Description
High strength, rapid set, abrasion-resistant epoxy reinstatement mortar
Uses
For fast and permanent patch repair of concrete, particularly where high strength, abrasion and chemical resistance is required within hours.
It is ideally suited for:
- Airports
- Sewage tanks
- Sea walls
- Industrial floors
- Use as a bedding mortar
- Joint arris repairs
Advantages
- High ultimate strength – suitable for structural
- Rapid Set – cures in 3 hours
- Early development of strength minimizes
- Abrasion-resistance: suitable for heavily trafficked
- Highly resistant to a wide range of
- Pre-weighed components ensure
Specification
High strength epoxy repair mortar
The high strength repair mortar shall be Nitomortar FS, a three-component epoxy resin.
The cured mortar shall achieve a compressive strength of 70 N/mm2, a flexural strength of 20 N/mm2 and a tensile strength of 10 N/mm2 when tested at 7 days.
The water absorption of the cured mortar shall not exceed 0.2% and the strength gain should be rapid.
Description
Nitomortar FS is a three-component material supplied in pre-weighed quantities ready for on-site mixing and use.
It is based on a high quality, solvent-free, epoxy resin system; with special aggregates to provide high strength and excellent abrasion resistance.
Properties
The following results were obtained at a temperature of 20°C unless otherwise specified.
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Compressive strength (BS 6319, Part 2) @ 23°C |
: |
25 N/mm2 @ 1 hour
60 N/mm2 @ 3 hours 70 N/mm2 @ 6 hours 90 N/mm2 @ 24 hours 95 N/mm2 @ 7 days |
|
| Flexural strength (BS 6319, Part 3) | : | 20 N/mm2 @ 7 days | |
| Tensile strength (BS 6319, Part 7) | : | 12 N/mm2 @ 7 days | |
| BRE Impact Resistance (BS 8204, Part 1:1987) | : | Category A | |
|
Pot Life |
: |
@ 20°C | @ 35°C |
| 25 minutes | 15 minutes | ||
| Initial hardness | : | 3 hours | 1 hour |
| Full cure | : | 24 hours | 16 hours |
| Fresh wet density | : | Approximately 2000 kg/m3 (fully compacted) | |
| Bond strength
(BS 1881, Part 207) |
: | Concrete failure | |
Fully cured blocks of Nitomortar FS were continually immersed at 20°C in a wide range of aggressive chemicals found in industrial environments. Tests were performed by constant immersion over a set period, followed by visual inspection and testing for Shore D hardness.
Acids (m/v)
| Citric acid 10%
Tartaric acid 10% Hydrochloric acid 25% Sulphuric acid 10% Nitric acid 10 % |
:
: : : : |
Resistant Resistant Resistant Resistant Resistant |
Alkalis (m/v)
| Sodium Hydroxide 25% | : | Resistant |
Solvents & organics
| Diesel fuel/petrol 100% | : | Resistant |
| Hydrocarbons 100% | : | Resistant |
Aqueous solutions
| Sugar solution (sat.) | : | Resistant |
| Salt solutions (sat.) | : | Resistant |
Note: All the above results have been determined by laboratory controlled tests and are in excess of those expected in practice. Nevertheless, success in use will be determined by the implementation of good housekeeping practice.
Design criteria
Nitomortar FS can be applied in sections up to 50 mm thickness in horizontal locations, and 12 mm in vertical locations, in a single application and without the use of form work, dependent upon the repair geometry.
Nitomortar FS can be used for emergency repairs where fast strength gain is important. When properly compacted, the mortar is highly impermeable.
For fast repairs in vertical and overhead locations where a higher-build, lightweight formulation is required, the use of Nitomortar HB*h is recommended.
Instructions for use
Preparation
Clean the surface and remove any dust, unsound material, plaster, oil, paint, grease, corrosion deposits or algae. Roughen the surface and remove any laitence by light scabbling or grit-blasting.
Saw cut or cut back the extremities of the repair locations to a depth of at least 5 mm to avoid feather-edging and to provide a square edge.
Break out the complete repair area to a minimum depth of 5 mm up to the sawn edge.
Oil and grease deposits should be removed by steam cleaning, detergent scrubbing or the use of a proprietary degreaser.
The effectiveness of decontamination should then be assessed by a pull-off test.
Expose fully any corroded steel in the repair area and remove all loose scale and corrosion deposits.
Steel should be cleaned to a bright condition paying particular attention to the back of exposed steel bars.
Grit-blasting is recommended for this process.
Substrate priming
Horizontal substrates should be primed using Nitoprime 25IR*. Predominantly vertical and metal substrates should be primed using Nitocote Primer Sealer*.
In both cases, the primer should be mixed in the proportions supplied, adding the entire contents of the ‘hardener’ tin to the ‘base’ tin.
The two components should be thoroughly mixed together mechanically for 3 minutes.
The mixed primer should be scrubbed well into the prepared substrate, taking care that all imperfections in the surface are properly coated and avoiding ‘ponding’ in depressions.
If the primer is absorbed within 30 minutes, a second coat should be applied before continuing.
Nitomortar FS can be applied as soon as the primer has started to gel but still has surface ‘tack’.
This is normally between 30 minutes and 4 hours dependent on the ambient and substrate temperatures.
If the primer cures hard, a second application must be made before application of Nitomortar FS.
The usable life of the mixed primer is approximately 60 minutes at 20°C or 30 minutes at 35°C.
Mixing
Care should be taken to ensure that Nitomortar FS is thoroughly mixed to produce a fully homogeneous, trowellable mortar.
Nitomortar FS must be mixed mechanically. The ‘hardener’ and ‘base’ components should be stirred thoroughly in order to disperse any settlement before mixing them together.
The entire contents of the ‘hardener’ container should then be emptied into the ‘base’ container and mixed until homogeneous, then emptied into a forced action mixer of adequate capacity (e.g. Creteangle or Pennine).
Add the aggregate slowly with the mixer running and continue for 2 minutes until all the components are thoroughly blended. Under no circumstances should part packs be used.
Application
Apply the mixed Nitomortar FS to the prepared substrate by wood float, pressing firmly into place to ensure positive adhesion and full compaction.
Thoroughly compact the mortar around any exposed reinforcement.
In restricted location, or where exposed reinforcing steel is present, application by gloved hands is an acceptable alternative but, in all cases, the product must be finished to a tight surface with a steel trowel.
Nitomortar FS can be applied in sections up to 50 mm thickness in horizontal locations or up to 12 mm thickness in vertical locations in a single application and without the use of form work.
Thicker vertical sections may sometimes be possible dependent on the profile of the substrate and the volume of exposed reinforcing steel but should generally be built up in layers.
When larger areas are being rendered, a chequer board application technique is recommended. Note: the minimum
Limitations
- Nitomortar FS should not be used when the temperature is below 5°C and falling.
- Do not mix part packs under any
applied thickness of Nitomortar FS is 5 mm. § Nitomortar FS should not be exposed to moving water
during application.
Build-up § Exposure to heavy rainfall prior to the final set may
Additional build-up can be achieved by application of
result in surface scour.
multiple layers. § The material should not be applied at less than 5 mm
Exposed steel reinforcing bars should be firmly secured to avoid movement during the application process as this will affect mortar compaction, build and bond.
Where thicker sections are required, the surface of the intermediate applications should be scratch-keyed to provide a suitable surface for subsequent layers.
The application of additional layers should follow between 8 and 24 hours (@ 20°C) after the first application. This time should be reduced at higher temperatures.
Re-priming and a further application of Nitomortar FS may then proceed.
If sagging occurs during application, the Nitomortar FS should be completely removed and reapplied at a reduced thickness on to the correctly re-primed substrate.
Finishing
Nitomortar FS is finished by the use of a wood float and closed with a steel trowel. The completed surface should not be overworked.
thickness.
- Greater thicknesses than those specified above can be achieved by application of subsequent layers.
- Larger areas should be applied in a ‘chequer board’
- For higher build characteristics to vertical locations, or for overhead application, Nitomortar HB is
recommended.
If any doubts arise concerning temperature or substrate conditions, consult the local Fosroc office.
High temperature working
At ambient temperatures above 35°C, Nitoprime 25IR, Nitocote Primer Sealer and Nitomortar FS will have shorter pot lives and open working time.
The materials should be stored in the shade or in an air- conditioned environment and should not be applied in direct sunlight.
Curing Estimating
Curing protection is not necessary for Nitomortar FS.
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Supply
Cleaning
Nitoprime 25IR, Nitocote Primer Sealer and Nitomortar FS should be removed from tools, equipment and mixers with Fosroc Solvent 102* immediately after use.
|
Technical support Coverage
Fosroc offers a comprehensive technical support service to specifiers, end users and contractors.
It is also able to offer on-site technical assistance, an AutoCAD facility and dedicated specification assistance in locations all over the world.
Note: The coverage figures for Nitoprime 25IR and Nitocote Primer Sealer are theoretical – due to wastage factors and the variety and nature of possible substrates, practical figures will be reduced.
Storage
All products have a shelf life of 6 months at 20°C if kept in a dry store in the original, unopened bags or packs. Store in dry conditions in the original, unopened bags or packs. If stored at high temperatures, the shelf life may be reduced to 4 – 6 months.
Precautions
Health and safety
Nitoprime 25IR, Nitocote Primer Sealer, Nitomortar FS and Fosroc Solvent 102 should not come in contact with skin or eyes, or be swallowed.
Ensure adequate ventilation and avoid inhalation of vapours. Some people are sensitive to resins, hardeners and solvents.
Wear suitable protective clothing, gloves and eye protection. If working in confined areas, suitable respiratory protective equipment must be used.
The use of barrier creams provides additional skin protection.
In case of contact with skin, remove immediately with resin removing cream followed by washing with soap and water. Do not use solvent.
In case of contact with eyes, rinse immediately with plenty of clean water and seek medical advice.
If swallowed, seek medical attention immediately – do not induce vomiting.
Fire
Nitomortar FS & Nitocote Primer Sealer are non flammable. Nitoprime 25IR and Fosroc Solvent 102 are flammable.
Keep away from sources of ignition. No smoking. In the event of fire, extinguish with CO2 or foam. Do not use a water jet.
Flash points
Nitoprime 25IR : 39°C
Fosroc Solvent 102 : 33°C
The Right Chemistry for Construction
Fosroc is one of the world’s major manufacturers of advanced technology chemical based products for the construction and refurbishment industries. It operates internationally through a network of operating companies, licensees, distributors and agents.
Having over 70 years experience and using global resources for research and technical development, Fosroc has built a substantial worldwide reputation in manufacturing the most comprehensive range of high performance construction chemicals:
- Concrete admixtures
- Surface treatments
- Grouts and anchors
- Concrete repair
- Industrial flooring
- Protective coatings
- Joint sealants
- Waterproofing
- Adhesives
- R.P Structural Strengthening
- Specific building products
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