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Unipak mortar is a rapid-set, high strength bedding mortar designed to prevent bedding failure, and is suitable for all UK BS EN 124-2 applications.

It can be used on its own or with UniForm chamber extension units which are made from the same two part polyester resin material (a proven material used in highway construction) which sets to form a highly durable, homogenous structure

WRc and Nottingham University research observed that up to 89% of ironwork failures have suffered foundation issues and that in 44% of cases foundation issues were the sole cause of failure. Unipak was developed to overcome this issue.

Unipak installation

The resin product avoids many of the problems associated with cement based mortar and allows rapid road opening as it cures in as little as 25 minutes. Operatives simply mix both parts, giving a consistent and repeatable result removing issues of performance loss due to operator judgement or personal mix preferences.

The mortar has a very low slump factor, compared with other mortars, giving excellent support to ironwork in an uncured condition. Its inherent low notch sensitivity means it resists cracking which might be caused by any sharp or angular ironwork.

Unipak has a unique colour so that it can be easily identified and comes in three tub sizes (6.5, 12.5 and 25Kg), suitable for fixing small surface boxes up to largest of covers, reducing waste to a minimum.

The system comprises of two components:

  • Fast curing resin-based mortar to replace traditional poor performance cement mortar.
  • Multi-sized packing plates, replacing ad- hoc packing methods with bricks, wood or other unsuitable materials.

Unipak benefits

Easy to store

Unopened containers can be stored in a cool, dry location, away from extremes of temperature.

Simple to use

Easy to mix, manipulate and form. Unipak has low notch sensitivity and high slump resistance.

Standard installation

Simple installation process using conventional tools

Meets and exceeds the standards

Exceeds CD 534 and ideal for BS EN 124 applications (Group 1 to 4)

Early road opening

Unipak cures rapidly, in as little as 30 minutes.

UniPak addresses numerous issues

  • Poor performance of cement based mortars under traffic and weather conditions
  • Premature road opening before bedding has reached full strength
  • Incorrect mixing of mortar components
  • High notch sensitivity of conventional bedding materials
  • Use of inappropriate or poor-performance packing materials
UniPak materials

Why Unipak

Did you know 89% of highway ironwork failures suffer foundation issues and 44% are solely due to foundation failure.

Conventional packing and cement bedding just aren't good enough for the job. Unchanged methods over a hundred years have to change. We also have an increased emphasis of service life, long term economies and rapid road opening after works completion.

Three components are our innovative solution to an age old problem. Even better, the three components – mortar, packing plates and wedges – can each be used with conventional materials if required*.

* Performance won’t be the maximum achievable when compared to using the complete Unipak system, but the principles of mortar & packing remain unchanged, so Unipak is easily integrated with the ‘old’ installation methods.

UniForm chamber extension units

UniForm overcomes many of the common issues of alternative packing methods which are often manufactured from wood pulp, resulting in swelling and weakness over time. Additionally, their smooth surfaces mean lateral forces break the mortar bond and angular edges result in the cracking of surrounding brittle foundation materials. 

UniForm chamber extension units are manufactured from the same materials as UniPak, ensuring compatibility and longevity. We offer chamber blocks in two widths (100 & 150mm) and three thicknesses (15, 25 & 45mm), which can be easily cut and fixed using conventional techniques and step wedges (up to 75mm in height, with 5mm increments)

Both materials interlock with bedding mortar and resist lateral forces with no reliance on friction or mortar adhesion. Manufactured from the same compound as UniPak, they form an integral part of the system. These packing plates are suitable for BS EN 124 highway applications, groups 1 to 4.

Unipak materials



Stock code Product name Description Datasheet My Wrekin
YPCR/U6.5 UniPak Mortar 6.5Kg UniPak rapid curing polyester resin mortar
YPCR/U12.5 UniPak Mortar 12.5Kg UniPak rapid curing polyester resin mortar
YPCR/U25 UniPak Mortar 25Kg UniPak rapid curing polyester resin mortar
PC/UNIFORM/151076 UniForm UniForm packing plate 760mm x 100mm x 15mm
PC/UNIFORM/151576 UniForm UniForm packing plate 760mm x 150mm x 15mm
PC/UNIFORM/251076 UniForm UniForm packing plate 760mm x 100mm x 25mm
PC/UNIFORM/251576 UniForm UniForm packing plate 760mm x 150mm x 25mm
PC/UNIFORM/451076 UniForm UniForm packing plate 760mm x 100mm x 45mm
PC/UNIFORM/451576 UniForm UniForm packing plate 760mm x 150mm x 45mm
PC/UNIWEDGE/755012 UniForm UniForm support wedge 120mm x 50mm x 75mm
Related case study

Improving Reliability with Dudley Metropolitan Borough Council

Dudley Metropolitan Borough Council is responsible for maintaining and improving Dudley’s roads and highways, which consists of a network of some 600 miles of both major and minor roads. Wrekin's Unite range and UniPak mortar were used in the improvement of the quality of roads around the Dudley area.

Dudley Metropolitan Borough Council
Dudley Metropolitan Borough Council
Read the full Case Study