Product Overview

MC-RocTec FFC is the fibre-reinforced variant of the MC-Bauchemie MC-RocTec structural repair mortar range — the key product differentiator being anti-sag performance for overhead and steep vertical application, achieved through the combination of short polypropylene or PVA fibres and a thixotropic cellulose ether or silica fume modifier in the factory-blended powder. The fundamental challenge in overhead concrete repair (bridge soffits, beam undersides, tunnel linings, column soffits, overhanging canopy soffits) is that plastic repair mortar is subject to gravity — a non-thixotropic mortar at a workable consistency will sag and drop away from an overhead repair area before it achieves sufficient set to be self-supporting; conventional mortar applied at overhead typically drops off the repair area in layers thicker than 5 to 10 mm unless formwork is used to hold it in place; MC-RocTec FFC solves this problem by providing a stiff, thixotropic mortar that: behaves like a stiff paste at rest (high viscosity at zero shear rate — does not sag under gravity on overhead surfaces); flows and becomes soft when worked with a trowel (thixotropic thinning under the shear of trowelling — allowing the mortar to be pressed firmly against the substrate and compacted into all corners of the repair); returns to stiff, sag-resistant consistency when trowelling stops — remaining in place on the overhead repair face without formwork until set. The fibre reinforcement provides the additional micro-tensile strength to resist the gravity-induced tensile stress at the mortar-substrate interface in overhead application before the mortar achieves adequate strength through cement hydration. EN 1504-3 Class R3 compliance of MC-RocTec FFC ensures the structural performance of the fibre-reinforced repair mortar matches the standard (unfibre-reinforced) MC-RocTec 30: compressive strength above 45 MPa, tensile adhesion above 1.5 MPa, chloride content below 0.05 percent. Space Arc Engineering supplies MC-RocTec FFC for bridge repair contractors, structural repair specialists, and civil maintenance firms in Ghaziabad, Delhi NCR, Noida, and Uttar Pradesh.

Applications

• Bridge deck soffit and T-beam underside repair without formwork — structural repair of the soffit surfaces of reinforced and prestressed concrete T-beams, box girders, and bridge deck slabs where chloride or carbonation-induced corrosion has caused concrete cover loss and spalling on the underside faces of the beams; in bridge repair, the soffit faces of the beams are overhead and cannot be accessed from below by a scaffold without either a full underdeck scaffold structure or a mobile underbridge inspection unit (MUBI); MC-RocTec FFC can be applied directly from overhead access (underbridge inspection unit, suspended scaffold, or scaffold from below) without formwork by an experienced repair mortar operative using a trowel; the anti-sag characteristic allows layer thicknesses of 20 to 30 mm per coat on overhead soffit surfaces without sag or fall-off
• Reinforced concrete beam soffit repair in industrial and commercial buildings — repair of the soffit of floor beams, transfer beams, and exposed beam soffits in multi-storey parking structures, industrial buildings, and commercial building structures where the overhead beam concrete has spalled from corrosion or impact damage; without MC-RocTec FFC or equivalent anti-sag repair mortar, the structural repair contractor must erect full-height formwork under each beam to retain the repair mortar — a time-consuming and expensive operation that may require temporary closure of the occupied floor below; MC-RocTec FFC eliminates the need for formwork, substantially reducing repair cost and programme duration
• Vertical wall and column face repair in exposed marine and coastal structures — structural repair of the vertical faces of reinforced concrete jetty piles, sea wall faces, coastal building columns, and bridge piers in tidal and marine exposure environments where the combination of chloride-induced corrosion and wave splash-zone abrasion causes deep concrete section loss on the vertical and near-vertical faces of the structure; the anti-sag property of MC-RocTec FFC allows thick layers of repair mortar to be applied on steep vertical concrete faces without sag or slump, and the fibre reinforcement improves the impact resistance of the repair against wave action and debris impact
• Tunnel lining and underground structure overhead repair — structural repair of the crown and haunch zones of concrete tunnel linings in road tunnels, railway tunnels, metro tunnels, and underground structure linings where carbonation, chloride ingress, and alkali-silica reaction (ASR) cause concrete cover loss and delamination of the lining concrete on overhead faces; MC-RocTec FFC can be applied directly to the overhead and curved tunnel lining surfaces without formwork, providing structural repair mortar that does not drop on workers or plant below during application

Key Advantages

• Anti-sag thixotropic rheology for overhead and vertical application without formwork — the combination of thixotropic rheological modifier and short fibre reinforcement provides the critical anti-sag property that allows MC-RocTec FFC to be hand-applied by trowel to overhead soffit and steep vertical surfaces in 20 to 30 mm layers without formwork; eliminating formwork from overhead structural repair projects reduces cost (formwork material, labour, and time) by 30 to 60 percent and eliminates the risk of formwork collapse under the weight of wet repair mortar — a significant safety consideration in bridge repair and high-level structure repair projects
• Fibre reinforcement for improved crack resistance and post-crack ductility — the dispersed short polypropylene or PVA fibre reinforcement (typically 12 to 18 mm length, 0.5 to 1.5 kg per cubic metre fibre dosage) provides micro-crack arresting in the plastic and early hardening stages of the repair mortar, reducing plastic shrinkage cracking and early-age thermal cracking; after hardening, the fibre reinforcement provides post-crack ductility (the mortar can sustain load beyond the point of first cracking rather than fracturing suddenly), improving the impact and freeze-thaw resistance of the hardened repair
• EN 1504-3 Class R3 structural performance compliance — maintaining the same structural classification (compressive strength above 45 MPa, tensile adhesion above 1.5 MPa, low chloride content) as the non-fibre-reinforced MC-RocTec 30, ensuring that the addition of fibre reinforcement and thixotropic modifier does not compromise the structural repair mortar performance — the bridge specification engineer or structural repair consultant can specify MC-RocTec FFC for overhead surfaces within the same EN 1504-3 Class R3 repair system specification as MC-RocTec 30 for vertical and horizontal surfaces
• System compatibility within MC-Bauchemie EN 1504 structural repair system — MC-RocTec FFC is engineered for use as part of the complete MC-Bauchemie structural repair system with MC-Dur 900 corrosion protection primer for cleaned reinforcement (EN 1504 Principle 11) and MC-Contact bonding slurry as the substrate interface bond coat (EN 1504 Principle 3), providing a complete and system-warranted structural repair solution for overhead and overhead-vertical combination repairs