Forms a good bond with old concrete
- It provides an excellent finished surface in contact with the formwork
- Mix 12.5% water by weight of POLYCRETE
- Mix thoroughly in a bucket to form a mix of uniform and flowable consistency
- Normally, 2-3 minutes of mixing is adequate
- Mix only as much quantity as can be consumed within 20-30 min
- Use ice-cold water in hot weather
- Start initial curing within 4-6 hours of placement and continue curing for the next 7 days
SUNMIX EP: Ready-to-use, epoxy based repair mortar
- Ready to use epoxy repair and bonding mortar
- Repairs to spalled and cracked concrete structures
- Industrial floor joint repairs
- For vertical and overhead filling of cavities
- Rehabilitation of bridges, dams, buildings, columns, beams, and other structural elements.
- The lining of outfalls, sewers, manholes, and similar structures.
- Resistant to a wide range of acids, alkalis, and industrial chemicals.
- Superior chemical and physical bonds to almost all substrates.
- Suitable for bedding mortar for bridge bearings, beams, and runway lights.
- Repairs worn or damaged floors, stair nosing, and treads.
- Not affected by the freeze-thaw attack, eliminating common issues with water-based materials.
- No need for priming the concrete surface, reducing labour costs and the risk of poor priming.
- Pre-packed for easy mixing.
- Equipment can be cleaned with thinners.
- SUNMIX EP, applied by trowel, behaves like slumping mortar.
- It can be hand packed on vertical and roughened horizontal surfaces.
- Maximum layer thickness: 30 mm.
- Non-sag limit on vertical surfaces: 20 mm.
- Large sections require shuttering for support.
- Shutter treatment ensures easy release.
POLYPLUG: Rapid setting cementitious plugging compound
- To plug cracks and openings
- To stop water seepage at the junctions of walls and floors
- It is effective even under hydrostatic pressure
- It can be used for anchoring bolts and other inserts in concrete
- Inexpensive to use
- Formulations set fast
- Very simple to use, requiring no special skills
- Sets underwater
- Cracks and openings are to be plugged by cutting out loose materials
- Then shape the crack to an inverted ‘V’
- Mix POLYPLUG Powder with the requisite quantity of water to produce a mix of putty-like consistency
- Mix small quantities at a time so that wastage can be avoided
- Mix only for one minute
- After filling the crack or the hole, keep it damp to ensure full hydration
- Do not re-temper or remix once materials are mixed
- In hot weather, use ice-cold water to extend working time
GUNMIX AID: Chloride-free gunniting admixture
- Product used for all gunniting or concrete spraying jobs
- Accelerates hardening
- Waterproofs the mix and makes the applied layer more impermeable
- Plasticizes the wet mix
- GUNMIX AID is specially formulated to suit most cement mortar mixes
- The reactive constituents of the product combine with cement particles
- The above process results in accelerating the setting and hardening process
- The gunnited layer very quickly becomes rock hard
- An advantage of the product is that gunniting rebound loss is reduced
- Add GUNMIX AID to the dry cement-sand mix in the ratio of 1 to 6 % by weight of the cement
- Mix thoroughly
- Do not add any water at this stage
- Water should be added only in the nozzle at the actual gunniting stage
- The mix sets and hardens quickly, hence take precautions while executing the work
SUNPOTPATCH: Pothole repairing material
- Pothole repair work in concrete as well as bituminous roads
- User-friendly, inexpensive, quick setting
- High mechanical strength
- Excellent resistance to sea water, sulphated waters, de-icing salt, and oil
- Easy placement at high or low temperatures (with precautions)
- Prepare the following mix in a concrete mixer: 25 kg Sunpot Patch, 75 kg graded aggregate (6 mm to 20 mm), 50 kg crushed sand, and 50 kg cement.
- Add water to the dry mix, with the water demand ranging from 30 to 35 liters depending on site conditions for a workable consistency.
- Fill potholes with the mix and compact properly using a hand-operated roller.
- Ensure uniform tamping/compaction to establish proper bond and contact between the pothole surface and the SUNPOT PATCH mix.
- Barricade the repaired portion for 24 hours and preferably cover it with a plastic sheet.
- Start curing with water or apply curing compound after 3 hours of filling the pothole. Continue curing for 7 days.
- Allow traffic to resume after 24 hours.
- Avoid carrying out the procedure during rain or when showers are expected to interrupt the filling process. Clear weather is preferable.
- The performance of the patch depends on proper compaction and curing after placement.
- Note: For potholes deeper than 150 mm, follow regular road-crust building procedures before applying Sunpot Patch mix as described above.
SUNSUPERWRAP: Carbon fiber wrap
- Bridges, concrete, masonry walls, beams, slabs, columns, chimneys, silos
- Tanks, pipes, and tunnels, strengthening of heritage structures, etc
- High strength-to-weight ratio
- Tailor-made designs using glass
- Lightweight and easily applied by hand
- Fast curing and quick installation to minimise downtime
- Simple in-situ installation on existing structures
- Apply SUNSUPERWRAP using a soft roller on primed surfaces.
- Maintain an application thickness of 0.8-1.0 mm.
- Lay SUNSUPERWRAP on the wet adhesive.
- Use a roller or rubber spatula to press the sheets firmly in the longitudinal direction to allow primer penetration and remove air from the resin coat.
- Apply primer between multiple layers of SUNSUPERWRAP.
- Use UV-resistant paint to coat the fibres for protection against UV radiation.
- Spread clean and sound sand on the fibre surface for plastering while the adhesive is wet.
- Once the adhesive has cured, apply any desired plaster.
- Apply special fire-resistant coatings on the fibres for fire resistance.
FAQs
Why concrete repair is important?
Concrete repair is crucial for maintaining structural integrity and safety. Over time, factors like weathering, cracks, and deterioration can compromise concrete structures. Timely repairs prevent further damage, ensuring longevity, and stability, and avoiding costly replacements. Proper maintenance preserves the functionality and aesthetic appeal of concrete elements in buildings and infrastructure.
What is concrete repair material?
Concrete repair materials are specially formulated substances used to restore and strengthen damaged or deteriorated concrete structures. These materials include polymer-modified mortars, epoxy resins, grouts, and patching compounds designed to repair cracks, spalls, and other defects. They enhance the durability and performance of concrete, extending the lifespan of structures.
What is the durability of concrete repair?
The durability of concrete repair depends on factors like material selection, proper application, and adherence to recommended procedures. High-quality repair materials, expert workmanship, and suitable curing contribute to long-lasting results. Regular maintenance and addressing underlying issues also play a crucial role in ensuring the sustained durability of concrete repairs.
What is the best way to repair concrete?
The most effective method of repairing concrete is to evaluate the damage, completely clean the surface, and choose a suitable repair material, like epoxy or polymer-modified mortar. Concrete repairs that are both efficient and long-lasting are achieved through careful surface preparation, application of the repair material following instructions, and sufficient curing.
What are the main components of concrete?
Concrete is composed of four main components: cement, water, aggregates (such as sand and gravel), and admixtures. Cement binds the mixture, water activates the cement, and aggregates provide strength and volume. Admixtures modify the properties, enhancing workability, durability, or other specific characteristics of the concrete.