MC-Bauchemie Nafufill KS Concrete Repair Mortar
A one-component, fibre-reinforced, dual shrinkage-compensated PCC repair mortar from MC-Bauchemie for structural concrete replacement, certified to EN 1504-3 Class R4.
What is it?
A factory-blended, one-component polymer-cement concrete (PCC) repair mortar from MC-Bauchemie’s Nafufill family, fibre-reinforced and dual shrinkage-compensated for structural concrete replacement.
Where is it used?
Spalled and carbonated reinforced concrete in bridges, tunnels, dock yards, water-retaining structures and industrial buildings, on vertical, overhead and horizontal faces.
Why use it?
It rebuilds section and restores load-bearing capacity to EN 1504-3 Class R4, with high carbonation resistance and chloride/de-icing-salt resistance for long durability.
How is it applied?
Machine-mixed with clean water, applied by hand or wet-spray onto a saturated-surface-dry substrate over a Nafufill KMH bond coat, in lifts of 10-50 mm.
About MC-Bauchemie Nafufill KS Concrete Repair Mortar
MC-Bauchemie Nafufill KS belongs to the German manufacturer’s well-established Nafufill concrete-replacement range, the workhorse mortars specifiers reach for when reinforced concrete has lost section to corrosion, carbonation or mechanical damage. It arrives as a grey, ready-blended dry powder that a crew gauges on site with clean water, mixes to a homogeneous lump-free mortar, and applies to rebuild the original profile. Because it is a polymer-modified cementitious (PCC) system with dual shrinkage compensation and fibre reinforcement, it develops the mechanical strength and dimensional stability needed for genuine structural repair rather than cosmetic patching. It is classified as a Class R4 mortar to EN 1504-3, the highest structural class in the European concrete-repair standard, and it satisfies a wide band of exposure classes from XO through XC, XD, XS, XF and XA per EN 206-1.
For engineers and applicators across Delhi NCR and Pan-India, the appeal is dependability under difficult site conditions. The mortar can be built up in generous lifts, worked overhead and on vertical faces without slumping, and finished cleanly with a float or sponge. It resists carbonation and chloride ingress, so once the repair is cured it protects the freshly exposed reinforcement it now encases. Space Arc Engineering supplies Nafufill KS as an authorised MC-Bauchemie channel, pairing the material with the correct bonding coat, primer and curing regime so that what leaves our warehouse actually performs the way the datasheet promises on your structure.
The technical insight
The performance of Nafufill KS comes from three engineered mechanisms working together. First, the polymer modification: the redispersible polymer in the blend co-cures with the cement to form a tougher, less permeable matrix that bonds tenaciously to a prepared, saturated-surface-dry substrate and flexes with the parent concrete instead of debonding. Second, dual shrinkage compensation: the formulation counters both the early plastic shrinkage and the later drying shrinkage that normally crack thick repair lifts, which is what lets the mortar be placed up to 50 mm per pass and 80 mm total without through-cracking. Third, fibre reinforcement, which bridges micro-cracks as they try to form and holds the placed mortar together during build-up on vertical and overhead faces. The dense, low-permeability hardened matrix is the same feature that gives the near-zero carbonation depth measured at 90 days and the chloride resistance, meaning the repair does not just restore the concrete but also re-establishes a protective cover over the reinforcement.
Where it is used
- Reprofiling spalled and delaminated reinforced concrete on bridge piers, girders and decks
- Structural repair of carbonated or chloride-attacked columns, beams and soffits
- Concrete replacement in tunnels and underground structures
- Repairs to dock yards, jetties and other marine and splash-zone concrete
- Rehabilitation of water-retaining structures such as tanks, sumps and treatment works
- Patch and section repair in industrial buildings and process plants
- Vertical and overhead repairs where a non-slump, buildable mortar is required
- Restoration of concrete cover to protect exposed reinforcement after de-rusting
Key advantages
- Certified EN 1504-3 Class R4, the top structural class for repair mortars
- Dual shrinkage compensation minimises cracking in thick lifts up to 50 mm
- Fibre reinforcement improves cohesion and reduces micro-cracking
- High carbonation resistance with near-zero carbonation depth at 90 days
- Chloride-proof and resistant to de-icing salts for durable protection
- One-component: only clean water is added on site, reducing batching error
- Applies by hand or wet-spray, suiting both small patches and large areas
- Covers a broad exposure-class range (XO, XC, XD, XS, XF, XA)
Limitations & considerations
- Requires a properly prepared, sound substrate brought to saturated-surface-dry condition
- A separate bond coat (Nafufill KMH or MC Solid Range) is needed for hand application
- Exposed reinforcement must first be de-rusted to blast grade Sa 2 per EN ISO 12944
- Must be machine-mixed for at least 5 minutes; hand mixing and part-batching are not permitted
- Needs protection from rapid drying, direct sun and wind, with curing for about 3 days
- Not a rapid-set or trafficable-in-minutes product; strength develops over 48 hours to 28 days
Selection & best practice
Start by cutting back all unsound and contaminated concrete to a sound edge and, where reinforcement is exposed, remove corrosion to blast grade Sa 2 (EN ISO 12944) and apply corrosion protection where specified. Pre-wet the substrate thoroughly and bring it to a saturated-surface-dry state with no standing water before you begin. For hand application, work a Nafufill KMH bond coat into the prepared surface and place the mortar wet-on-wet. Gauge only clean water at roughly 4.5-5.1 litres (15-17%) per 30 kg bag and mix for at least 5 minutes in a forced-action or slowly rotating double mixer until lump-free; never mix by hand or make partial batches. Build up in lifts of 10-50 mm, respecting the 80 mm total maximum, and finish with a wooden or plastic float or a sponge-rubber squeegee. In Indian summer conditions, use cool mixing water, work early or shaded, and protect the fresh repair from sun and wind, curing for about three days to reach the datasheet strengths.
Specifications
| Type | One-component fibre-reinforced polymer-cement concrete (PCC/SPCC), dual shrinkage compensated |
| Standard | EN 1504-3 Class R4 (structural repair) |
| Compressive strength | 30 N/mm² @ 48 h, 42 N/mm² @ 7 d, 55 N/mm² @ 28 d (ASTM C-109, 50 mm cube) |
| Flexural strength | >5 N/mm² @ 28 days |
| Tensile strength | >1.5 N/mm² @ 28 days |
| Layer thickness | 10 mm min / 50 mm max per work step; 80 mm max total |
| Water demand | 4.5-5.1 litres (15-17%) per 30 kg bag |
| Fresh mortar density | 2090 kg/m³ (max grain size 3 mm) |
| Pack size | 30 kg sacks; shelf life 9 months in unopened packaging |
Industry use cases
Bridges & Highways
Reprofiling spalled piers, girders and deck soffits to restore section and re-establish protective cover over corroded rebar.
Marine & Ports
Chloride-proof repair of dock yards, jetties and splash-zone concrete where de-icing and sea-salt attack is severe.
Water & Environmental
Structural rehabilitation of tanks, sumps and treatment works needing a dense, low-permeability R4 mortar.
Industrial & Infrastructure
Section repair of columns, beams and soffits in plants, tunnels and multi-storey buildings, applied by hand or wet-spray.
Frequently asked questions
Is Nafufill KS a structural repair mortar?
Do I need a separate bonding coat?
How thick can I apply it in one pass?
Can it be spray-applied for large areas?
How much water do I add, and can I hand-mix it?
How long before the repair reaches full strength?
How we position MC-Bauchemie Nafufill KS Concrete Repair Mortar
Nafufill KS sits in the middle of a complete MC-Bauchemie repair system that Space Arc supplies as a set rather than a single bag. For hand-applied work it is placed over the Nafufill KMH bonding coat and reinforcement-protection layer from the same brand family, and finished with MC’s cosmetic and protective coatings where an even face is required. Where the equivalent Fosroc system is specified instead, we stock Renderoc HB for lightweight vertical and overhead patch repair and Renderoc RG flowable microconcrete for congested, hard-to-vibrate sections, and our team will help you match the right mortar, bond coat and cure to the exposure class and access on your structure.
Fosroc Renderoc HB — Choose the Fosroc Renderoc HB where a lightweight, high-build mortar is preferred for vertical and overhead patch repair, or where the project specification is standardised on the Fosroc Renderoc system.
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