Thoro® Structurite R4

Thoro Structurite R4 is a one-component fast-setting, polymer-modified structural repair mortar. It contains a specially

incorporated corrosion inhibitor that prevents the offset of corrosion of any embedded reinforcement. The product is ideally

suited for the repair of concrete, there where application times are limited. Typical applications involve the structural repair

of damage caused by reinforcement corrosion, mechanical damage, alkali-aggregate reaction, etc.

The product can be used in all possible exposure conditions as it fulfils all testing requirements of EN 1504 part 3, more

specific the harshest durability tests.

Technical data:• Pot-Life: ca. 20 minutes at 20 ºC

• Final setting time: ca. 30 minutes at 20 ºC

• Compressive strength: ≥ 45 MPa after 28 days

• Adhesion strength: ≥ 2.3 MPa

• Modulus of elasticity: 25 GPa

• For layer thickness: 5 – 50 mm

Product benefits:• Thoro Structurite R4 meets the requirements of a class

R4 mortar according EN 1504-3

• Excellent bond strength

• Low capillary water absorption, but vapour permeable

• Freeze/Thaw resistant

• Polymer modified

• Long pot life that helps application, but fast setting

• No formwork required

• No separate primer required

• Carbonation resistant

• Corrosion inhibitor inside: Excellent protection of

reinforcement, even with low cover

• Can be used in vertical and overhead applications

Thoro® specification guide

Selecting the right product for each application…

With this specification guide you can easily find which product to be used for your needs. Following scheme and tables

summarise the main features of the described products to assist the right product selection. Contact your nearest

BASF Construction Chemical technical office or your nearest Thoro distributor for further or detailed advice.

Thoro Structurite R4 Thoro Structurite LightThoro Crete SL

Thoro Structurite 100ThoroStructuritePrimer

Thoro Structurite FR

Thoro Crete HS

Thoro Structurite Level

Thoro Crete SL

Product Type of material Certified according

Thoro Structurite R4 PCC mortar EN 1504-3/Class R4

Thoro Structurite 100 CC mortar EN 1504-3/Class R4

Thoro Structurite FR CC mortar EN 1504-3/Class R4

Thoro Structurite Light PCC mortar EN 1504-3/Class R3

Thoro Structurite Level PCC mortar EN 1504-3/Class R2

Thoro Crete HS PCC mortar EN 1504-3/Class R4

Thoro Crete SL PCC mortar n.a.

Thoro Structurite Primer PCC mortar EN1504-7/Class AP

Product selection

Thoro Structurite R4 √ √ √ √ √ √ √

Thoro Structurite 100 √ √ √ √ √ √

Thoro Structurite FR √ √ √ √ √ √

Thoro Structurite Light √ √ √ √ √ √

Thoro Structurite Level √ √ √ √ √ n.a. n.a.

Thoro Structurite Primer √ √ n.a. n.a. n.a. n.a. √

Thorocrete HS √ √ √ √ √ n.a. n.a.

Thorocrete SL √ √ √ √ √ n.a. n.a.

Thoro Structurite R4 ca. 20 minutes – 11 MPa 45 MPa ≥ 2.3 MPa

Thoro Structurite 100 ca. 60 minutes – 16 MPa 50 MPa ≥ 2.5 MPa

Thoro Structurite FR ca. 30 minutes – 25 MPa 55 MPa ≥ 3.5 MPa

Thoro Structurite Light ca. 30 minutes – 12 MPa 30 MPa ≥ 1.5 MPa

Thoro Structurite Level ca. 45 minutes – 10 MPa 35 MPa ≥ 0.8 MPa

Thoro Crete HS ca. 20 minutes 15 MPa 30 MPa 55 MPa ≥ 2.4 MPa

Thoro Crete SL ca. 20 minutes – 10 MPa 35 MPa ≥ 2.0 MPa

vert

ical

/ o

verh

ead

Pot Life @

20 ºC

Compressive

Strength after

2 Hours (*)

Compressive

Strength after

1 Day (*)

Compressive

Strength after

28 Days (*)

Adhesion

(*)

horiz

onta

l

thix

otro

pic

flow

able

cold

clim

ate

(fr

eeze

/ th

aw)

hum

id c

limat

e

(thun

der

/ sh

ower

)

hot c

limat

e

(dry

cyc

les)

carb

onat

ion

re

sist

ance

corr

osio

n in

hibi

tor

in

side

n.a. = not applicable

Products Typical Consistency Exposure Conditions Rebar Application Protection

Product Hardening Strength

(*) These values are typical values and not warranted minima

THORO STRUCTURITE R4

A fast-setting structural repair mortar Description of product THORO STRUCTURITE R4 is a blend of Portland cement, well-graded sand, specially selected fibres and a re-dispersible spray-dried polymer which, when mixed with water, forms a fast-setting, polymer-modified structural repair mortar. It cures to a concrete-grey colour. A specially incorporated Corrosion Inhibitor prevents the offset of corrosion of any embedded reinforcement. THORO STRUCTURITE R4 meets the requirements of a class R4 mortar according EN1504-3. Uses For the structural repair of concrete where a high compressive strength is desirable and time is limited. Suitable for repairing damage caused by: - Mechanical damage. - Corrosion of reinforcement bars. - Alkali-aggregate reaction. Benefits Durable - Excellent bond strength. - Excellent protection of reinforcement, even with low

cover. - Vapour permeable. - Freeze/Thaw resistant. - Polymer modified. Cost effective - Fast-setting, ca. 30 minutes at 20°C. - Single component, only water to be added. Easy to be used - No formwork required. - No separate bonding material required. - For layer thickness: 5 – 50 mm. - Slightly retarded version available, especially for wet

spray applications.

Cert. Nr BB-563-0013-0012-001 Cert. Institute BCCA Environmentally friendly - Cement-based. - Low chromate content. Cr VI < 2 ppm on cement

weight. Product data Typical physical properties(a) declared value Maximum grain size 0,8 mm Modulus of elasticity 25.200 N/mm² (EN 13412) Capillary water Absorption ≤ 0,36 kg/m2 x h-0.5 (EN 13057) Chloride ion content ≤ 0,05 % (EN1015-17) Mechanical properties Compressive strength 28 d. ≥ 45 N/mm² (EN 12190) Flexural 28 d. ≥ 7 N/mm² (EN 12190) Adhesive Bond 28 d. 2,3 N/mm² (EN 1542) Adhesive Bond after 28 d. 2,4 N/mm² Freeze/Thaw (EN 13687-1) (a) Typical values. All tests were carried out with 3,25 litres

water/25 kg powder under temperature controlled conditions of 21°C.

Colour Grey. Coverage Approximately 1.9 kg powder/dm³. Packaging 25 kg sack. Storage THORO STRUCTURITE R4 should be stored under cover and clear of the ground. Protect the materials from all sources of moisture and frost (+5°C). Rotate stock in order not to exceed the shelf life of 12 months. Application Substrate quality Substrates to be repaired must be clean and sound. Substrate preparation Remove all damaged concrete back to a sound base. Remove all concrete from around exposed reinforcement to give 5 mm clear cover and for 50 mm at each end. The edges of the repair area must be cut square to give a minimum depth of 5 mm. Ultra high-pressure water methods are preferred. If percussion tools are used, ensure that the cutting edges are maintained in a sharp condition. Remove all loose rust and scale from reinforcement by using a needle gun or by abrasive blasting; wire brushing is not recommended. Saturate the surface with water and remove standing water. If chlorides are present, or where it is not possible to apply a minimum of 5 mm of THORO STRUCTURITE R4 over the reinforcement, it is necessary to clean back to bright steel before applying 2 coats of THORO STRUCTURITE PRIMER. Mixing Wet density 2,10 kg/dm³ Pot life 10 - 20 minutes Initial setting time approx. 20 minutes Final setting time approx. 30 minutes Mixing liquid Mortar ± 3,25 litres (3.0 – 3,5) clean water / 25 kg powder. Bonding slurry The slurry requires 10 to 15% more mixing liquid then for the mortar consistency. The average water demand of 3.25 litres / 25 kilograms of THORO STRUCTURITE R4 will vary slightly

depending on ambient conditions. Do not exceed a maximum of 3.5 litres. It is the consistency of the mixed material that is important. Bonding slurry Add THORO STRUCTURITE R4 powder to the mixing liquid with a trowel until a lump-free slurry consistency is obtained. Trowel mix Add THORO STRUCTURITE R4 powder to the water and mechanically or manually mix until a cohesive mass is formed. Leave the mixed material to stand for 2 - 3 minutes to allow full saturation to take place. Briefly re-mix (during 1 minute). Add more powder or water, if required, to obtain the correct consistency. DO NOT OVERMIX. Do not exceed the maximum water demand. Do not mix more than can be placed in 10 minutes (at 20°C). Do not re-temper. Application method Do not apply THORO STRUCTURITE R4 to frozen substrates or when the temperature is below 5°C and above 30°C, or expected to fall below 5°C within 8 hours. Apply THORO STRUCTURITE R4 bonding slurry to a pre-dampened surface using a THORO brush. Brush firmly into the surface, completely covering the area to be repaired and any reinforcement bars. DO NOT ALLOW TO DRY OUT. Trowel THORO STRUCTURITE R4 (trowel mix) into the wet slurry, using firm pressure to compact the material fully, taking particular care around reinforcement bars. Apply in layers from 5-50 mm per application, allowing approximately 30 minutes (at 20°C) between layers. Scratch previous application to improve bond. If THORO STRUCTURITE R4 hardens before completion of repair, re-apply a bonding slurry. To obtain complicated profiles or sharp arises, simply overfill the repair area, leave until the initial set has taken place and shave to the required shape with a clean trowel. Curing Under hot or windy conditions, fog spray all applications after initial set has taken place for as long as practicable. In cool conditions, cover with insulated tarpaulin, polystyrene or other insulating material. Wait at least 4 hours before recovering THORO STRUCTURITE R4 with a water vapour permeable protective system (at 20°C). Setting and hardening times will vary, dependent upon ambient temperatures and conditions. Curing compounds are not advised. Clean up and spillages Not hardened material may simply be removed with water.

Health and safety THORO STRUCTURITE R4 is based on cement and thus can be irritating to the skin and eye. Gloves and eye protection should be worn. The use of dust masks is recommended. Accidental splashes of the material to the skin or eyes should be immediately washed off with clean water. In the event of prolonged irritation seek medical advice. In the case of ingestion give water or milk to drink and treat symptomatically. Medical advice should be sought. A Material Safety Data Sheet for this product is available on request.

Thoro

BASF Belgium Coordination Center Comm. V.- Business Belux – Construction Chemicals Nijverheidsweg 89 B-3945 Ham

www.thoro.com Tel. +32 11 34 04 32 Fax +32 11 40 13 92

B.T.W./T.V.A. BE 0862.390.376

RPR/RPM Antwerpen

Your distributor:

Important note: Whilst all reasonable care is taken in compiling technical data on the company’s products, all recommendations or suggestions regarding the use of such products are made without guarantee since the conditions of use are beyond the control of the company. It is the customer’s responsibility to make sure that each product is appropriate for the purpose for which he intends to use it and that the actual conditions of use are suitable. This edition replaces all previous editions.