MC-RocTec 30
Polymer-Modified Cementitious Structural Repair Mortar for 15 to 40 mm Layer Thickness — EN 1504-3 Class R3 Structural Repair of Beams, Columns, Slabs, and Walls with Moderate to Heavy Concrete Section Loss
Authorized Project Distributor — MC-Bauchemie India | Space Arc Engineering, Ghaziabad
Product Overview
MC-RocTec 30 is a factory-blended polymer-modified cementitious repair mortar from MC-Bauchemie designed for structural concrete repair at 15 to 40 mm layer thickness — the standard layer thickness range for the majority of concrete spall and section loss repairs encountered in Indian bridge rehabilitation, building structure repair, and industrial facility maintenance. The MC-RocTec range is MC-Bauchemie principal family of structural repair mortars — MC-RocTec 45 (fine grain, 5 to 15 mm), MC-RocTec 30 (standard grain, 15 to 40 mm), and MC-RocTec FFC (fibre-reinforced, for unsupported soffit applications) — together covering the full range of structural concrete repair depths and application geometry encountered in practice. The designation of MC-RocTec 30 reflects the approximate maximum one-coat application thickness of 30 mm, though with appropriate technique and the addition of aggregate extension for thick repairs, the product can be applied in 40 mm layers. The polymer modification (SBR or acrylate polymer) improves key performance properties versus standard unmodified cementitious repair mortars: improved adhesive bond to the existing concrete substrate (tensile bond above 1.5 to 2.0 MPa versus 0.5 to 1.0 MPa for unmodified cement mortar); reduced shrinkage during curing (reducing the risk of bond failure or reflective cracking from differential shrinkage between the repair and the parent concrete); improved durability (reduced chloride permeability, reduced carbonation rate, and improved resistance to freeze-thaw and chemical attack compared to unmodified cement mortar). These properties are specified in EN 1504-3 Class R3 criteria: compressive strength above 45 MPa, tensile adhesion above 1.5 MPa, chloride content below 0.05 percent by weight of cement. Space Arc Engineering supplies MC-RocTec 30 for structural repair contractors, bridge rehabilitation consultants, and infrastructure maintenance teams in Ghaziabad, Delhi NCR, Noida, and Uttar Pradesh.
Applications
- Structural repair of reinforced concrete beams with corrosion-induced spalling — repair of beam soffits, beam sides, and corbels in reinforced concrete framed buildings, bridges, flyovers, and industrial structures where chloride or carbonation-induced corrosion of the main reinforcement has caused concrete cover spalling at depths of 15 to 40 mm; the repair sequence follows EN 1504 structural repair principles: full removal of delaminated cover concrete to expose corroded bars, cleaning of bar corrosion to bright metal, application of MC-Dur 900 corrosion protection primer to cleaned bars, application of MC-Contact bonding slurry to the prepared substrate, and hand or spray application of MC-RocTec 30 in 15 to 30 mm layers to restore the beam section dimensions and re-establish the design reinforcement cover
- Column repair and section restoration in industrial buildings and infrastructure — repair of reinforced concrete columns with concrete cover loss from corrosion or mechanical impact in industrial buildings, warehouses, multi-storey car parks, and bridge piers; column repairs at 15 to 40 mm depth are typically carried out using profiled timber or GRP formwork to contain the plastic MC-RocTec 30 mortar on all four column faces simultaneously, or using a hand application technique with a stiff-consistency mix for repair of individual column face defects without full circumferential formwork; the EN 1504-3 Class R3 classification of MC-RocTec 30 ensures the repair mortar meets the structural performance requirements (strength, adhesion, durability) for column repair in all IS 456 exposure classes
- Bridge deck soffit and pier cap repair in highway and railway infrastructure — structural repair of reinforced concrete bridge deck soffits, bridge pier caps, and bridge abutment faces on NHAI national highways, state PWD roads, and railway bridges in Delhi NCR and Uttar Pradesh where periodic inspection has identified corrosion-induced concrete spalling and delamination requiring structural repair mortar application to restore cover and structural section; MC-RocTec 30 is approved for bridge structural repair under EN 1504-3 Class R3 specification and is compatible with the structural repair material requirements of MORTH Standard Specifications for Roads and Bridges and IRC:58 bridge maintenance guidelines
- Industrial floor and slab repair at 15 to 40 mm depth — repair of industrial concrete floor slabs in warehouses, factories, and logistics centres where localised areas of deep concrete degradation (pothole deterioration with concrete loss to 15 to 40 mm depth, construction joint edge damage with full joint edge removal, and deep core holes from utility penetration repairs) require a structural-grade repair mortar that achieves the strength and bond to withstand industrial wheeled traffic and fork-lift loads; MC-RocTec 30 at C45 to C50 characteristic strength matches or exceeds the concrete grade of the original floor slab, ensuring the repair area does not become a weakness under the design floor loading
Key Advantages
- EN 1504-3 Class R3 compliance for structural concrete repair specification compliance — tested and classified under EN 1504-3 Class R3 (compressive strength above 45 MPa, tensile adhesion above 1.5 MPa to substrate, chloride content below 0.05 percent, carbonation resistance coefficient below 0.01 mm/square root of days) — the standard structural repair mortar classification required by specifications on bridge rehabilitation, infrastructure maintenance, and industrial facility repair projects in India; Class R3 compliance provides the specifying engineer with the assurance that the repair mortar meets defined minimum performance criteria for structural concrete repair applications
- Polymer modification for high bond strength and low shrinkage — the SBR or acrylate polymer modification provides tensile adhesion above 1.5 to 2.0 MPa to properly prepared concrete, substantially exceeding the 0.5 to 1.0 MPa of unmodified cementitious repair mortars; this high bond strength is critical for the long-term performance of structural concrete repair because the repair mortar must remain bonded to the parent concrete under the cyclic thermal, mechanical, and moisture stresses of the service environment; the polymer also reduces drying shrinkage by 20 to 30 percent versus unmodified cement mortar, reducing the differential shrinkage between repair and parent concrete that is the primary driving force for repair detachment
- Compatible with the MC-Bauchemie EN 1504 structural repair system — MC-RocTec 30 is designed for use as part of the complete MC-Bauchemie structural repair system under EN 1504: MC-Dur 900 rebar corrosion protection primer (Principle 11, method 11.3) plus MC-Contact bonding slurry (Principle 3, method 3.3 — substrate bonding) plus MC-RocTec 30 repair mortar (Principle 3, method 3.3 — structural repair); the system compatibility ensures the individual products are engineered to work together in terms of chemical compatibility, mechanical compatibility (matched moduli of elasticity), and corrosion protection system performance
Technical Data
| Type | Polymer-modified single-component cementitious structural repair mortar — factory-blended, gauged with water on site |
| EN 1504-3 Classification | Class R3 — Structural Repair Mortar (compressive strength above 45 MPa, tensile adhesion above 1.5 MPa) |
| Compressive Strength at 28 days | Greater than 45 to 55 MPa — EN 12390-3 cube test method |
| Tensile Adhesion to Concrete | Greater than 1.5 MPa (substrate failure) — EN 1542 pull-off test on properly prepared substrate |
| Layer Thickness | 15 to 30 mm per coat — up to 40 mm with extended aggregate addition (consult product data sheet) |
| Chloride Ion Content | Below 0.05 percent by weight of cement — IS 456 and EN 1504-3 compliance |
| Application Method | Hand application by trowel or spray application — on MC-Contact bonding slurry primer |
| Curing | Apply wet hessian or curing membrane for minimum 3 days — critical in Indian summer above 35 degrees Celsius |
Get a Quote
+91 9999155255 | info@space-arc.com | Space Arc Engineering, Sahibabad, Ghaziabad
Frequently Asked Questions
A structural engineer at a PWD bridge maintenance division in Uttar Pradesh is inspecting a 30-year-old prestressed concrete T-beam bridge on a state highway with a span of 24 metres — inspection has found severe concrete deterioration on the soffit of all 4 beams: carbonation depth of 30 to 40 mm (through the entire cover zone) with extensive rebar corrosion producing longitudinal cracks and delamination of the cover concrete over approximately 60 percent of the beam soffit area — the inspection report has recommended structural repair to EN 1504 standards — how should MC-RocTec 30 be specified in the repair method statement, and what quantities of material are needed for a single beam 24 metres long with 450 mm web width and 35 percent delamination area?
Specifying a structural repair method statement for a severely carbonated and corroded prestressed T-beam soffit using MC-RocTec 30 requires following the EN 1504 structural repair principles rigorously — and for a prestressed concrete beam in particular, requires additional precautions not needed for ordinary reinforced concrete repair. Here is the complete method statement framework and the material quantity calculation. EN 1504 principle and method selection for this case: the beam shows Principle 3 (concrete restoration — restoring original concrete section and reinforcement cover) with method 3.1 (hand-applied mortar) plus Principle 11 (preserving or restoring passivity of reinforcement) with method 11.3 (applying corrosion-inhibiting coatings to rebar); the complete system: MC-Dur 900 (corrosion protection primer for cleaned rebar) plus MC-Contact (bonding bridge coat) plus MC-RocTec 30 (structural repair mortar). Special precaution for prestressed concrete: before carrying out any concrete removal or repair on prestressed T-beam beams, the structural engineer MUST confirm by structural calculation or existing design drawing review that removing the delaminated cover concrete does not expose or damage the prestressing tendons; the prestressing cables in a 30-year-old T-beam are typically located in the lower flange and lower web — the cover to the prestressing tendons is typically 50 to 75 mm from the soffit face; the delamination depth of 30 to 40 mm described here is within the passive cover zone and should not expose the prestressing tendons, but this must be confirmed before chipping begins; if chipping exposes or damages a prestressing tendon, STOP immediately and consult the bridge design engineer — this is a structural safety issue requiring a full structural review before repair can proceed. Method statement for beam soffit repair with MC-RocTec 30: Stage 1 — Concrete removal: use a pneumatic chipping hammer (jack hammer 7 to 9 kg weight) to remove all delaminated, hollow, and carbonated concrete from the beam soffit and lower beam web faces to a depth that: includes all concrete with carbonation depth through the cover (phenolphthalein test on freshly exposed concrete — remove to the depth where the concrete first turns pink indicating alkaline pH above 9); includes all concrete with visible crack planes or delamination (remove at least 10 to 15 mm behind the deepest visible crack); exposes the full circumference of all corroded reinforcing bars (not just the top face) — the repair can only provide corrosion protection to the full bar surface if the bar is completely surrounded by repair mortar; Stage 2 — Rebar cleaning and MC-Dur 900 application: clean all exposed bars to bright metal by power wire brush, needle gun, or light grit blast; apply two coats of MC-Dur 900 corrosion protection primer to the full circumference of all cleaned bars within 4 hours of cleaning; allow first coat to dry for minimum 30 to 60 minutes before second coat; Stage 3 — Substrate preparation and MC-Contact application: saturate the concrete substrate (bond coat preparation surface) with clean water — maintain saturated surface dry (SSD) condition; apply MC-Contact bonding slurry by brush to the entire repair substrate immediately before MC-RocTec 30 application; apply MC-RocTec 30 into wet MC-Contact — do not allow the bond coat to dry before applying the repair mortar; Stage 4 — MC-RocTec 30 application for soffit repair: for a soffit repair (applying mortar overhead), use MC-RocTec 30 at a stiffer consistency than for vertical or horizontal surfaces — use the minimum water content specified to achieve a stiff, tacky consistency that stays in position without sagging; apply in layers of maximum 20 to 25 mm per coat for soffit application (overhead application requires thinner layers than vertical application due to gravity); for the typical 35 to 45 mm repair depth on this beam (removing 30 to 40 mm carbonated cover plus additional depth for rebar exposure), two coats of MC-RocTec 30 may be required — allow first coat to achieve initial set (typically 2 to 4 hours) before second coat; Stage 5 — Curing: apply wet hessian and polythene sheet over all repair areas immediately after finishing — maintain continuous wet curing for minimum 72 hours; in Uttar Pradesh summer above 35 degrees Celsius, curing is critical — without wet curing, the high ambient temperature causes rapid surface drying and shrinkage cracking in the repair mortar within 2 to 4 hours of application. Material quantity calculation for one 24-metre T-beam: beam soffit width: 450 mm = 0.45 metres; total soffit area: 24 x 0.45 = 10.8 square metres; delamination area (35 percent): 10.8 x 0.35 = 3.78 square metres of repair area; average repair depth including bar exposure: 45 mm; MC-RocTec 30 volume: 3.78 x 0.045 = 0.17 cubic metres; MC-RocTec 30 consumption: approximately 2,100 kg per cubic metre density of mortar = 0.17 x 2,100 = 357 kg — round up to 375 kg = 15 bags of 25 kg; add 20 percent wastage = 18 bags per beam, 72 bags for 4 beams; MC-Contact bonding slurry: 3.78 square metres per beam x 0.3 kg per square metre = 1.1 kg per beam, 4.4 kg for 4 beams; MC-Dur 900 rebar primer: estimate exposed rebar area as 2 times the repair area (bar circumference coverage) = 7.56 square metres of bar per beam x 0.2 kg per square metre = 1.5 kg per beam, 6 kg for 4 beams; Space Arc Engineering supplies MC-RocTec 30, MC-Dur 900, MC-Contact, and the complete EN 1504 structural repair system for PWD and NHAI bridge rehabilitation projects in Uttar Pradesh, Delhi NCR, and Ghaziabad — contact +91 9999155255 for project-specific method statement review and material supply.
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