Description

High strength jointing and multi-purpose repair compounds

Uses

For fast and emergency reinstatement of concrete, bedding, jointing and reprofiling of concrete, masonry and brickwork. Nitomortar PE is ideally suited for the repair & reprofiling of precast concrete units, damaged arrises & treads. It can be used to infill hollows & holes in concrete floors, bedding & fixing kerbstones, manhole sets, frames, brick slips, ceramic tiles, slabs & coping stones. Nitomortar PE Concrete should be used to repair larger voids. The products are especially useful where fast strength gain is important. When properly compacted, they are highly impermeable.

Advantages

• Fast development of strength minimizes disruption – stronger than concrete within 2 hours
• Primer less – excellent bond to wide variety of substrates
• High chemical and oil resistance
• Extremely versatile – can be poured, trowelled or modified with aggregate without significantly affecting

setting times or strengths

• Extremely low wastage due to ability to mix part packs to consistencies required
• Will cure under damp or wet conditions and can be used down to 0°C
• Pre-weighed components ensure consistency

Specification

Jointing & multi-purpose polyester repair mortar

The high strength jointing and repair mortar shall be Nitomortar PE Mortar, a two-component polyester resin. The mortar shall be capable of use at a wide range of consistencies without significantly affecting setting times or strengths. When applied at a flowable consistency, the cured product shall exhibit a compressive strength of 100 N/mm², a flexural strength of 28 N/mm² and a tensile strength of 14 N/mm² at 7 days. Young’s Modulus of Elasticity shall be 16 KN/mm^2.

Multi-purpose polyester repair concrete

The high strength repair concrete shall be Nitomortar PE Concrete, a two-component polyester resin capable of site modification with suitable aggregates. The repair concrete shall be capable of use at a range of consistencies without significantly affecting setting times or strengths. The cured product shall exhibit a compressive strength of 100 N/mm², a flexural strength of 25 N/mm² and a tensile strength of 12 N/mm² at 7 days. Young’s Modulus of Elasticity shall be 23 KN/mm².

Description

Nitomortar PE products are based on a polyester resin system. There are two grades:

• Nitomortar PE – For general purpose use
• Nitomortar PE Concrete – A special grade allowing users to add suitable aggregate, thereby substantially

reducing the cost of infilling larger voids

Winter versions of both products are available which are faster setting at low ambient temperatures. Both grades of Nitomortar PE are supplied as two-component products with pre-weighed quantities of liquid resin and powdered hardener, ready for on-site mixing and use. The hardener system enables the mix to be varied from a pourable consistency to a trowellable mortar without significantly affecting the setting times or strengths achieved. This makes the product extremely reliable in use.

Design criteria

The following guidelines should be used:

Nitomortar PE			Nitomortar PE Concrete
Maximum thickness	:	12 mm	40 mm
Maximum thickness	:	5 mm	5 mm(1)
Maximum plan area	:	0.25 m2	0.50 m2
Maximum linear run	:	1 m	1 m

Note (1): When using aggregate larger than a sand grading, the minimum thickness will be increased. Consult the local Fosroc office for further information.

Greater thicknesses should be built up in layers and larger areas should be applied in a ‘chequerboard’ Fashion. Consult the local Fosroc office for further information.

Properties

General

Bond strength: Nitomortar PE forms a strong bond to most structural materials provided the surfaces are suitably prepared. The resulting bond between Nitomortar PE and concrete will be stronger than the tensile strength of the concrete itself.

Shrinkage: The polyester resin used in Nitomortar PE is formulated to reduce shrinkage to a minimum. Linear shrinkage will be approximately 0.8%. No further shrinkage will occur after the material has cured.

Durability: Cured Nitomortar PE performs under temperatures as high as 60°C & down to sub-zero conditions.

Underwater use: Nitomortar PE will cure under water. The local Fosroc office should be consulted when considering this type of application.

Chemical resistance: Fully cured Nitomortar PE is unaffected by water, petrol, oil & most corrosive chemicals. It is not recommended for use in contact with ketones, phenols, strong alkalis and oxidising agents. Because chemical resistance can be affected by external variable factors (e.g. temperature), the local Fosroc office should be consulted for specific applications.

Compressive strength gain: All grades of Nitomortar PE will develop strengths equivalent to mature concrete within a 2 to 6 hour period at temperatures above 15°C.

Typical compressive strength development is shown below:

Property @ 20°C		Nitomortar PE flowable consistency	Nitomortar PE Concrete
Compressive Strength @ 7days (BS 6319, Part 2)	:	100 N/mm2	100 N/mm2
Flexural strength (BS 6319, Part 3)	:	28 N/mm2	25 N/mm2
Tensile strength (BS 6319, Part 7)	:	14 N/mm2	12 N/mm2
Young’s modulus of elasticity	:	16k N/mm2	23k N/mm2
Thermal conductivity                            :       1.0 Watt/m/°C
Coefficient of thermal expansion			:     30× 10-6 per °C

Note: Strengths quoted for Nitomortar PE Concrete may vary dependent on the type of aggregate selected.

Nitomortar PE

Nitomortar PE Concrete

Working time                                                       

Temperature		Nitomortar PE	Nitomortar PE Concrete
Standard grade:		Minutes	Minutes
5°C	:	120 – 150	90 – 120
15°C	:	45 – 60	45 – 60
25°C	:	15 – 20	25 – 30
Tropical grade	:	Minutes	Minutes
25°C	:	70 – 90	80 – 100
35°C	:	45 – 60	45 – 60

Mix design – Nitomortar PE                                 

Hardener:Resin ratio			Density	Yield
(volume)		(weight)	Kg/m3	litres/kg
Trowellable:	3.2:1	4.2:1	1920	0.52
Flowable:	2.5:1	3.5:1	1840	0.54
Fluid:	1.6:1	2.0:1	1680	0.60

Mix design – Nitomortar PE Concrete

For each full pack of Nitomortar PE Concrete use one of the alternative aggregate type described in this table:

Dried aggregate		Quantity	Yield (litres)
Grade C sand	:	17 litres (30 kg)	20
Grade M sand	:	14 litres (25 kg)	17.5
Grade F sand	:	11.5 litres (21 kg)	15
Grade M sand	:	6.5 litres (12 kg)
10 mm aggregate	:	12 litres (21 kg)	22.5
Grade M sand	:	5.5 litres (10 kg)
10 mm aggregate	:	5.5 litres (9.5 kg)	27.5
20 mm aggregate	:	11 litres (19 kg)

Instructions for use                                                    Application

Preparation

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.

Clean the surface and remove any dust, unsound or contaminated material, plaster, oil, paint, grease, corrosion deposits or algae. Where breaking out is not required, roughen the surface and remove any laitance by light scabbling or grit-blasting.

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.

Where corrosion has occurred due to the presence of chlorides, the steel should be high-pressure washed with clean water immediately after grit-blasting to remove corrosion products from pits and imperfections within its surface.

Reinforcing steel priming

Exposed steel reinforcement should be treated with one full coat of Nitoprime Zincrich. This should be allowed to dry before continuing. If any doubt exists about having achieved an unbroken coating, a second application should be made and, again, allowed to dry before continuing.

Substrate priming

No priming is necessary when using Nitomortar PE

Apply the mixed Nitomortar PE to the prepared substrate by steel trowel, pressing firmly into place to ensure positive adhesion and full compaction. In the case of repairs to very dense or non-absorbent substrates, the first layer of Nitomortar PE should be made slightly ‘resin-rich’ to ensure that the surface to be bonded is properly ‘wetted-out’. Thoroughly compact the mortar around any exposed reinforcement. Refer to the ‘Design criteria’ Chart above for maximum thicknesses in a single application. Thicker sections should be built up in layers.

If sagging occurs during application, the Nitomortar PE should be completely removed and reapplied at a reduced thickness. When larger areas are being rendered (generally over 0.25 m² for Nitomortar PE Mortar and 0.50 m² for Nitomortar PE Concrete) a chequerboard application technique is recommended.

For certain applications, particularly where access is restricted, the mixed Nitomortar PE can be poured into place. The local Fosroc office should be consulted before proceeding. When used for bedding purposes or for fixing brick slips, ceramic tiles, slabs, coping stones, etc, provision might be necessary for temporary support.

Note: the minimum applied thickness of Nitomortar PE and Nitomortar PE Concrete is 5 mm.

Build-up

Additional build-up can be achieved by application of multiple layers. 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 after the first application.

Finishing

products.                                                                                                    Nitomortar PE is finished by the use of a steel trowel

Mixing

Pour the required quantity of liquid resin into a clean plastic mixing bucket and add the powdered hardener slowly, stirring thoroughly and continuously. Continue mixing for 3 minutes until a uniform consistency is achieved. For Nitomortar PE Concrete, measure out the correct volume of surface dry aggregate (coarse/fine) appropriate to the proposed application. Add this to the previously mixed resin (see above) until a uniform consistency is achieved. Mechanical mixing is recommended for Nitomortar PE Concrete and a forced-action mixer (e.g. Mixal or Cretangle- type) should be used. Do not mix more material than can be used within the pot-life of the product.

which may be wiped from time to time with a cloth moistened with Fosroc Solvent 102. The completed surface should not be overworked.

Curing

Curing protection is not necessary for Nitomortar PE products.

Cleaning

Nitomortar PE and Nitoprime Zincrich should be removed from tools, brushes, equipments and mixers with Fosroc Solvent 102 immediately after use.

Limitations

• Nitomortar PE products should not be used when the temperature is below 0°C or if the substrate is

contaminated with frost or ice

• The products should not be applied to damp or wet surfaces where there is total reliance on bond nor

should be exposed to moving water during application

Estimating

Supply                                                                   

Nitomortar PE Mortar      :  5 litre packs

Nitoprime PE Concrete :  5 litre packs

Coverage                                                               

Nitomortar PE Mortar : 5.0 litre/pack

• Exposure to heavy rainfall prior to the final set may result in surface scour

Nitoprime PE Concrete

: 15 – 27.5 litres/5 litre pack (depend on aggregate addition)

If any doubts arise concerning temperature or substrate conditions, consult the local Fosroc office.

Low temperature working

Nitomortar PE can be applied in cold conditions down to 0°C. The material should not be applied when the substrate and/or air temperature is below freezing or where the substrate is contaminated with frost or ice. In cold conditions, the winter grade may be more appropriate. Consult the local Fosroc office for further information.

High temperature working

It is suggested that, for temperatures above 35°C, the following guidelines are adopted as good working practice:

1. Store unmixed material in a cool environment (preferably temperature controlled), avoiding exposure to direct sunlight.
2. Keep equipment cool, arranging shade protection if necessary. It is especially important to keep cool those surfaces of the equipment which will come into direct contact with the material itself.
3. Try to eliminate application during the hottest times of the day and in direct sunlight.
4. Make sufficient material, plant and labour available to ensure that application is a continuous process.
5. Water (below 20°C) should be used for mixing the grout prior to placement.

Storage

Nitomortar PE Mortar and Nitomortar PE Concrete have a shelf life of 9 months at 20°C if kept in a dry store in the original, unopened bags or packs. If stored at high temperatures and/or high humidity conditions the shelf life will be significantly reduced.

Note: Coverage figures for Nitoprime Zincrich are theoretical – due to wastage factors and the variety and nature of possible substrates, practical coverage figures will be reduced.

Precautions

Health and safety

Nitomortar PE products and Fosroc Solvents 102 and 105 should not come in contact with the skin and 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, rinse with plenty of clean water, then cleanse with soap and water. In case of skin contact, 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 PE products and Fosroc Solvents 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                                                          

Nitomortar PE Mortar      :  29°C

Fosroc Solvent 102         :  33°C