Self-Compacting Castable Structural Mortar — Class R4

Repair 400 C — Self-Compacting Castable Structural Mortar

Super-fluid, self-compacting, controlled shrinkage, fibre-reinforced polymer-modified castable mortar — classified R4 to UNI EN 1504-3, walkable in 2 hours, compressive strength exceeding 60 MPa

Repair 400 C is Licata's highest-performance castable structural mortar — a single-component, super-fluid, self-compacting R4-class product designed for precision machine fixing, structural casting and the reconstruction or cross-section increase of reinforced concrete elements. Its pliable, flowable texture reaches and fills all cavities without compaction, and it can be applied from 5mm up to 100mm with aggregate addition. Walkable in 2 hours and driveable in 3–4 hours.

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Certified UNI EN 1504-3 — Class R4 Compressive Strength > 60 MPa Adhesion > 2.0 MPa Walkable in 2 Hours Driveable in 3–4 Hours

Classification R4 — Highest Class

Application Thickness 5–30mm / 30–100mm

Compressive Strength > 60 MPa

Walkable From 2 hours

Driveable From 3–4 hours

Features & Benefits

Why specify Repair 400 C self-compacting castable structural mortar?

Class R4 — Highest Structural Classification

Repair 400 C reaches the highest class under UNI EN 1504-3, achieving compressive strength exceeding 60 MPa against a 45 MPa requirement and an elastic modulus above 20 GPa. It is the right choice wherever the most demanding structural repair specification applies.

Super-Fluid & Self-Compacting

Purpose-devised additives give Repair 400 C exceptional fluidity and self-compacting flow, allowing it to reach and fill the most inaccessible cavities without mechanical compaction. The fluidity can be adjusted within the specified water range to suit specific casting requirements.

Walkable in 2 Hours — Driveable in 3–4

Special accelerating additives drastically reduce completion times. Repair 400 C is ready for foot traffic after just 2 hours and for vehicle traffic after 3–4 hours — delivering rapid return to service in industrial, infrastructure and flooring repair applications.

Precision Machine Fixing

The combination of super-fluid consistency, controlled shrinkage and exceptional compressive and adhesion strength makes Repair 400 C the specified choice for precision in-ground fixing of heavy industrial machinery — including presses, turbines, compressors, cranes and milling machines.

5mm to 100mm — One Product

Used as supplied for applications from 5 to 30mm. For depths from 30 to 100mm, Repair 400 C is extended with clean washed aggregates (4–10mm, to UNI EN 12620) at a ratio of 25kg aggregate per two 25kg bags — a single product solution across a wide range of casting depths.

Adhesion > 2.0 MPa — Freeze/Thaw Stable

As a polymer-modified mortar (PCC), Repair 400 C achieves adhesion exceeding 2.0 MPa and maintains that bond after frost cycles, heat exposure, thundershower simulation and dry thermal cycling — confirming long-term reliability across the full range of service environments.

Product Description

Repair 400 C — R4-Class Castable Structural Mortar

Repair 400 C is Licata's super-fluid, self-compacting, controlled shrinkage, fibre-reinforced polymer-modified castable structural mortar — classified R4 under UNI EN 1504-3, the highest available classification. Manufactured with high-resistance hydraulic binders, selected aggregates, pozzolanic additives and HP fibres, it is designed for applications where maximum structural performance, precision filling and rapid return to service are all required simultaneously.

Unlike the trowel-applied Repair 250 series, Repair 400 C is a castable product — poured with continuous flow and allowed to self-level. Its fluidity is adjustable within the specified water range to achieve flat floors or slightly sloping surfaces. For depths from 5 to 30mm it is used as supplied; for 30 to 100mm, clean washed aggregates are added at the specified ratio to extend the product without compromising performance.

Repair 400 C develops full resistance after 28 days of curing and is suitable for exposed reinforcement applications in conjunction with BetonFIP Passivante as a passivating primer. For horizontal castings on smooth or absorbing substrates, Aggrappante LG bonding primer is recommended.

Certifications

UNI EN 1504-3 — Class R4 · Compressive strength >60 MPa · Adhesion >2.0 MPa · Elastic modulus >20 GPa

Applications

Where to use Repair 400 C

Precision fixing of heavy industrial machinery

In-ground fixing of anchor rods and structural castings

Reconstruction of beams, pillars and kerbstones

Cross-section increase of reinforced concrete structures

Restoration of concrete flooring — horizontal castings

Filling cavities and rigid connections between concrete elements

Restructuring in formwork of common cement substrates

For trowel-applied structural repair at 3–30mm, see Repair 250 N or Repair 250 R. For other substrates, contact our technical team.

Technical Data

Repair 400 C — technical specification

AppearanceGrey powder

Particle size< 3mm

Consumption≈ 19 kg/m² per 10mm

Mixing water per 25kg4.0–4.5 L (16–18%)

Working time at 20°C≈ 20 minutes

Thickness — as supplied5–30mm

Thickness — with aggregate30–100mm

Aggregate addition ratio25kg per 2 × 25kg bags

Walkable from2 hours

Driveable from3–4 hours

Full strength28 days curing

Application temperature+5°C to +35°C

Density2,150–2,250 kg/dm³

Mix pH≈ 12

Packaging25kg bags

Shelf life12 months (sealed, dry store)

Compressive strength (EN 12190)> 60 MPa

Adhesion strength (EN 1542)> 2.0 MPa

Elastic modulus (EN 13412)> 20 GPa

Thermal compat. freeze/thaw (EN 13687-1)> 2.0 MPa

Thermal compat. thundershower (EN 13687-2)> 2.0 MPa

Thermal compat. dry cycling (EN 13687-4)> 2.0 MPa

Preparation & Mixing

Preparing Repair 400 C

Substrate preparation: Mechanically remove all flaking or easily detachable material. Clean the area thoroughly — free from dust, detergents, oils, greases, waxes, gypsum and salts. For exposed reinforcement, apply BetonFIP Passivante before proceeding.

Mixing: Add 4.0–4.5 litres of clean water per 25kg bag (16–18% by mass). Pour the product into a container with ¾ of the water and mix for 3 minutes at low speed, gradually adding the remaining water until a homogeneous, lump-free mixture is achieved. Fluidity can be adjusted within this water range. Do not split bags for partial mixes.

Aggregate extension (30–100mm): For casting depths between 30 and 100mm, add clean washed round or crushed aggregates (4–10mm particle size, to UNI EN 12620) at a ratio of 25kg aggregate per two 25kg bags of Repair 400 C.

Application

Casting Repair 400 C

Substrate condition: Wet the substrate with water until saturated — Saturated Surface Dry (SSD). For horizontal castings on absorbing or particularly smooth substrates, treat the dry surface with a coat of Aggrappante LG bonding primer instead of wetting.

Casting: Pour Repair 400 C with a continuous flow onto the substrate. The self-compacting mix will flow and fill cavities unaided. Assist flow with a trowel where needed and adjust slope by light compacting if a fall is required.

Return to service: Repair 400 C is ready for foot traffic after 2 hours and vehicle traffic after 3–4 hours. Full structural resistance is achieved after 28 days of curing.

Curing: Protect fresh mortar for at least 24 hours from rapid drying, direct sunlight, strong wind and heavy rain. Do not add water or additional powder to already-mixed product.

Note: Do not apply to substrates with a film of surface water, completely dry substrates, surfaces exposed to direct midday sun, or frozen surfaces. Fluidity may be regulated by varying the water content strictly within the 16–18% range specified. Ambient, substrate and product temperatures must be between +5°C and +35°C.

Buy Repair 400 C self-compacting castable structural mortar

Available from all six Licata branches across the UK. Speak to our team about pricing and technical support.

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