Newton HydroCoat 203-RM - Rapid Set & High Strength Repair Mortar

Name: Newton HydroCoat 203-RM - Rapid Set & High Strength Repair Mortar
Brand: John Newton & Co. Ltd
Price: 78.50 GBP
Availability: InStock

Newton HydroCoat 203-RM is a single-component, fast-setting, Portland cement-based structural mortar, used primarily for the durable repair of concrete. Ideal for roads, runways, bridges, decks, floors and footpaths.

Polymer-modified, and fibre-reinforced, Newton HydroCoat 203-RM is physically and chemically compatible with the host concrete, quickly exhibiting high adhesive and compressive strength.

Supplied in 25Kg Bags. Available in Grey Colour only.

Newton HydroCoat 203-RM

Newton HydroCoat 203-RM is a single-component, fast-setting, Portland cement-based structural mortar, used primarily for the durable repair of concrete.

Setting in just 10 minutes at 20ºC, Newton HydroCoat 203-RM is ideal for areas that cannot be taken out of service for long periods, or where the concrete is subjected to heavy wear such as roads, runways, bridges, decks, floors and footpaths.

Polymer-modified, and fibre-reinforced, HydroCoat 203-RM is physically and chemically compatible with the host concrete, quickly exhibiting high adhesive and compressive strength.

As a single component, requiring only the addition of water, the resulting mortar is rapid curing with enhanced polymeric properties and reliable strength development which is not significantly affected by low temperature use. The mortar can be used as supplied up to 100 mm deep, or bulked out with clean, washed, sharp sand to form a high performance screed or for floor or deck repairs up to maximum depth of 300mm.

Typical Applications:

✔ Rapid, durable and strong repair to concrete including leading edge repairs to step nosings

✔ Bonded low thickness screed

✔ Very strong and durable floors to areas subjected to heavy wear such as roads, runways, bridges, decks, floors and footpaths

✔ High bond and quick drying smoothing fillet for use with Newton Liquid Waterproofing Membranes.

Product Benefits:

Incorporates the latest proven cement chemistry, fibre and styrene acrylic copolymer technology.
Reliable strength development, even at sub-zero temperatures, gives rapid return to service.
Pre-packaged material only requires mixing with clean water. Can be bulked out with clean, washed, sharp sand or aggregate.
High bond strength exceeds tensile strength of concrete, thus ensuring monolithic performance of the repair.
Sets in 10 minutes at 20°C yielding a durable, high strength mortar.
Dense matrix resists 10 bar water pressure. Very high diffusion resistance to acid gases and chloride ions.
Sulphate resistance to class DS-5/5m of BRE Special Digest 1 and ideally suited for sewage and wastewater applications.
Portland cement base with physical properties of cured material similar to base concrete.
Non-toxic when cured and is listed as authorised under Regulation 31 for use in the supply of drinking water.
Economic mortar requiring no substrate or inter-layer priming. Part bags can be mixed.

Compliance:

CE-marked in accordance with EN 1504-3. Suitable for repair methods 3.1, 7.1, 7.2 as defined by BS EN 1504-3.
Compliant with Highways Agency Standard BD27/86 for the repair of Highway Structures.
Compliant with LU Standard 1-085 ‘Fire Safety Performance of Materials’.

Suitable Substrates:

Correctly prepared concrete of at least 20kN.

Ancillary Products:

HydroCoat 905-CM - Curing membrane to prevent accelerated drying during hot or very windy conditions

Surface Preparation:

Mechanically remove all damaged concrete back to a sound core. Wherever possible, the full circumference of the steel reinforcement should be exposed to at least 25mm behind the bars and 50mm beyond the point at which corrosion is visible.

On cutting back, feather edges must be avoided.

The perimeter of the repair area should be stepped to a depth of 10mm by means of saw, disc cutting or preferably using a power chisel. The areas to be repaired must be free from all unsound material, i.e. dust, oil, grease, corrosion by-products and organic growth.

Smooth surfaces should be roughened, all loose material and surface laitance removed, and reinforcement cleaned to bright steel using wet grit blasting techniques or equivalent approved methods. The strength of the concrete sub-base should be a minimum of 20 MPa.

The prepared substrate should be thoroughly soaked with clean water until uniformly saturated without any standing water. In winter, use warm water or a heat source to ensure the substrate temperature is a minimum of +5⁰C before application.

Application to new horizontal concrete will require the grinding away of surface laitance with specialist grinding equipment.

Priming:

Priming is generally not required. Highly porous substrates should be be primed with HydroCoat 908-LB mixed 1-1 with water.

Mixing:

HydroCoat 203-RM should be mechanically mixed using a forced action pan mixer or in a clean drum using a drill and paddle. A normal concrete mixer is NOT suitable.

For normal applications, typically use 3.5 litres of clean water per 25 kg bag. For part bags, use 5.5 volumes of powder to one volume of water. In cold temperatures tepid water may be used to adjust working life.

For screeding applications or larger pockets in decks up to a maximum depth of 100mm, a clean, washed, Medium Grade concreting sand can be introduced, up to 50% by weight.

For deep repairs up to a maximum of 300 mm in a single application, or where a pourable concrete is required, coarse, clean aggregates (5-10 mm size) can be introduced into the mix, in up to equal proportions by weight, without adversely affecting its physical performance.

Application Method:

Apply Newton HydroCoat 203-RM with a Trowel or Putty Knife.

Placing:

For normal applications, HydroCoat 203-RM should be compacted, using a placing technique to remove entrapped air, in layers not exceeding 50mm in vertical or soffit situations, or 100mm deep in pockets.

When bulking out to the maximum of 300mm, support with shuttering and compact to remove entrapped air.

For repairs which require multi-layer applications, it is important to ensure that the previous layers are well keyed and stable but not fully set (usually 15-30 minutes dependent upon temperature) prior to the application of subsequent layers.

If necessary, support with shuttering to allow for compaction if working to reveals, etc.

Final profiling of a high quality is achieved with a steel float.

When applying material to floors, the area should be divided up and each bay completed within the working life of the HydroCoat 203-RM. Typically bay sizes should be restricted to 1m².

Do not polish the surface with a steel float, but use a stiff brush on the wet surface to provide a slip-resistant finish.

Internal smoothing fillets should be 25 mm x 25 mm.

Push the mortar tightly into the corner to ensure there is no trapped air.

Yield:

One bag of Newton HydroCoat 203-RM produces 13.3 litres of usable product and up to 23 litres when bulked out with aggregate.

When used to create a smoothing fillet, one bag of HydroCoat 203-RM will produce 42.5 linear metres of a fillet that is 25mm x 25mm.

Curing:

For curing/drying times please refer to Page 2 of the Technical Data Sheet.

Newton HydroCoat 203-RM is a cement based product and so requires curing. Accelerated drying must be avoided. Shade the applied material from strong sunlight.

If the conditions are hot, sunny and/or very windy the finished membrane must be protected from accelerated drying with the application of HydroCoat 905-CM, a simple to apply liquid curing membrane, or polythene sheeting, damp hessian or similar.

If required, spray further coats of HydroCoat 905-CM.

Pot Life & Further Use:

Newton HydroCoat 203-RM is a single component powder that is mixed with clean water. Pot life about 10 minutes, depending on the temperature and humidity.

Part bags can be used at 5.5 volumes of powder to one volume of water.

Technical Data Sheet

Declaration of Performance

Safety Data Sheet

Newton HydroCoat 203-RM

Newton HydroCoat 203-RM is a single-component, fast-setting, Portland cement-based structural mortar, used primarily for the durable repair of concrete.

Setting in just 10 minutes at 20ºC, Newton HydroCoat 203-RM is ideal for areas that cannot be taken out of service for long periods, or where the concrete is subjected to heavy wear such as roads, runways, bridges, decks, floors and footpaths.

Polymer-modified, and fibre-reinforced, HydroCoat 203-RM is physically and chemically compatible with the host concrete, quickly exhibiting high adhesive and compressive strength.

As a single component, requiring only the addition of water, the resulting mortar is rapid curing with enhanced polymeric properties and reliable strength development which is not significantly affected by low temperature use. The mortar can be used as supplied up to 100 mm deep, or bulked out with clean, washed, sharp sand to form a high performance screed or for floor or deck repairs up to maximum depth of 300mm.

Typical Applications:

✔ Rapid, durable and strong repair to concrete including leading edge repairs to step nosings

✔ Bonded low thickness screed

✔ Very strong and durable floors to areas subjected to heavy wear such as roads, runways, bridges, decks, floors and footpaths

✔ High bond and quick drying smoothing fillet for use with Newton Liquid Waterproofing Membranes.

Product Benefits:

Incorporates the latest proven cement chemistry, fibre and styrene acrylic copolymer technology.
Reliable strength development, even at sub-zero temperatures, gives rapid return to service.
Pre-packaged material only requires mixing with clean water. Can be bulked out with clean, washed, sharp sand or aggregate.
High bond strength exceeds tensile strength of concrete, thus ensuring monolithic performance of the repair.
Sets in 10 minutes at 20°C yielding a durable, high strength mortar.
Dense matrix resists 10 bar water pressure. Very high diffusion resistance to acid gases and chloride ions.
Sulphate resistance to class DS-5/5m of BRE Special Digest 1 and ideally suited for sewage and wastewater applications.
Portland cement base with physical properties of cured material similar to base concrete.
Non-toxic when cured and is listed as authorised under Regulation 31 for use in the supply of drinking water.
Economic mortar requiring no substrate or inter-layer priming. Part bags can be mixed.

Compliance:

CE-marked in accordance with EN 1504-3. Suitable for repair methods 3.1, 7.1, 7.2 as defined by BS EN 1504-3.
Compliant with Highways Agency Standard BD27/86 for the repair of Highway Structures.
Compliant with LU Standard 1-085 ‘Fire Safety Performance of Materials’.

Suitable Substrates:

Correctly prepared concrete of at least 20kN.

Ancillary Products:

HydroCoat 905-CM - Curing membrane to prevent accelerated drying during hot or very windy conditions

Surface Preparation:

Mechanically remove all damaged concrete back to a sound core. Wherever possible, the full circumference of the steel reinforcement should be exposed to at least 25mm behind the bars and 50mm beyond the point at which corrosion is visible.

On cutting back, feather edges must be avoided.

The perimeter of the repair area should be stepped to a depth of 10mm by means of saw, disc cutting or preferably using a power chisel. The areas to be repaired must be free from all unsound material, i.e. dust, oil, grease, corrosion by-products and organic growth.

Smooth surfaces should be roughened, all loose material and surface laitance removed, and reinforcement cleaned to bright steel using wet grit blasting techniques or equivalent approved methods. The strength of the concrete sub-base should be a minimum of 20 MPa.

The prepared substrate should be thoroughly soaked with clean water until uniformly saturated without any standing water. In winter, use warm water or a heat source to ensure the substrate temperature is a minimum of +5⁰C before application.

Application to new horizontal concrete will require the grinding away of surface laitance with specialist grinding equipment.

Priming:

Priming is generally not required. Highly porous substrates should be be primed with HydroCoat 908-LB mixed 1-1 with water.

Mixing:

HydroCoat 203-RM should be mechanically mixed using a forced action pan mixer or in a clean drum using a drill and paddle. A normal concrete mixer is NOT suitable.

For normal applications, typically use 3.5 litres of clean water per 25 kg bag. For part bags, use 5.5 volumes of powder to one volume of water. In cold temperatures tepid water may be used to adjust working life.

For screeding applications or larger pockets in decks up to a maximum depth of 100mm, a clean, washed, Medium Grade concreting sand can be introduced, up to 50% by weight.

For deep repairs up to a maximum of 300 mm in a single application, or where a pourable concrete is required, coarse, clean aggregates (5-10 mm size) can be introduced into the mix, in up to equal proportions by weight, without adversely affecting its physical performance.

Application Method:

Apply Newton HydroCoat 203-RM with a Trowel or Putty Knife.

Placing:

For normal applications, HydroCoat 203-RM should be compacted, using a placing technique to remove entrapped air, in layers not exceeding 50mm in vertical or soffit situations, or 100mm deep in pockets.

When bulking out to the maximum of 300mm, support with shuttering and compact to remove entrapped air.

For repairs which require multi-layer applications, it is important to ensure that the previous layers are well keyed and stable but not fully set (usually 15-30 minutes dependent upon temperature) prior to the application of subsequent layers.

If necessary, support with shuttering to allow for compaction if working to reveals, etc.

Final profiling of a high quality is achieved with a steel float.

When applying material to floors, the area should be divided up and each bay completed within the working life of the HydroCoat 203-RM. Typically bay sizes should be restricted to 1m².

Do not polish the surface with a steel float, but use a stiff brush on the wet surface to provide a slip-resistant finish.

Internal smoothing fillets should be 25 mm x 25 mm.

Push the mortar tightly into the corner to ensure there is no trapped air.

Yield:

One bag of Newton HydroCoat 203-RM produces 13.3 litres of usable product and up to 23 litres when bulked out with aggregate.

When used to create a smoothing fillet, one bag of HydroCoat 203-RM will produce 42.5 linear metres of a fillet that is 25mm x 25mm.

Curing:

For curing/drying times please refer to Page 2 of the Technical Data Sheet.

Newton HydroCoat 203-RM is a cement based product and so requires curing. Accelerated drying must be avoided. Shade the applied material from strong sunlight.

If the conditions are hot, sunny and/or very windy the finished membrane must be protected from accelerated drying with the application of HydroCoat 905-CM, a simple to apply liquid curing membrane, or polythene sheeting, damp hessian or similar.

If required, spray further coats of HydroCoat 905-CM.

Pot Life & Further Use:

Newton HydroCoat 203-RM is a single component powder that is mixed with clean water. Pot life about 10 minutes, depending on the temperature and humidity.

Part bags can be used at 5.5 volumes of powder to one volume of water.

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