Structural Concrete Repair Mortar — Class R4

Repair 450 — Structural Concrete Repair Mortar

Thixotropic, structural, fibre-reinforced polymer-modified cement mortar — classified R4 to UNI EN 1504-3, up to 50mm in a single coat, with compressive strength exceeding 58 MPa and adhesion exceeding 2.8 MPa

Repair 450 is Licata's trowel-applied R4-class structural repair mortar — the highest classification under UNI EN 1504-3, achieved in a hand or machine-applied product. Its defining characteristic is dimensional stability: specific R&D effort by Licata's laboratories resulted in controlled hygrometric shrinkage that allows single-coat application up to 50mm while minimising cracking at every phase — application, plastic and curing. Suitable for structural strengthening of pillars, bridges and infrastructure pylons as well as standard concrete repair.

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Certified UNI EN 1504-3 — Class R4 Compressive Strength > 58 MPa Adhesion > 2.8 MPa Elastic Modulus > 27 GPa 50mm Single Coat

Classification R4 — Structural

Single Coat Depth 5–50mm

Consumption ≈ 18 kg/m² per 10mm

Working Time at 20°C ≈ 40 minutes

Temperature Range +5°C to +35°C

Features & Benefits

Why specify Repair 450 structural concrete repair mortar?

Class R4 — Trowel Applied

Repair 450 achieves the highest classification under UNI EN 1504-3 in a hand or machine-applied mortar — delivering compressive strength exceeding 58 MPa, adhesion exceeding 2.8 MPa and an elastic modulus above 27 GPa. R4 performance without the need for formwork or casting.

Up to 50mm in a Single Coat

Dimensional stability — the result of dedicated R&D by Licata's laboratories — is the defining characteristic of Repair 450. Controlled hygrometric shrinkage allows application up to 50mm in a single coat while minimising cracking at every phase: application, plastic and curing.

Structural Strengthening

Repair 450 is formulated for structural reinforcement and strengthening of pillars, infrastructure pylons, bridges and buildings — not just surface repair. The combination of R4 mechanical performance and 50mm single-coat depth makes it suitable for significant cross-section restoration.

Adhesion > 2.8 MPa — Freeze/Thaw Stable

As a polymer-modified mortar (PCC), Repair 450 achieves adhesion exceeding 2.8 MPa — well above the 2.0 MPa R4 requirement — and maintains that bond after frost cycles, thundershower simulation and dry thermal cycling throughout its service life.

Thixotropic — Vertical & Overhead

Special additives deliver excellent thixotropy and wetting capacity, making Repair 450 equally suited to vertical surfaces and overhead applications. Critical for pillar, soffit and bridge structure repairs where gravity works against the applicator.

HT Fibre Reinforced

High-tenacity fibres contribute to the controlled shrinkage performance, reducing cracking even at high application thicknesses. The fibre reinforcement works alongside the specially developed formula to maintain dimensional stability throughout all curing phases.

Product Description

Repair 450 — R4-Class Trowel-Applied Structural Mortar

Repair 450 is Licata's thixotropic, structural, fibre-reinforced polymer-modified cement mortar — classified R4 under UNI EN 1504-3 and applied by hand or machine trowel. Manufactured with high-resistance hydraulic binders, selected aggregates, pozzolanic additives and HT fibres, it delivers the highest class of structural repair performance without requiring formwork or casting equipment.

Where Repair 250 N and Repair 250 R are R3-class products limited to 30mm per coat, Repair 450 extends that capability to 50mm in a single coat at R4 class — the result of specific R&D focus by Licata's laboratories on dimensional stability and controlled hygrometric shrinkage. This makes it the product of choice for deep structural repairs, pillar strengthening and bridge infrastructure work where significant section loss has occurred.

Repair 450 is paintable from 24 hours and develops full resistance after 28 days of curing. It is compatible with BetonFIP Passivante as a passivating primer on exposed reinforcement and with FinishPro 280 as a final skim coat where a fine cosmetic finish is required.

Certifications

UNI EN 1504-3 — Class R4 · Compressive strength >58 MPa · Adhesion >2.8 MPa · Elastic modulus >27 GPa

Applications

Where to use Repair 450

Structural strengthening of pillars and columns

Reinforcement of infrastructure pylons and bridges

Deep structural concrete repair — up to 50mm single coat

Concrete repair with exposed reinforcement bars

Local repairs to cement-based flooring

Balcony risers, corners and damaged edges

Reconstruction of spalled or heavily deteriorated sections

For castable applications or depths beyond 50mm, see Repair 400 C. For R3-class trowel repair at 3–30mm, see Repair 250 N.

Technical Data

Repair 450 — technical specification

AppearanceGrey powder

Particle size< 2mm

Consumption≈ 18 kg/m² per 10mm

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

Working time at 20°C≈ 40 minutes

Thickness per coat5–50mm

Paintable from24 hours

Full strength28 days curing

Application temperature+5°C to +35°C

Density1,950–2,050 kg/dm³

Mix pH≈ 12

Packaging25kg bags

Shelf life12 months (sealed, dry store)

Compressive strength (EN 12190)> 58 MPa

Adhesion strength (EN 1542)> 2.8 MPa

Elastic modulus (EN 13412)> 27 GPa

Chloride ion content (EN 1015-17)< 0.003%

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

Capillary water absorption (EN 13057)0.16 kg/m²h½

Preparation & Mixing

Preparing Repair 450

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 thixotropic mixture is achieved. Do not split bags for partial mixes.

Substrate condition: Prior to application, wet the substrate until saturated — Saturated Surface Dry (SSD) condition. This prevents premature moisture loss from the mortar, which is particularly important at the greater application depths this product is designed for.

Application

Applying Repair 450

Bonding layer: Apply a thinner, well-pressed bonding coat first before building to the required thickness. Even out with a trowel, compacting as necessary.

Single coat depth: Repair 450 can be applied in a single coat from 5 to 50mm by hand or machine. For repairs exceeding 50mm, apply a second coat onto the fully hardened first coat.

Finishing: Paint or decorative treatments can be applied from 24 hours. For a fine cosmetic finish, overcoat with FinishPro 280. 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, walls exposed to direct midday sun, or frozen surfaces. Ambient, substrate and product temperatures must all be between +5°C and +35°C throughout application.

Buy Repair 450 structural concrete repair mortar

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

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