Ultra Patch — Polymer-Modified Concrete Repair Mortar for Deep, Fast-Setting Repairs
Ultra Patch is a trowel-grade, polymer-modified concrete repair mortar engineered for filling, repairing, and reshaping indoor and outdoor concrete surfaces. Formulated for concrete floors, walls, precast, tilt-up, and masonry applications above or below grade, it delivers a light, workable consistency that holds a no-slump form once placed. With a full 1-inch single-lift depth neat — twice the depth of typical trowel-grade patch mortars — and a ready-to-seal window of as little as 24 hours, Ultra Patch is designed for contractors who need reliable, high-strength repairs with minimal downtime. It is equally suited to horizontal, vertical, and overhead applications.
Technical Specifications
| Specification | Details |
|---|---|
| Product Type | Trowel-grade, polymer-modified concrete repair mortar |
| Set Time — Initial Set (ASTM C266, 70°F) | 30 min |
| Set Time — Final Set (ASTM C266, 70°F) | 90 min |
| Compressive Strength — 1 Day (ASTM C109) | 1,500 psi |
| Compressive Strength — 7 Days (ASTM C109) | 3,000 psi |
| Compressive Strength — 28 Days (ASTM C109) | 4,000 psi |
| Length Change — 28 Days, Air Cure (ASTM C157) | -0.08% |
| Length Change — 28 Days, Water Cure (ASTM C157) | +0.03% |
| Freeze-Thaw Scaling Resistance (ASTM C672) | 25 cycles = 0% loss |
| Slant Shear Bond Strength — 7 Day (ASTM C882) | 1,480 psi |
| Flexural Strength — 28 Days (ASTM C348) | 465 psi |
| Yield Per Bag | 0.47 cu ft |
| Max Single-Lift Depth (neat) | 1 inch |
| Mixing Water Per 50 lb Bag | 5.5 quarts |
| Ready to Seal | As little as 24 hours |
| Packaging | 50 lb bag & 50 lb plastic pail |
| Shelf Life | 12 months (unopened, stored in dry facility) |
| Physical State (dry) | Solid / Powder |
| Color | Gray |
| Relative Density (mixed) | 2.6 – 3.2 |
Ultra Patch stands apart from standard trowel-grade mortars by offering a full 1-inch single-lift depth neat — double the typical limit — combined with excellent hang for vertical and overhead work, eliminating the need for multiple thin lifts on deeper repairs. Its polymer modification delivers a 1,480 psi slant shear bond strength at 7 days and zero scaling loss after 25 freeze-thaw cycles, performance levels that support long-term durability in exposed exterior environments. When extended with 3/8-inch SSD pea stone, it can address repairs well beyond 1 inch while maintaining thermal compatibility with the surrounding concrete.
Key Features & Benefits
Full 1-Inch Single-Lift Depth (Neat)
Ultra Patch allows repairs up to 1 inch deep in a single lift without aggregate extension — twice the depth of typical trowel-grade patch mortars. This reduces labor time on spalls and gouges that would otherwise require multiple staged lifts.
Fast Set with Early Seal Window
With an initial set of 30 minutes and a final set of 90 minutes at 70°F, Ultra Patch returns repaired surfaces to service quickly. The ready-to-seal window of as little as 24 hours minimizes project downtime on floors and flatwork.
Excellent Hang for Vertical and Overhead Repairs
The no-slump consistency holds firm once placed, making Ultra Patch suitable for vertical walls, curbs, and overhead concrete without sagging or slipping. Contractors can shape the material after initial set by shaving to final profile with a steel trowel.
Outstanding Freeze-Thaw and Bond Performance
ASTM C672 testing shows 0% scaling loss after 25 freeze-thaw cycles, confirming durability in exterior and cold-climate applications. A 7-day slant shear bond strength of 1,480 psi (ASTM C882) ensures the repair integrates structurally with the host concrete.
Extendable for Deep or Large Repairs
For repairs exceeding 1 inch, Ultra Patch can be extended with clean 3/8-inch SSD pea stone up to 50% by weight (25 lbs per bag), creating a repair with thermal properties closely matching the surrounding concrete. This flexibility makes it practical for large-volume applications without switching products.
Compatible with SpecChem Bonding and Curing Systems
Ultra Patch is designed to work with SpecPrep SB as a primer/bond coat and can be mixed with SpecChem Strong Bond Acrylic Bonder to increase durability, abrasion resistance, and bond strength — particularly recommended for thin horizontal applications under heavy traffic. Under severe drying conditions, an ASTM C309-compliant, water-based SpecChem curing compound can be applied.
Common Applications
Concrete Floor Spalls and Gouges
Ultra Patch fills spalls and impact damage in concrete floors, with a finished surface suitable for foot and rubber-tire traffic once cured.
Vertical Wall and Column Repairs
The no-slump, high-hang formulation holds on vertical concrete surfaces, making it effective for repairing walls, columns, and formed concrete without forming or bracing.
Precast and Tilt-Up Panel Repairs
Designed specifically for precast and tilt-up concrete, Ultra Patch addresses surface defects and edge damage on panels both above and below grade.
Curbs and Sidewalks
Suitable for outdoor horizontal and vertical curb repairs and sidewalk spall patching, with freeze-thaw resistance confirmed by ASTM C672 testing.
Concrete Pipe Repairs
Ultra Patch is identified for use on concrete pipe, where its workable consistency and strong bond allow effective repair of pipe surfaces and joints.
Overhead Concrete Repairs
The no-slump consistency supports overhead placement, allowing contractors to repair soffits and overhead structural concrete without the material falling away during application.
Compatible Materials
- Concrete floors (interior and exterior)
- Concrete walls (above and below grade)
- Precast concrete
- Tilt-up concrete panels
- Masonry
- Concrete curbs
- Sidewalks
- Concrete pipe
- Formed concrete
Product Documents
Application Instructions
Surface Preparation
- Ensure the concrete is sound and free of all foreign material, including oil, grease, dust, laitance, and other surface contaminants.
- For maximum durability, saw cut the perimeter of the repair 1/8 inch deeper than the repair depth to create a notched, reinforced edge.
- Mechanically abrade the surface by an engineer-approved method in accordance with ICRI 310.2 Guideline to a minimum CSP 5.
- Bring all concrete surfaces to a saturated-surface-damp (SSD) condition with no standing water on the surface.
Priming / Scrub Coat
- Thoroughly clean all exposed steel reinforcing of rust and coat with SpecPrep SB.
- Prime the prepared SSD concrete with a spray or brush coat of SpecPrep SB and apply the repair mortar wet on wet, or within the recommended open time per the SpecPrep SB technical data sheet.
- Alternatively, apply a scrub coat of properly mixed Ultra Patch by scrubbing a thin layer into the pre-dampened substrate with a stiff brush. Place the repair mortar immediately before the bond coat dries.
Mixing
- Add 5.5 quarts of clean water (adjust for desired consistency) per 50 lb bag into the mixing container.
- Add Ultra Patch powder to the water.
- Mix with a low-speed drill for 2 to 3 minutes. Mix only what can be used within the working time.
- Optional: Mix with SpecChem Strong Bond Acrylic Bonder neat or 1:1 with water per 50 lbs of powder to increase durability, abrasion resistance, and bond strength. Recommended for thin horizontal applications under heavy traffic or wear.
Deep / Large Applications (Over 1 Inch)
- Extend Ultra Patch with clean 3/8-inch SSD pea stone up to 50% by weight (25 lbs per bag) for repairs exceeding 1 inch in depth.
- Mix an additional 2 minutes after adding aggregate.
- This extension creates a repair with thermal properties similar to the surrounding concrete.
Placement
- Trowel Ultra Patch firmly into the prepared area, ensuring intimate contact with the bonding surface.
- Use slightly more material than needed and roughly shape during placement.
- After initial set, when Ultra Patch is surface hard, shave the material to the desired final shape using a steel trowel.
- Maximum depth of neat repair mortar is 1 inch per lift. For additional lifts, allow the original lift to achieve set and leave its surface rough to improve inter-lift bond.
Finishing and Curing
- Finish the repair to the desired texture to match the surrounding concrete.
- Ultra Patch is self-curing under most conditions.
- In severe drying conditions, apply an ASTM C309-compliant, water-based SpecChem curing compound.
Safety Data Summary
Hazard Information
- Causes skin irritation (Category 2; H315)
- Causes serious eye damage (Category 1; H318)
- May cause an allergic skin reaction (Skin sensitizer Category 1; H317)
- May cause cancer — contains respirable crystalline silica (Quartz), classified IARC Group 1 / ACGIH A2 (Carcinogen Category 1A; H350)
- Risk of cancer depends on duration and level of exposure
- Does not contain PBT/vPvB/vPvM chemicals, endocrine disrupting chemicals, or PFAS substances
Personal Protective Equipment
- Respiratory protection: Use appropriate certified respirator if workers are exposed to concentrations above established exposure limits for crystalline silica or other ingredients
- Eye protection: Protective safety glasses required; full face protection recommended
- Skin protection: Protective gloves required; avoid skin contact
- Engineering controls: Provide adequate ventilation using local exhaust ventilation and good general extraction
Safe Handling
- Obtain special instructions before use; do not handle until all safety precautions have been read and understood (P201, P202)
- Avoid breathing dust, fume, gas, mist, vapors, or spray (P261)
- Wash hands and exposed skin thoroughly after handling (P264)
- Contaminated work clothing must not leave the workplace (P272)
- If on skin: wash with plenty of soap and water; seek medical attention if irritation or rash develops (P302+352, P333+313)
- If in eyes: rinse cautiously with water for at least 15 minutes, remove contact lenses if present and easy to do, continue rinsing, and immediately call a poison center or physician (P305+351+338, P310)
- If exposed or concerned: get medical advice or attention (P308+313)
- Remove and wash contaminated clothing before reuse (P362+364)
- Do not allow spills to enter drains or waterways
- Contain and absorb spillage with non-combustible materials (sand, earth, vermiculite); place in closed containers and dispose per local and national regulations (P501)
- Store in a cool, dry area away from direct sunlight; store locked up (P405); shelf life is 12 months unopened
- Emergency telephone: VelocityEHS 1-800-255-3924 (North America) / +1-813-248-0585 (International)
Frequently Asked Questions
Q: What is the maximum single-lift depth for Ultra Patch applied neat?
A: The maximum depth for a single lift of neat (unextended) Ultra Patch is 1 inch. Additional lifts can be placed after the original lift has achieved set; the original lift surface should be left rough to improve inter-lift bond.
Q: Can Ultra Patch be used for repairs deeper than 1 inch?
A: Yes. For repairs exceeding 1 inch, extend Ultra Patch with clean 3/8-inch SSD pea stone up to 50% by weight (25 lbs per 50 lb bag) and mix an additional 2 minutes. This creates a repair with thermal properties closely matching the surrounding concrete.
Q: How soon can a repaired surface be sealed after applying Ultra Patch?
A: Ultra Patch is ready to seal in as little as 24 hours under normal conditions.
Q: Is Ultra Patch suitable for vertical and overhead repairs?
A: Yes. Ultra Patch is formulated with excellent hang — it mixes to a no-slump consistency that holds firm once placed, making it appropriate for vertical walls and overhead concrete surfaces.
Q: When should Strong Bond Acrylic Bonder be added to the mix?
A: The addition of SpecChem Strong Bond Acrylic Bonder is recommended when using Ultra Patch in thin, horizontal applications subjected to heavy traffic or wear. It can be added neat or mixed 1:1 with water per 50 lbs of powder to increase durability, abrasion resistance, and bond strength.
Q: Does Ultra Patch require a curing compound?
A: Ultra Patch is self-curing under most conditions. In severe drying conditions, an ASTM C309-compliant, water-based SpecChem curing compound should be applied.