MC-RocTec SP
Fibre-Reinforced Spray-Applied Cementitious Repair Mortar for Large-Area Overhead Soffit Repair, Bridge Beam Reinstatement, and Tunnel Lining Restoration
Authorized Project Distributor — MC-Bauchemie India | Space Arc Engineering, Ghaziabad
Product Overview
MC-RocTec SP is a fibre-reinforced, polymer-modified cementitious repair mortar from MC-Bauchemie specifically engineered for spray application to deteriorated reinforced concrete. The product is supplied as a factory-premixed dry powder incorporating a blended rapid and normal-hardening Portland cement base; polymer modification to improve adhesion and cohesion of the sprayed layer; alkali-resistant (AR) glass or polypropylene synthetic fibres at a factory-controlled dosage to provide crack-arresting reinforcement and prevent plastic shrinkage cracking; and balanced aggregate grading selected to produce low rebound when applied by wet-process pump-spray equipment. The spray application method provides three fundamental productivity and quality advantages over hand-applied trowel mortars for large-area concrete repair: application rate — a competent spray operator can cover 300 to 500 square metres per shift at 10 mm thickness versus 50 to 100 square metres for trowel work; overhead application — spray mortar adheres and builds up on overhead soffits without temporary shuttering; and density — impaction of sprayed mortar produces a dense, low-porosity repair layer. In the Indian infrastructure maintenance context, MC-RocTec SP is the appropriate specification for National Highway bridge deck soffit repair programmes, metro viaduct pier and beam soffit restoration, tunnel lining concrete restoration, and retaining wall repair programmes covering large elevations. Space Arc Engineering supplies MC-RocTec SP for specialist repair contractors, NHAI-approved bridge rehabilitation agencies, and metro authority maintenance divisions across Ghaziabad, Delhi NCR, Noida, and Uttar Pradesh.
Applications
- Bridge beam soffit repair programmes — spray-applying MC-RocTec SP to the soffits of multiple pre-stressed and reinforced concrete bridge beams on National Highway and state highway maintenance contracts where the volume of repair (typically 50 to 500 square metres per bridge) makes hand-application uneconomical and spray application achieves the required productivity within the traffic management window
- Metro viaduct beam and pier soffit restoration — restoring deteriorated concrete cover on metro rail viaduct beam soffits and pier columns across Delhi Metro, Noida Metro, and other urban rail networks in Delhi NCR where operational proximity to live traffic and running trains makes speed of application critical
- Tunnel lining concrete restoration — applying MC-RocTec SP to deteriorated sections of road and railway tunnel concrete linings where circular geometry and restricted access makes spray application the only practical method for the arch and sidewall sections, with spray equipment mounted on a tunnel work platform
- Retaining wall face repair over large elevations — reinstating the concrete cover on high retaining walls (5 to 15 metre heights) where spray application from a mobile elevated work platform provides the most cost-effective method for covering large areas at consistent application thickness
- Parking structure soffit repair — restoring the soffits of multi-level car park concrete decks where chloride-induced corrosion has caused widespread delamination and spalling across full deck areas — spray application delivers the volume required to treat full deck bay areas in a single shift
- Large-volume repair on power plant cooling towers and chimney structures — applying MC-RocTec SP to the interior and exterior faces of reinforced concrete cooling towers, chimney shafts, and FGD structures at thermal power plants where curved geometry and large surface areas make spray application the standard method
Key Advantages
- High application productivity — covers 300 to 500 square metres per shift at 10 mm thickness versus 50 to 100 square metres for trowel application — dramatically reduces repair programme duration and total labour cost for large-area concrete repair contracts where site access and traffic management costs make programme speed a primary economic factor
- Overhead application without formwork — spray mortar builds up in vertical and overhead positions without temporary formwork or props — eliminates significant cost and logistics of installing shuttering for overhead repairs, particularly on bridge soffits and tunnel linings
- Factory fibre dosage for crack resistance — alkali-resistant fibres incorporated at the factory provide crack-arresting reinforcement throughout the mortar matrix, reducing plastic shrinkage cracking and improving long-term resistance to reflective cracking from substrate movement
- Low rebound formulation — aggregate grading and polymer modification optimised for spray application minimise mortar rebound, reducing material waste and improving economics particularly in overhead applications where rebound creates safety and waste management issues
- EN 1504-3 structural repair classification — satisfies EN 1504-3 Class R3 or R4 structural repair mortar performance requirements, providing specification-grade performance assurance consistent with hand-applied MC-Dur and MC-RocTec HB products
- Compatible with full MC-Bauchemie repair system — designed as part of the MC-Bauchemie integrated concrete repair system and compatible with MC-Bauchemie bonding primers, rebar corrosion protection coatings, and surface protection coatings
Technical Data
| Type | Fibre-reinforced polymer-modified factory-premixed cementitious spray repair mortar — wet-process pump-spray application |
| Classification | EN 1504-3 Class R3 Structural Repair Mortar (spray application method) |
| Compressive Strength | Minimum 25 MPa at 28 days (EN 12190) |
| Fibre Type and Dosage | Factory-incorporated alkali-resistant glass or polypropylene fibres — dosage per current PDS |
| Application Thickness per Pass | 10 to 30 mm per spray pass — multiple passes for greater repair depths |
| Application Equipment | Wet-process pump-spray machine (rotor-stator or piston pump) with spray nozzle — minimum 30 litre per minute output |
| Rebound | Less than 15 percent by mass on vertical substrate at standard application technique |
| Substrate Preparation | Mechanical preparation to ICRI CSP 6-9 by jack-hammer, scabbling, or UHPWJ — saturated surface dry before spraying |
Get a Quote
+91 9999155255 | info@space-arc.com | Space Arc Engineering, Sahibabad, Ghaziabad
Frequently Asked Questions
An NHAI bridge rehabilitation contractor has been awarded a contract to repair 8 bridges on NH-9 (Delhi-Meerut Expressway) with a combined soffit repair area of approximately 3200 square metres — the programme has a 45-day completion window with lane closures permitted only between 10 PM and 6 AM — how should the contractor plan the MC-RocTec SP spray repair programme to complete the work within the window, and what equipment is required for a typical night-shift bridge soffit repair operation?
A 3200-square-metre soffit repair programme across 8 bridges on NH-9 within a 45-day window with 8-hour night-shift lane closures is a demanding but achievable programme with MC-RocTec SP spray application. Programme mathematics: total repair area 3200 square metres across 8 bridges — average 400 square metres per bridge; assume average repair depth 25 mm; total mortar volume approximately 80 cubic metres; available productive repair shifts approximately 38 shifts within the 45-day window; required productivity approximately 85 square metres per shift — comfortably within the MC-RocTec SP spray application capability of 100 to 120 square metres per 4-hour spray window. Required equipment for 85 square metre per shift output: one wet-process pump-spray machine (rotor-stator or piston pump, minimum 30 litre per minute — Putzmeister P13 or equivalent); one UHPWJ unit (500 to 800 bar) for substrate preparation during the preparation phase of each shift; one diesel generator (minimum 50 kVA — to power spray machine, UHPWJ, and lighting independently of grid); one mobile elevated work platform (MEWP — knuckle boom, 15 to 18 metre working height for beam soffit access); tower lighting (4 x 1 kW LED floodlights for the full repair zone — essential for safety and quality in night operations). Typical night-shift schedule (10 PM to 6 AM, 8 hours): hours 0 to 1 — mobilisation, lane closure setup per IRC:SP:55 requirements, MEWP positioning and safety checks; hours 1 to 3 — UHPWJ substrate preparation of the night repair area (100 to 120 square metres); hour 2.5 — erect temporary polythene sheeting downstand from deck edge to contain spray rebound and protect traffic below; hours 3 to 7 — MC-RocTec SP spray application: mix dry powder with calibrated water in machine hopper, spray at 20 to 25 mm thickness, target 25 to 30 square metres per hour with a crew of three (gun operator on MEWP platform, machine operator at ground level, helper for mixing and product supply); apply corrosion protection coating to exposed rebar before each spray pass — mandatory for NHAI compliance under IRC:SP:80; hour 7 — complete spray, cover freshly applied repair with polyethylene curing sheet; hours 7 to 8 — site demobilisation, lane closure removal, traffic restoration before 6 AM deadline. Bridge-by-bridge programme phasing: allocate 4 to 5 productive shifts per bridge for a 400 square metre bridge; include 1 mobilisation shift and 1 quality inspection shift per bridge; total 6 shifts per bridge across 8 bridges equals 48 shifts — with 45 shifts available, maintain a parallel working arrangement on 2 bridges simultaneously from week 3 to recover the schedule. Key quality control actions: prepare cube samples from sprayed mortar at the start of each shift (same water-cement ratio as machine output) — test at 7 and 28 days for compressive strength compliance; check rebound percentage by collecting and weighing rebound material — if rebound exceeds 20 percent, reduce water addition slightly and adjust nozzle distance to 600 to 800 mm; after each shift repair has cured 24 hours, carry out hammer-tap delamination check on the sprayed area — any hollow-sounding zones to be removed and resprayed. Corrosion protection mandatory note: before spray application at each repair location, all exposed rebar must be cleaned to bright metal (Sa 2.5 standard by wire brushing or grit blasting) and two coats of MC-Bauchemie rebar corrosion protection coating applied — spraying MC-RocTec SP directly over corroded rebar results in incipient anode corrosion failure within 3 to 5 years, making the repair expenditure entirely wasted. Space Arc Engineering supplies MC-RocTec SP, corrosion protection coatings, and bonding primers for NHAI bridge rehabilitation contracts across Delhi NCR, Uttar Pradesh, and Ghaziabad — call +91 9999155255 for quantities and application guidance.
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Space Arc Engineering is an Authorized Project Distributor for MC-Bauchemie India serving Delhi NCR, Ghaziabad, Noida and Uttar Pradesh.
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