FORBUILD 100 High-Performance Repair Mortar

Name: FORBUILD 100 High-Performance Repair Mortar
Brand: Forspec Protective Coatings
SKU: FFOT796
Price: 88.00 AUD
Availability: InStock

$88.00

or 4 interest-free payments with

Structural repair mortar with corrosion inhibitors. 56 MPa, just add water, no formwork.

FORBUILD 100 is a single-component, cement-based structural repair mortar: fibre reinforced, microsilica and polymer modified, with corrosion inhibitors that protect the steel and put alkalinity back into carbonated concrete. Thixotropic, so it goes on vertical, overhead and on ramps by hand or wet spray with no formwork. 20 kg bag, clean water only.

Where to use it

Corroded reinforcement repairs: marine structures, bridges, dams, tunnels and retaining walls
Vertical, horizontal and overhead patch repairs, ramping, falls correction and edge rebuilding
Water-retaining structures: tanks, canals, culverts and treatment plants
Prime with ACTFLEX 300, place while the primer is tacky

Why waterproofers buy it

Corrosion inhibitors protect reinforcement against chlorides and aggressive agents
56 MPa compressive strength at 28 days, 2.34 MPa bond to concrete
Meets the EN 1504-3 Class R4 thresholds
60 minute pot life, final set 120 minutes
3.2 to 3.4 L of water per 20 kg bag
10 year Forspec product warranty

Coverage

1.85 kg of powder per m² per mm. One 20 kg bag yields about 11 litres: approximately 3.6 m² at 3 mm, 1.1 m² at 10 mm, 0.22 m² at 50 mm. Build 3 to 100 mm per layer horizontal, 3 to 40 mm per pass vertical and overhead.

Not for

Below 5°C or above 35°C, frozen substrates, bituminous coatings, weak or friable substrates, or active rising damp without treatment. No added cement, lime, gypsum or additives, no extra water, no curing compounds, no re-tempering.

All times at 25°C and 50% RH.

Corrosion inhibitors protect reinforcement against chlorides and aggressive agents

Single component, mixed with clean water only, no site-batched additives or mixing ratios

60 minute pot life at 25C, 50% RH for efficient repair of large areas

Quantity: 1

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Pickup available at The Waterproofing Shop

Usually ready in 24 hours

FORBUILD 100 High-Performance Repair Mortar

The Waterproofing Shop

Pickup available, usually ready in 24 hours

22/872 Canterbury Road
Roselands NSW 2196
Australia

+61280213517

How to Use

Mix one 20kg bag with 3.2-3.4 L of clean water and place by trowel, screed bar or wet-spray onto the tacky ACTFLEX 300 primer or slurry coatRemove all damaged, weak and loose concrete from the repair zone
Cut edges square to a minimum depth of 5 mm and do not feather-edge
Where reinforcement is corroded, expose the bar and remove surrounding concrete to allow a minimum 10mm cover of mortar behind and over the bar
Clean reinforcement to a bright metal finish by wire brushing, needle gunning or abrasive blasting
Rectify structural cracks with the FORSPEC epoxy crack repair range, and seal active leaks with ACTFLEX FLEXIPLUG before mortar application
Mechanically roughen ramps and horizontal surfaces by grinding, bush-hammering or scabbling, and remove all laitance, dust, grease and standing water
Dampen the substrate to a saturated surface dry condition before application, with no free water
Prime the prepared substrate with ACTFLEX 300 evenly by brush or roller, two coats on porous or highly absorbent substrates
For maximum adhesion, brush in a slurry bonding coat of 1 part ACTFLEX 300 to 1 part clean water to 3 parts FORBUILD 100 powder and let it set for 10 minutes
Pour 3.2-3.4 L of clean water per 20kg bag into a clean container first, then add the powder slowly into the water
Mix mechanically with a low-speed drill at 400-600 RPM and paddle for 3 to 4 minutes to a homogeneous, lump-free mortar
Rest the mix for 1 to 2 minutes, then re-mix briefly before placing
Place the mortar while the primer or slurry coat is still tacky, mixing only what can be placed inside the 60 minute pot life
On horizontal surfaces spread with a trowel or screed bar, compact well, level falls with a straightedge and float as the mortar firms
On vertical and overhead surfaces apply by trowel or wet-spray in passes of 5-40mm built up to 100mm total, compacting firmly around exposed reinforcement
Roughen and dampen any previous layer that has fully hardened before the next pass
Lightly broom-finish before final set where the repair will receive tile adhesive, screed or coatings
Mist the surface with clean water for at least 1 hour immediately after finishing in drying conditions, and maintain curing for a minimum of 48 hours without curing compounds
Allow a minimum of 7 days, with moisture verified, before overcoating with FORSPEC membranes and coatings

Technical Specifications

Product Type: Single-component, cement-based structural repair mortar
Chemical Base: Fibre-reinforced, microsilica and polymer modified cementitious mortar with corrosion inhibitors
Standard Referenced: EN 1504-3 Class R4 structural repair thresholds
Appearance and Colour: Grey powder
Packaging: 20kg bag
Mixing Water: 16% plus or minus 1% by weight, 3.2-3.4 L per 20kg bag; up to 3.6 L for spray or pump application
Apparent Density, Powder: 1,130 plus or minus 50 kg/m3
Apparent Density, Hardened: 2,140 plus or minus 50 kg/m3
Compressive Strength: 56 MPa at 28 days (EN 12190 basis)*
Flexural Strength: 6.8 MPa at 7 days, 10.3 MPa at 28 days (EN 1015-11 basis)*
Adhesion to Concrete: 2.34 MPa (EN 1542 basis)*
Dynamic Modulus of Elasticity: 30,000 MPa, 30 GPa (EN 13412 basis)*
Capillarity: 0.40 g/dm2 per root minute
Pot Life: 60 minutes @ 25C, 50% RH
Initial Set: 75 minutes @ 25C, 50% RH
Final Set: 120 minutes @ 25C, 50% RH
Mixing Time: 3-4 minutes at 400-600 rpm, rest 1-2 minutes, re-mix briefly
Build Thickness, Horizontal: 3-100 mm per layer
Build Thickness, Vertical and Overhead: 3-40 mm per pass, to 100 mm total
Application Temperature: 5-35C, ambient and substrate
Light Foot Traffic: 24 hours @ 25C, 50% RH*
Overcoating with FORSPEC Membranes and Coatings: Minimum 7 days, moisture verified*
Powder Consumption: 1.85 kg per m2 per mm of thickness
Yield: Approximately 11 litres of mortar per 20kg bag, approximately 0.54 L per kg of powder
Minimum Cover to Reinforcement: 10 mm of mortar
Shelf Life: 12 months, unopened bags, stored dry
Hazard Classification: HAZARDOUS CHEMICAL, NON-DANGEROUS GOODS, signal word Danger (Chemwatch SDS 7971-29)
* Typical Forspec R&D characteristic values on standard production material; compressive strength at 1 and 7 days is derived from the verified 28-day result against the standard strength-gain curve for this mortar class

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System Build-Up Guide

Correct application makes all the difference.

View All Details

Pool System Build-Up

1 Concrete Substrate
2 Crack Repair (if required)
3 ACTFLEX FLEXPLUS
4 ACTFLEX HYDROPLUG
5 ACTFLEX AT MESH
6 ACTFLEX 988 CWP (2 Coats)
7 Tile Adhesive
8 Pool Finish

Retaining Wall System Build-Up

1 Concrete Substrate
2 Crack Repair (if required)
3 ACTFLEX MS PRO
4 ACTFLEX AT MESH
5 ACTFLEX 988 CWP (2 Coats)
6 Protection Board (Optional)
7 Drainage System
8 Backfill

Tank System Build-Up

1 Concrete Substrate
2 Crack Repair (if required)
3 ACTFLEX FLEXPLUS
4 ACTFLEX AT MESH
5 ACTFLEX 988 WMP (2 Coats)
6 Protective Coating (Optional)
7 Water

Technical overview

FORBUILD 100 is a single-component, cement-based structural repair mortar, fibre-reinforced, microsilica and polymer modified, and formulated with corrosion inhibitors. It is designed for the repair and reinstatement of reinforced concrete in aggressive environments: it protects embedded steel against chloride-driven corrosion and restores an alkaline environment to carbonated concrete. It is thixotropic, so vertical, horizontal and overhead repairs are placed by hand or wet-spray without formwork, and it needs only clean water on site. It is a repair mortar of the type covered by EN 1504-3 and meets the Class R4 thresholds at 56 MPa compressive strength at 28 days. No Australian Standard specifically governs proprietary concrete repair mortars, and no accredited certificate is currently held. Full classification testing to EN 1504-3 is available on request from Forspec.

Key applications

Structural concrete repairs where reinforcement has been affected by corrosion, including marine structures, bridges, harbours, ports, dams, tunnels and retaining walls
Repair of carbonated concrete, restoring alkalinity and protecting steel reinforcement
Rehabilitation of concrete exposed to de-icing salts, freeze-thaw cycles, chloride attack and mechanical impact
Maintenance and restoration of concrete damaged by acid rain, industrial emissions and atmospheric pollution
Vertical, horizontal and overhead repairs, patch repairs, ramping, falls correction, edge rebuilding and protective layers
Water-retaining and water-resistant structures such as tanks, canals, culverts and treatment plants
Preventive maintenance and durability enhancement of new and existing reinforced concrete

Surface suitability

Concrete (all damaged, weak and loose material removed, edges cut square to a minimum depth of 5 mm, never feather-edged)
Concrete (ramps and horizontal surfaces mechanically roughened by grinding, bush-hammering or scabbling to a sound mechanical key)
Concrete (dampened to a saturated surface dry condition with no free water before application)
Concrete (primed with ACTFLEX 300, two coats on porous or highly absorbent substrates)
Corroded steel reinforcement (exposed and cleaned to bright metal by wire brushing, needle gunning or abrasive blasting, with a minimum 10 mm cover of mortar behind and over the bar)

Do not apply below 5C or above 35C, ambient or substrate, or onto frozen or frost-covered substrates. Protect fresh applications from rain, frost and rapid drying caused by wind or direct sunlight. Build thickness is 3-100mm per layer horizontally and 3-40mm per pass vertically and overhead to 100mm total, with deeper repairs in multiple layers and curing between coats. Do not add cement, lime, gypsum or any other additive. Never exceed the mixing water dose of 3.2-3.4 L per 20kg bag, as excess water reduces strength, adhesion and durability. Never re-temper or reuse stiffened mortar, and apply a fresh slurry coat if the previous one dries. Do not apply curing compounds; cure by water misting or protective coverings only. Not suitable over bituminous coatings, weak or friable substrates, or substrates with active rising damp without prior treatment. Reinforcement must be cleaned to bright metal and covered by a minimum of 10mm of mortar. FORBUILD 100 contains portland cement and may contain respirable crystalline silica: wear a P2 dust respirator, chemical-resistant gloves, protective eyewear and covering clothing, and read the SDS before use.

Technical Specifications

Product Type	Single-component, cement-based structural repair mortar
Chemical Base	Fibre-reinforced, microsilica and polymer modified cementitious mortar with corrosion inhibitors
Standard Referenced	EN 1504-3 Class R4 structural repair thresholds
Appearance and Colour	Grey powder
Packaging	20kg bag
Mixing Water	16% plus or minus 1% by weight, 3.2-3.4 L per 20kg bag; up to 3.6 L for spray or pump application
Apparent Density, Powder	1,130 plus or minus 50 kg/m3
Apparent Density, Hardened	2,140 plus or minus 50 kg/m3
Compressive Strength	56 MPa at 28 days (EN 12190 basis)*
Flexural Strength	6.8 MPa at 7 days, 10.3 MPa at 28 days (EN 1015-11 basis)*
Adhesion to Concrete	2.34 MPa (EN 1542 basis)*
Dynamic Modulus of Elasticity	30,000 MPa, 30 GPa (EN 13412 basis)*
Capillarity	0.40 g/dm2 per root minute
Pot Life	60 minutes @ 25C, 50% RH
Initial Set	75 minutes @ 25C, 50% RH
Final Set	120 minutes @ 25C, 50% RH
Mixing Time	3-4 minutes at 400-600 rpm, rest 1-2 minutes, re-mix briefly
Build Thickness, Horizontal	3-100 mm per layer
Build Thickness, Vertical and Overhead	3-40 mm per pass, to 100 mm total
Application Temperature	5-35C, ambient and substrate
Light Foot Traffic	24 hours @ 25C, 50% RH*
Overcoating with FORSPEC Membranes and Coatings	Minimum 7 days, moisture verified*
Powder Consumption	1.85 kg per m2 per mm of thickness
Yield	Approximately 11 litres of mortar per 20kg bag, approximately 0.54 L per kg of powder
Minimum Cover to Reinforcement	10 mm of mortar
Shelf Life	12 months, unopened bags, stored dry
Hazard Classification	HAZARDOUS CHEMICAL, NON-DANGEROUS GOODS, signal word Danger (Chemwatch SDS 7971-29)
* Typical Forspec R&D characteristic values on standard production material; compressive strength at 1 and 7 days is derived from the verified 28-day result against the standard strength-gain curve for this mortar class