ACTFLEX HBR Epoxy repair mortar
Two-component pre-proportioned structural epoxy bonding and repair mortar
Pre-filled epoxy repair mortar, 80 MPa compressive at 7 days. Goes on damp concrete.
ACTFLEX HBR coverage, coats and cure times
Two-component, pre-proportioned epoxy mortar for structural concrete repair, rebuilding, bonding and anchoring. Nothing is added on site: it mixes to a non-slump, trowelable mortar for horizontal, vertical and overhead work.
- Compressive
- 80 MPatypicalat 7 days, 25°C · TDS p2
- Bond strength
- > 2.5 MPatypicaldirect tensile, concrete failure · TDS p2
- Mix ratio
- 2 : 1Part A to Part B, by volume and by weight · TDS p2
- Pack
- 5 kg, 30 kg30 kg kit: Part A 20 kg + Part B 10 kg · TDS p2
- Pot life
- 40 mintypicalat 25°C and 50% RH · TDS p2
- Touch dry
- 10–12 htypicalinitial set; overcoat after this · TDS p2
- Full cure
- 7 daystypicalmechanical and chemical, at 25°C · TDS p4
- Per pass
- 20–25 mmvertical and overhead; build deeper in passes · TDS p3
- Apply at
- 15–35°Cwith relative humidity below 80% · TDS p3
From the FORSPEC data sheet, TDS-HBR · Revision 5 · 12 November 2026. Times are at 25°C and 50% relative humidity unless the data sheet says otherwise. Typical = FORSPEC’s own typical value, not a laboratory-certified one.
Where ACTFLEX HBR is used
Use it for
- Spalled or eroded concrete in industrial and infrastructure assets
- Concrete bays, plinths, kerbs and edge nosings
- Stairs, steps and loading dock edges
- Floor voids and damaged slabs before coating
- Bonding precast elements, concrete, masonry and stone
- Chemical plant floors, mechanical rooms and workshop bays
Know before you start
- Not a waterproofing membrane
- Apply only at 15 to 35°C with relative humidity below 80%
- Not over standing water, or on concrete under 28 days old or below 25 MPa
- Safety-critical anchoring needs project design and written FORSPEC confirmation
Its FORSPEC systems
How to apply ACTFLEX HBR
- 01
Prepare
Concrete cured 28 days and at least 25 MPa. Grind, shot-blast or scarify to a sound, open surface and vacuum. Damp is fine, but remove standing water and any water film.
- 02
Cracks
Rectify structural and live cracks first with PROBOND 1100, CRACK PRO 1200PS or CRACKLOCK E400L, per their TDS. Use FORBUILD 100 or FORCRETE 100 for larger sections.
- 03
Prime
Where the specification calls for it, prime with ACTFLEX EPOXY GROUT and place the mortar while the primer is tacky. If it cures hard, abrade and re-prime.
- 04
Mix
Full kits only, 2 parts A to 1 part B. Mix at 300–400 rpm with a helical or paddle blade for 2 to 3 minutes to a streak-free grey. No solvents, fillers or sand. Use within 40 minutes.
- 05
Apply
Trowel firmly into the surface to remove voids. Place vertical and overhead work in passes of 20 to 25 mm, letting each stiffen and keying it before the next. Test a small area first.
- 06
Cure
Protect from rain, standing water, traffic and load until initial set (10 to 12 hours), and from immersion or chemicals until full cure at 7 days. Overcoat after initial set.
A short guide from the data sheet. Read the full ACTFLEX HBR TDS before you start.
Drawings for the systems it goes in
FORSPEC standard details as PDF and DXF. Each sheet is a generic detail: the specification names the products.
ACTFLEX HBR questions
Can ACTFLEX HBR go on damp concrete?
Yes. The substrate may be damp, but there must be no standing water or surface water film, and the repair must be protected from standing water until fully cured.
How much HBR do I need?
1.5 kg per m² per mm of thickness. A 5 kg kit covers about 0.33 m² at 10 mm and a 30 kg kit about 2.00 m² at 10 mm (theoretical, before wastage).
Do I add sand or filler?
No. It is pre-filled and pre-proportioned. Do not add solvents, fillers or sand, and do not split kits or change the ratio.
How thick can I place it?
Up to 25 mm per pass on patch and structural repairs, and 20 to 25 mm per pass on vertical and overhead work. Build greater depths in successive passes.
When can I coat or render over it?
After initial set, which is 10 to 12 hours at 25°C (typical). Finish with a stippled key and confirm compatibility with the coating manufacturer.
Can I use it to anchor bolts?
Yes for bolts and fixings, but safety-critical anchoring needs project-specific design and written FORSPEC confirmation.
Used with ACTFLEX HBR
ACTFLEX HBR TDS and SDS
Always work from the current data sheet. Every FORSPEC TDS and SDS →
Specify it. Or buy it.
Send the drawings or photos and FORSPEC comes back with the system, the details and the quantities. Or find a FORSPEC stockist for ACTFLEX HBR.