MC-Bauchemie MC-RocTec 222
Single-component, polymer-modified fine repair mortar to EN 1504-3 Class R3 — rebuilds spalled cover concrete in one 5 to 50 mm pass, no formwork.
What is it?
A factory-batched, cement-based fine repair mortar carrying redispersible polymer powder, graded to EN 1504-3 Class R3 for hand-applied patch reinstatement of damaged concrete.
Where is it used?
Bridge decks and soffits, multi-storey car parks, industrial sheds, RCC facades, retaining walls and water-retaining structures where cover concrete has spalled or carbonated.
Why use it?
It bonds without a separate slurry coat, builds up to 50 mm in a single lift, and delivers structural strength (>35 MPa) with low shrinkage, so patches stay put and match the parent concrete.
How is it applied?
Saturate the sound, roughened substrate, gauge the 25 kg bag with 4 to 4.5 litres of clean water, trowel-apply in 5 to 50 mm lifts, finish, then cure for at least 7 days.
About MC-Bauchemie MC-RocTec 222
MC-RocTec 222 is a ready-to-use concrete repair mortar built around Portland cement, graded fine aggregate up to 1 to 2 mm, and a redispersible polymer that is dry-blended into the mix at the factory. Because every bag is batched under controlled conditions, the contractor only adds a measured quantity of water on site — there is no separate polymer liquid to gauge and no risk of an operator getting the ratio wrong. That consistency is what lets a repair crew reinstate spalled cover across a large deck or a run of columns and get the same strength, colour and finish from the first bag to the last. The product is classified R3 under EN 1504-3, the European standard that governs structural and non-structural concrete repair, so it sits squarely in the range specifiers reach for when a patch has to carry load and last.
In practical terms, MC-RocTec 222 is the mortar you use once corroded reinforcement has been exposed, cleaned and primed, and the section needs to be rebuilt back to profile. It handles like a good hand-applied render — it stays where it is troweled on vertical and overhead faces, builds from a feather-edge patch up to a full 50 mm lift, and closes off to a fine, floatable surface that takes a protective or anti-carbonation coating cleanly. Space Arc Engineering supplies MC-RocTec 222 across Delhi NCR and Pan-India as an authorised distributor and applicator, which means the material can arrive with method-statement support and, where the client wants it, a trained application crew rather than just a pallet of bags.
The technical insight
The performance of MC-RocTec 222 comes from the polymer film that forms as the mortar cures. Redispersible polymer powder, once re-wetted in the mix, reconstitutes into a flexible film that laces through the cement matrix. That film does three useful things at once: it raises tensile and bond strength so the repair grips the parent concrete (pull-off greater than 1.5 MPa) instead of debonding at the interface, it reduces the water demand and drying shrinkage that would otherwise crack a thick patch, and it tightens the pore structure so chlorides and CO2 migrate more slowly through the new mortar than through ordinary sand-cement. The chloride content of the mortar itself is held below 0.05 percent by mass of cement, which matters because you are placing this material directly against reinforcement you have just cleaned — you do not want the repair to reintroduce the very ion that drove the corrosion. The fine 1 to 2 mm aggregate grading is what allows a single-lift build up to 50 mm without slumping while still floating to a smooth face, and the polymer-improved bond is why no separate bonding slurry is needed on a properly prepared, saturated-surface-dry substrate.
Where it is used
- Reinstating spalled cover concrete on bridge decks, piers, crossheads and soffits
- Patch repair of carbonation- and chloride-damaged columns, beams and slab soffits in buildings
- Concrete repairs in multi-storey and basement car parks subject to de-icing salts and traffic
- Restoring RCC facades, chajjas, fins and parapets on high-rise structures
- Repair of retaining walls, culverts and other buried or earth-retaining structures
- Reinstatement of water treatment tanks, sumps and channels after aggregate exposure
- Making good honeycombing, tie-holes and form defects on freshly struck concrete
- Profile build-up around freshly cleaned and primed reinforcement steel
Key advantages
- Single-component — only clean water is added on site, removing on-site gauging error
- No separate bonding coat needed on a correctly prepared, saturated substrate
- Builds 5 to 50 mm in one lift on vertical and overhead faces without formwork
- Structural strength above 35 MPa at 28 days, comfortably clearing the R3 threshold
- High pull-off bond (>1.5 MPa) keeps patches integral with the parent concrete
- Low chloride content (<0.05 percent) protects the reinforcement it is placed against
- Fine grading floats to a smooth surface ready for protective or anti-carbonation coatings
- EN 1504-3 Class R3 classification supports specification and third-party audits
Limitations & considerations
- Working time is only about 30 to 45 minutes at 20 degrees C, so mix in batches the crew can place and finish
- Performance depends on substrate prep — corroded steel must be cleaned and primed and the concrete cut back to a sound, roughened surface
- Not a self-levelling or pourable micro-concrete; for reinstating large or reinforced sections by flow, a fluid micro-concrete is the correct tool
- Requires diligent curing for a minimum of 7 days; skipping curing invites shrinkage cracking on thicker patches
- Fine 1 to 2 mm mortar is intended for cover-zone repair, not for very deep structural voids in a single application
Selection & best practice
Cut the defective concrete back to a sound substrate with a square edge of at least 10 mm at the perimeter — never feather-edge onto weak concrete. Grit-blast or wire-brush exposed reinforcement to bright metal, treat it with an appropriate zinc-rich or polymer primer, and let it dry. Pre-soak the concrete so it is saturated but surface-dry (no free water) at the moment of application. Gauge each 25 kg bag with 4 to 4.5 litres of clean water and mix with a forced-action or slow-speed paddle mixer to a lump-free, cohesive consistency — do not over-water to make it easier to trowel, as that costs strength and invites shrinkage. Apply firmly in 5 to 50 mm lifts, working the first pass well into the substrate to expel air, and close the surface with a float or sponge once it has stiffened. Protect the finished repair from wind, direct sun and rain, and cure for at least 7 days using a compatible curing compound or wet hessian. In hot Indian site conditions, keep materials shaded, use cool mixing water, and reduce batch sizes to stay within the working time.
Specifications
| Product type | Single-component, polymer-modified fine concrete repair mortar |
| Standard / classification | EN 1504-3, Class R3 |
| Compressive strength (28 days) | >35 MPa |
| Bond strength (pull-off) | >1.5 MPa |
| Application thickness | 5 to 50 mm per lift |
| Maximum aggregate size | 1 to 2 mm |
| Chloride content | <0.05% by mass of cement |
| Water demand | Approx. 4 to 4.5 litres per 25 kg bag |
| Working time | Approx. 30 to 45 minutes at 20 degrees C |
Industry use cases
Bridges & Highways
Reinstating spalled cover on decks, piers and crossheads where chlorides and traffic have exposed reinforcement, restoring structural section to R3 grade.
Car Parks & Commercial RCC
Patching de-icing-salt and carbonation damage on soffits, columns and beams in multi-storey and basement parking, ready to receive a protective coating.
Water & Effluent Structures
Repairing aggregate-exposed tank walls, channels and sumps in treatment plants, with low chloride content suited to constant wet exposure.
Facades & High-Rise
Making good spalled chajjas, fins and parapets at height, where a formwork-free, hand-applied mortar that builds up to 50 mm speeds access-restricted work.
Industrial & Retaining Structures
Rebuilding damaged cover on retaining walls, culverts and factory frames, returning members to profile before overcoating.
Frequently asked questions
Do I need a separate bonding coat before applying MC-RocTec 222?
How thick can I go in one application?
Is MC-RocTec 222 a structural repair mortar?
How much water do I add per bag, and how long can I work it?
Why does the low chloride content matter?
Can Space Arc apply it for us, or only supply the material?
How we position MC-Bauchemie MC-RocTec 222
MC-RocTec 222 sits in the cover-zone patch-repair tier: hand-applied, fine-grade, R3, up to 50 mm per lift. Where a repair needs to be poured into a large or heavily reinforced section rather than troweled, step up to a fluid micro-concrete such as MC-Bauchemie’s Emcecrete or Fosroc Conbextra. Ahead of the mortar, clean and prime exposed steel with a compatible reinforcement primer, and after curing protect the whole element with an anti-carbonation or protective coating (MC-Bauchemie’s MC-Color or a Fosroc Dekguard system) to slow re-ingress. Within the same fine-repair role, Fosroc Renderoc S2 is the closest cross-brand equivalent we stock; for lighter, non-structural build-up on facades, Fosroc Renderoc HB (R2) is the value option.
Fosroc Renderoc S2 — Choose Renderoc S2 when the specification calls out a Fosroc structural patch-repair mortar or a two-component system with defined polymer liquid, reaching 45 N/mm2 for localised column, beam and soffit reinstatement.
Related Concrete Repair products
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