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ID- MAY 2023

PATCHROC RSP constructive solutions

Rapid-setting patch repair concrete for

pavements and floors

Technical Support
Fosroc offers a comprehensive range of high quality, high
Uses
performance concrete repair and construction products. In
For the emergency reinstatement of damaged or addition, Fosroc offers a worldwide technical support and
deteriorated concrete. The material is particularly suitable on-site service to specifies, end-users and contractors.
for repairs to airport runways, aprons and areas where Design Criteria
wheeled traffic requires fast return to service. It may be
PATCHROC RSP is designed for horizontal use but can
used internally and externally.
also be used vertically the aid of formwork. It is suitable for
For the reinstatement of very large areas of concrete
use at nominal thickness of 100 mm. Thicker sections up
pavements and floors, the use of Paveroc is
to 250 mm may be applied by the addition of graded silt-
recommended.
free coarse aggregate.
The material should not be applied at less than 20mm
Advantages thickness. Aggregate should not be added at applied
thickness between 20mm and 100mm without specific

▪ Rapid strength gain, accept vehicular traffic within advice from fosroc. Horizontal surface areas should be

hours with high strength, abrasion and weather restricted to bay sizes not exceeding 4m2. Consult the

resistance. local Fosroc office for further information.

▪ Pre-bag supply contain selected coarse aggregate Typical Properties

▪ Economical-can be ‘bulked-out’ with graded The following results were obtained at water: powder ratio
aggregate in some locations. of 0.18 and temperature of 25+/-2°C.
▪ Self-compacting-eliminates honeycomb and voids. Compressive strength
BS EN12390-3 30 N/mm2 @ 4 hours
Description Cube10x10x10cm 40 N/mm2 @ 1 days
PATCHROC RSP is supplied as a ready to use blend of Tolerance +/- 10% 50 N/mm2 @ 7 days
dry powders and graded aggregates which requires only 60 N/mm2 @ 28 days
the site addition of clean water to produce a highly Setting time
consistent, high strength, free-flowing repair concrete Initial set 10-15 mins
which self-compacts. Final set 30-40 mins
The material is a blend of inorganic cements, special filler Traffic time
and chemical additives to control the rate of strength gain Pedestrian 1 - 2 hours
to provide a fluid micro-concrete with good handling Vehicular approx. 4 hours
characteristics. PATCHROC RSP exhibits excellent Flexural Strength : 30 kg/cm2 @ 4 hours
thermal compatibility with concrete. 55 kg/cm2 @ 7 days

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Application instructions Mixing

Care should be taken to ensure that PATCHROC RSP is

Preparation
thoroughly mixed. A forced-action mixer is essential.
Saw cut or cut back the extremities of the repair locations
Mixing in a suitably sized drum using an approved spiral
to a depth of at least 20mm to avoid feather edging and to
paddle in a slow speed (400/500 rpm) heavy-duty drill is
provide a square edge. Break out the complete repair area
acceptable. Free-fall mixers must not be used. Mixing of
to a minimum depth of 20mm up to the sawn edge.
part bags should never be attempted.
Clean the surface and remove any dust, unsound or
It is essential that machine mixing capacity and labor
contaminated material, plaster, oil, paint, grease,
availability is adequate to enable the placing operation to
corrosion deposits or algae. Where breaking out is not
be carried out continuously.
required, roughen the surface and remove any laitance by
Measure 5 to 5.5 liters of COLD drinking quality water and
light scrabble or grit-blasting.
pour +/- 75% quantity into the mixer. With the machine in
Oil and grease deposits should be removed by steam
operation, add one full 30 kg bag of PATCHROC RSP and
cleaning, detergent scrubbing or the use of a proprietary
mix for 1 minute before adding the rest of the water.
degreaser. The effectiveness of decontamination should
Mix for further 3 to 4 minutes until a smooth even
then be assessed by a pull-off test.
consistency is obtained. Note that powder must always be
The prepared area should be blown clean with oil-free
added to water. The quantities mixed may be scaled up as
compressed air.
required.
Temporary formwork should be fitted tightly into all
When the drill and paddle mixing method is used, the
existing pavement and floor joints which about the repair
complete measured volume of water should be placed in
zone in order to prevent loss during the repair process.
the mixing drum. With the paddle rotating, add one full
30kg bag of PATCHROC RSP and mix for 3 to 5 minutes
Substrate priming
until a smooth even consistency is obtained.
It is recommended that the mixed product be passed
Prior to placing, the prepared concrete substrate should
through a suitable coarse metal screen prior to placing or
be saturated by flooding with clean water. Immediately
pumping to highlight any unmixed material.
prior to the application of PATCHROC RSP, the water
should be removed leaving the substrate fully saturated.
Placing
Providing the substrate has been properly soaked, further
priming is not normally necessary. Where soaking is not
The mixed material should be placed within 10 minutes of
possible, the following procedure should be used. The
mixing in order to gain the full benefit of fluidity. Each
substrate should be well soaked with clean water for as
repair should be poured or pumped in a single continuous
long as possible and any excess removed.
operation. Repair may be surface finished using a trowel
NITOBOND AR or NITOBOND SBR primer should then
or wood float. If a textured surface is required, this can be
be scrubbed well into the surface. PATCHROC RSP may
achieved using a suitable roller or brush as the material
be applied as soon as the primer becomes tacky.
begins to stiffen. The completed surface should not be
Note: If the primer dries before PATCHROCRSP is
overworked.
applied, re-priming should take place exactly as described
PATCHROC RSP can be applied up to 100mm thickness
above before continuing.
in a single application. For repair section deeper than
100mm, it will be necessary to ‘fill-out’ PATCHROC RSP

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PATCHROC RSP constructive solutions

with suitable and property graded aggregate in order to High temperature working
minimize temperature rise.
Aggregate should be in a saturated surface dry condition. At ambient temperature above 30oC, the material should
The quantity of aggregate required will vary dependent on be stored in the shade and cool water used for mixing.
the nature and configuration of the repair location. The best application is during nighttime to avoid over
Generally, for sections between 100mm and 250mm evaporation of water that can cause cracking.
deep, the following mix design shoul be considered :
Curing
30 kg PATCHROC RSP PATCHROC RSP is a cement-based product.
4.7-5.2 liter clean water In common with all cementitious materials. PATCHROC
12.5 kg of 8-12mm aggregate RSP must be cured immediately after finishing in
7.5 kg zone 2 sand accordance with good concrete practice.
The use of CONCURE series like Concure P, sprayed on
Adding above materials can influence the Compressive to the surface of the finished mortar in a continuous film, is
and Flexural strength result. Site trial is needed to check recommended.
the result. In fast drying conditions or hot condition, supplementary
curing with polythene sheeting tape down at the edges
The water demand may vary dependent on the condition must be used.
of the aggregate. In cold conditions, the finished repair must be protected
To place the filled PATCHROC RSP at the lower water from freezing.
content, the use of a vibrating poker is desirable, to aid
compaction. The quantity of aggregate should never Cleaning
exceed 1 part aggregate to 1 part PATCHROC RSP (by
dry weight). Trial mixes should be made in order to ensure PATCHROC RSP and primer should be removed from
the optimum addition of both water and aggregate. tools, equipment and mixers with clean water immediately
after use. Cured material can only be removed
Note the minimum applied thickness of PATCHROC RSP mechanically.
is 20mm. Aggregate should not be added at applied
thickness between 20mm and 100mm. Limitations

- PATCHROC RSP should not be used when the

Low temperature working temperature is bellow 5oC.
- Do not mix part bags.
In cold conditions down to 50C, the use of warm water (up - The product should not be exposed to moving water
to 300C) is advisable to accelerate strength development. during application. Exposure to heavy rainfall prior to the
Normal precautions for winter working with cementitious final set may result in surface scour.
materials should then be adopted. The material should not
be applied when the substrate and/or air temperature is
below 5oC.

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PATCHROC RSP constructive solutions

Estimating Precautions
Supply Health and safety
PATCHROC RSP 30 kg bags PATCHROC RSP contains cement powder which, when

Nitobond AR or SBR 5L & 20L mixed or become damp, release alkalis which can be

Concure P 20L and 210L harmful to the skin. During use, avoid inhalation of dust
and contact with the skin and eyes. Wear suitable

Coverage and Yield protective clothing, gloves, eye protection and respiratory
protective equipment.
PATCHROC RSP approx. 15.5 L /30kg
The use of barrier creams provide additional skin
bag (0.76m2 at 20 mm
protection. In case of contact with skin, rinse with plenty of
thickness)
clean water and seek medical advice. If swallowed, seek
Nitobond 6 to 8 m2 liter
medical attention immediately-do not induce vomiting.
Concure 3 to 5 m2 liter
Nitobond, Concure series should not come in contact with
the skin and eyes, or be swallowed.
Note: The actual yield per bag of PATCHROC RSP will
Ensure adequate ventilation. Wear suitable protective
depend on the consistency used. The coverage figures for
clothing, gloves, and eye protection. If working in confined
liquid products are theoretical-due to wastage factors and
areas, suitable respiratory protective equipment must be
the variety and nature of possible substrates, practical
used.
coverage figures will be reduced.
Fire
Storage PATCHROC RSP and NITOBOND AR, NITOBOND SBR

Shelf Life are non-flammable.

For further information, refer to the Safety Data Sheet.
All products have a shelf life of 6 months if kept in a dry
store in the original, unopened bags or packs, indoor with
good ventilation, T: 25 – 35oC, RH <55%.
If stored at high temperatures and/or high humidity
conditions the self-life can be reduced.

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