nitomortar 30 constructive solutions2.imimg.com/data2/ee/nw/my-3845120/nitomortar.pdf · 2019. 12....

Nito

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30

constructive solutionsNitomortar® 30

Chemical and abrasion resistant epoxy repair compound

Uses

For permanent repairs to concrete structure and cementitioussubstrates where strength, impermeability to water andresistance to aggressive chemicals is essential. Ideally suitedfor maintaining engineering, chemical handling andprocessing plants.

Advantages

Chemical Resistance :Unaffected by wide range of acids,alkalis and industrial chemicals

Easily applied :Designed for easy application to a fairfinish

Quality : Pre-weighed quality controlled materials ensureconsistency and reduce risk of site errors

Proven performance : Successful use proves for a widevariety of aggressive applications

Description

Nitomortar 30 is a three part solvent free combination of epoxyresin, modified amine hardeners filled with specially gradedchemically inert aggregates with high crushing strength.

It is applied by trowel as a durable chemical resistant repairmortar 3-6 mm thick depending upon the requirement. Thesystem includes Nitoprime 25 a two part epoxy resin primerand Nitomortar 30 which are both supplied in preweighedunits ready for onsite mixing and application. The finishedarea has a slightly granular texture of uniform self colour.However, as the natural grade takes its colour from theaggregates which is subjected to variation, colour matchingis not practicable with this grade.

Technical Support

Fosroc offers a technical support package to specifiers, endusers and contractors as well as onsite technical assistanceall over the country.

Properties

Curing characteristics at 300C

Nitomortar 30

Pot life : 30 min.

Initial hardness : 16 hrs

Full cure : 7 days

Mechanical characteristics @ full cure

Compressive strength : 45 N/mm2

Flexural strength : 12 N/mm2

Tensile strength : 4.5 N/mm2

Bond strength to concrete : 3.0 N/mm2

Nitoprime 25

Pot life : 30 min. @ 300C

Maximum overlay time : 30 min. @ 300C

Chemical Resistance

Acids

Hydrochloric 10% ExcellentSulphuric 10% ExcellentPhosphoric 30% ExcellentNitric 10% GoodLactic 10% ExcellentCitric 10% ExcellentAlkalis

Sodium Hydroxide 30% ExcellentAmmonia 10% ExcellentOrganic Solvents

Butanol GoodWhite Spirit ExcellentOil/Grease/Petrol ExcellentXylene GoodAcetone Not resistantSkydrol GoodSat. Sugar ExcellentAqueous solutions

Conc. Bleach ExcellentSat. Urea Excellent

Nitomortar® 30

INDIA/0409/C

Important note :Fosroc products are guaranteed against defective materials and manufacture and are sold subjectto its standard terms and conditions of sale, copies of which may be obtained on request. WhilstFosroc endeavours to ensure that any advice, recommendation specification or information it maygive is accurate and correct, it cannot, because it has no direct or continuous control over whereor how its products are applied, accept any liability either directly or indirectly arising from theuse of its products whether or not in accordance with any advice, specification, recommendationor information given by it.

telephone fax e-mail

++91 80-2334 3188 ++91 80-2334 3178 [email protected]

Fosroc Chemicals (India) Pvt. Ltd.Head Office‘Vishnu Chittam’, No. 10, 2nd FloorSirur Park B Street, SeshadripuramBangalore 560020www.fosroc.com

® Denotes the trademark of Fosroc International Limited

Regional OfficesBangalore Mumbai Delhi Kolkata‘Vishnu Chittam’, No.10, 1stFloor 208/209, Persepolis 109-113, 1st Floor, Vikrant Towers P-569, Lake Terrace Extn.Sirur Park B Street, Seshadripuram Sector 17, Vashi 4, Rajendra Place First FloorBangalore 560 020 Navi Mumbai 400 703 New Delhi 110 008 Kolkata 700 029Ph:080-2334 3188 Ph:022-2789 6411/12 Ph:011- 45062000-5 Ph: 033 24650917 / 55343188Fax : 080-23368667 Fax: 022 - 2789 6413 Fax: 011- 45062001 Fax: 033-24650891email: [email protected] email:[email protected] email:[email protected] email:[email protected]

Ahmedabad : (079) 26762799 Ankleshwar :(02646) 220704/224687 Bellary: 09845891690 Bhubaneshwar : (0674) 2521176 Chennai : (044) 24899949/24853383 Chandigarh : (0172) 2639360 Cochin : (0484) 2347465 Coimbatore : (0422) 2472966 Goa : (0832) 09423058696 Guwahati : (0361) 2462866 Hyderabad : (040) 27662324/27662425 Indore : (0731) 4049339 Jaipur : (0141) 2336103 Lucknow :(0522) 2239044 Nagpur: (0712) 2753510/2563242 Visakhapatnam : (0891) 2564850 / 2707607

Those materials marked 'Good' are suitable for areas ofoccasional spillage where good housekeeping is in force.

All the above properties have been determined by laboratorycontrolled tests and are typical of those expected in practice.

Estimating

Packaging and Coverage

Pack size Approx. Coverage rate

Nitoprime 25 1 & 4 Ltr 5.5 - 6.5 m2/Ltr.

Nitomortar 30 8 Ltr 2.67m2 @ 3mm thickness/pack

1.33m2 @ 6mm thickness/pack

The coverage rates are given for guidance only as actualquantities used will vary on nature of substrate and conditionson site.

Storage

Nitoprime 25 and Nitomortar 30 have a shelf life of 12 monthsif stored in unopened containers below 350C.

Additional information

Fosroc manufactures a wide range of products speciallydesigned for the repair and refurbishment of damagedreinforced concrete. This includes hand placed and spraygrade repair mortars, fluid microconcretes, chemical resistantepoxy mortars and a comprehensive package of protectivecoatings. In addition, a wide range of complementaryproducts are available.

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FC

constructive solutionsNitomortar® FC

Epoxy resin fairing coat and filler

Uses

Nitomortar FC is designed for application to minorimperfections in concrete surfaces. It is suitable forapplication from a feather-edge to 3 mm, and can be used inthe following situations :

Filling pinholes prior to overcoating with Nitocote*† orNitoflor*† products.

General reprofiling over large areas, up to 3 mm depth.

Sealing of surface cracks in preparation for crack injection.

Advantages

Cost effective - Reduces usage of subsequent coatings

High performance - Excellent chemical resistance, strongadhesion to concrete substrate

User friendly - Easy to apply and finish, manufactured tomeet local conditions

Description

Nitomortar FC is a two component thixotropic, solvent free,compound based on epoxy resins, graded fillers andthixotropic agents. It is applied directly to concrete substrates,without primer, and cures to a surface ready for over coating.The base component is light grey coloured and the hardenerblack to ease identification of uniform mixing.

Design criteria

Nitomortar FC is designed for filling pinholes and surfaceirregularities in concrete prior to the application of subsequentcoatings. It can be applied from a feather-edge up to 3 mmthickness.

For reprofiling or hole filling, with thicknesses in excess of3 mm, it is recommended to use Nitomortar FC(B)*.

Properties

Solids by weight : 100%Compressive strength: 70 N/mm2 @ 7 daysPot life : 4 hours @ 25ºC

11/2 hours @ 35ºCDrying time : 10 hours @ 25ºC

4 hours @ 35ºCOvercoating time : After 24 hour curing periodColour : Grey

Chemical resistance : Resistant to oils, fats, petrol,salt and sugar solution, bleach,dilute mineral acids, alkalis andvarious solvents

Instructions for use

Preparation

Concrete surfaces should be clean, dry and free from laitance.Sandblasting or mechanical wire brushing may be necessary.

Mixing

Care should be taken to ensure that Nitomortar FC isthoroughly mixed to produce a fully homogeneous paste.

The ‘hardener’ and 'base' components should be stirredthoroughly in order to disperse any settlement before mixingthem together. The entire contents of the 'hardener' should beemptied into the 'base' container and the components mixedtogether using a mixing paddle attached to a slow-speed(400/500rpm) heavy duty drill, until a uniform grey colour andconsistency is obtained. Mixing of 1Ltr packs can be done byhand but care must be taken to ensure homogenus mixing.Under no circumstances should part packs be used, or partmixing be attempted.

Application

Due to the easy workability of the product, a variety ofinstruments such as trowel, scraper, filling knife andsqueegee can be used. After mixing, material can be takendirectly from the can, or subdivided onto spot boards forindividual application.

Nitomortar FC can be overcoated with all epoxy coatings aftera minimum curing period of 24 hours. Prior to overcoating, thesurface of the fully cured Nitomortar FC should first be abradedto assist adhesion, and then cleaned to a dust-free finish.

Cleaning

Nitomortar FC should be removed from tools, equipment andmixers with Nitoflor Sol*† immediately after use. Hardenedmaterial can only be removed mechanically.

Estimating

SupplyNitomortar FC : 1.0 and 4.0 litre packsNitoflor Sol : 5 and 25 litre cans

Nitomortar® FC

INDIA/0448/A



++91 80-2334 3188 ++91 80-2334 3178 [email protected]





Coverage and yield:

Coverage of Nitomortar FC is wholly dependant upon surfaceconditions, site trials are therefore recommended to ascertainactual usage on uneven substrates. However, as a guideline,we can consider coverage as 0.33m2/litre at 3mm thicknessand 1m2/litre at 1mm thickness.

Storage

Shelf life

12 months if kept in unopened tins and stored in a dry placeaway from direct sunlight.

Storage conditions

Store in dry conditions in the original, unopened containers.If stored at high temperatures the shelf life may be reduced to4 to 6 months.

Limitations

Do not mix parts under any circumstances.

Nitomortar FC should not be exposed to moving waterduring application.

Exposure to heavy rainfall prior to final set may result insurface scour.

If any doubt arises concerning temperature or substratecondition, consult the local Fosroc office.

Precautions

Health and safety

Nitomortar FC and Nitoflor Sol should not come in contactwith skin or eyes, or be swallowed. Ensure adequateventilation and avoid inhalation of vapours. Some people aresensitive to resins, hardeners and solvents. Wear suitableprotective clothing, gloves and eye/face protection.

If working in confined areas, suitable respiratory protectiveequipment must be used. The use of barrier creams providesadditional skin protection. Should accidental skin contactoccur, remove immediately with a resin removing creamfollowed by soap and water. Do not use solvent. In case ofcontact with eye, rinse immediately with plenty of clean waterand seek medical advice. If swallowed seek medicalattention immediately - do not induce vomiting.

Fire

Nitomortar FC is non-flammable.

Nitoflor Sol is 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 pointsNitoflor Sol : 33ºC

For further information, refer to the materials safety data sheet.

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PE

constructive solutionsNitomortar® PE

High strength jointing and multi-purpose repaircompounds

Design criteria

The following guidelines should be used:

Nitomortar PE Nitomortar PEConcrete

Maximum thickness : 12 mm 40 mmMinimum thickness : 5 mm 5 mm*Maximum plan area : 0.25 m2 0.50 m2

Maximum linear run : 1 m 1 m

Greater thicknesses should be built up in layers and largerareas should be applied in a ‘chequerboard’ fashion. Consultthe local Fosroc office for further information.

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

Properties

General

Bond strength: Nitomortar PE forms a strong bond to moststructural materials provided the surfaces are suitablyprepared. The resulting bond between Nitomortar PE andconcrete will be stronger than the tensile strength of theconcrete itself.

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

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

Chemical resistance: Fully cured Nitomortar PE is unaffectedby water, petrol, oil and most corrosive chemicals. It is notrecommended for use in contact with ketones, phenols, strongalkalis and oxidising agents. Because chemical resistancecan be affected by external variable factors (e.g. temperature),the local Fosroc office should be consulted for specificapplications.

Underwater use: Nitomortar PE will cure under water. Thelocal Fosroc office should be consulted when consideringthis type of application.

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 and reprofiling ofprecast concrete units, damaged arrises and treads. It canbe used to infill hollows and holes in concrete floors, beddingand fixing kerbstones, manhole sets, frames, brick slips,ceramic tiles, slabs and coping stones. Nitomortar PEConcrete should be used to repair larger voids. The productsare especially useful where fast strength gain is important.When properly compacted, they are highly impermeable.

Advantages

Fast development of strength minimises disruption -stronger than concrete within 2 hours

No primer required - excellent bond to a wide variety ofsubstrates

High chemical and oil resistance

Extremely versatile - can be poured, trowelled or modifiedwith aggregate without significantly affecting setting timesor strengths

Extremely low wastage due to ability to mix part packs toconsistencies required

Will cure under damp or wet conditions and can be useddown to 0°C

Pre-weighed components ensure consistency

Description

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

Nitomortar PE - for general purpose use;

Nitomortar PE Concrete - a special grade allowing users toadd suitable aggregate, thereby substantially reducing thecost of infilling larger voids.

Winter versions of both products are available which arefaster setting at low ambient temperatures. Both grades ofNitomortar PE are supplied as two-component products withpre-weighed quantities of liquid resin and powderedhardener, ready for on-site mixing and use. The hardenersystem enables the mix to be varied from a pourableconsistency to a trowellable mortar without significantlyaffecting the setting times or strengths achieved. This makesthe product extremely reliable in use.

Nitomortar® PE

Working time

Temperature Nitomortar PE Nitomortar PEConcrete

Standard grade: Minutes Minutes

5°C : 120 - 150 90 -12015°C : 45 - 60 45 - 6025°C : 15 - 20 25 - 30Tropical grade: Minutes Minutes25°C : 70 - 90 80 - 10035°C : 45 - 60 45 - 60

Compressive strength gain: All grades of Nitomortar PE willdevelop strengths equivalent to mature concrete within a 2 to6 hour period at temperatures above 15°C. Typicalcompressive strength development is shown below:

Nitomortar PE

Property at 20°C Nitomortar PE Nitomortar PEflowable Concreteconsistency

Compressivestrength at 7 days(BS 6319, Pt 2) : 100 N/mm2 100 N/mm2

Flexural strength(BS 6319, Pt 3) : 28 N/mm2 25 N/mm2

Tensile strength(BS 6319, Pt 7) : 14 N/mm2 12 N/mm2

Young’s Modulusof Elasticity : 16 kN/mm2 23 kN/mm2

Thermal conductivity : 1.0 Watt/m/°CCoefficient ofthermal expansion : 30 x 10-6 per °C

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

Mix design – Nitomortar PE

Hardener: resin ratio Density Yield(volume) (weight) kg/m3 litres/kg

Trowellable: 3.2:1 4.2:1 1920 0.52Flowable: 2.5:1 3.5:1 1840 0.54Fluid: 1.6:1 2.0:1 1680 0.60

Nitomortar PE Concrete

Nitomortar® PE

Mix design – Nitomortar PE Concrete

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

Dried aggregate Quantity Yield (litres)Grade C sand : 17 litres (30 kg) 20Grade M sand : 14 litres (25 kg) 17.5Grade F sand : 11.5 litres (21 kg) 15Grade M sand : 6.5 litres (12 kg)10 mm aggregate : 12 litres (21 kg) 22.5Grade M sand : 5.5 litres (10 kg)10 mm aggregate : 5.5 litres (9.5 kg) 27.520 mm aggregate : 11 litres (19 kg)

Specification

Jointing and multi-purpose polyester repair mortar

The high strength jointing and repair mortar shall be NitomortarPE Mortar, a two-component polyester resin. The mortar shallbe capable of use at a wide range of consistencies withoutsignificantly affecting setting times or strengths. When appliedat a flowable consistency, the cured product shall exhibit acompressive strength of 100 N/mm2, a flexural strength of 28N/mm2 and a tensile strength of 14 N/mm2 at 7 days. Young’sModulus of Elasticity shall be 16 kN/mm2.

Multi-purpose polyester repair concrete

The high strength repair concrete shall be Nitomortar PEConcrete, a two-component polyester resin capable of sitemodification with suitable aggregates. The repair concrete shallbe capable of use at a range of consistencies withoutsignificantly affecting setting times or strengths. The curedproduct shall exhibit a compressive strength of 100 N/mm2, aflexural 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.

Instructions for use

Preparation

Saw cut or cut back the extremities of the repair locations to adepth of at least 5 mm to avoid feather-edging and to providea square edge. Break out the complete repair area to aminimum depth of 5 mm up to the sawn edge.

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

Oil and grease deposits should be removed by steamcleaning, detergent scrubbing or the use of a proprietarydegreaser. The effectiveness of decontamination should thenbe assessed by a pull-off test.

Expose fully any corroded steel in the repair area and removeall loose scale and corrosion deposits. Steel should becleaned to a bright condition paying particular attention to theback of exposed steel bars. Grit-blasting is recommended forthis process.

Where corrosion has occurred due to the presence ofchlorides, the steel should be high-pressure washed withclean water immediately after grit-blasting to remove corrosionproducts from pits and imperfections within its surface.

Reinforcing steel priming

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

Substrate priming

No priming is necessary when using Nitomortar PE products.

Nitomortar® PE

Mixing

Pour the required quantity of liquid resin into a clean plasticmixing bucket and add the powdered hardener slowly, stirringthoroughly and continuously. Continue mixing for 3 minutesuntil a uniform consistency is achieved.

For Nitomortar PE Concrete, measure out the correct volumeof surface dry aggregate (coarse/fine) appropriate to theproposed application. Add this to the previously mixed resin(see above) until a uniform consistency is achieved. Mechanicalmixing is recommended for Nitomortar PE Concrete and aforced-action mixer (e.g. Mixal or Cretangle-type) should beused.

Do not mix more material than can be used within the pot-lifeof the product.

Application

Apply the mixed Nitomortar PE to the prepared substrate bysteel trowel, pressing firmly into place to ensure positiveadhesion and full compaction. In the case of repairs to verydense or non-absorbent substrates, the first layer of NitomortarPE should be made slightly ‘resin-rich’ to ensure that thesurface to be bonded is properly ‘wetted-out’.

Thoroughly compact the mortar around any exposedreinforcement. Refer to the ‘Design criteria’ chart above formaximum thicknesses in a single application. Thicker sectionsshould be built up in layers. If sagging occurs duringapplication, the Nitomortar PE should be completely removedand 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 PEConcrete) a chequerboard application technique isrecommended.

For certain applications, particularly where access is restricted,the mixed Nitomortar PE can be poured into place. The localFosroc office should be consulted before proceeding.

When used for bedding purposes or for fixing brick slips, ceramictiles, slabs, coping stones, etc, provision might be necessaryfor temporary support.

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

Build-up

Additional build-up can be achieved by application of multiplelayers. Exposed steel reinforcing bars should be firmly securedto avoid movement during the application process as this willaffect mortar compaction, build and bond.

Where thicker sections are required, the surface of theintermediate applications should be scratch-keyed to providea suitable surface for subsequent layers. The application ofadditional layers should follow between 8 and 24 hours afterthe first application.

Finishing

Nitomortar PE is finished by the use of a steel trowel whichmay be wiped from time to time with a cloth moistened withFosroc Solvent 102. The completed surface should not beoverworked.

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/orair temperature is below freezing or where the substrate iscontaminated with frost or ice. In cold conditions, the wintergrade may be more appropriate. Consult the local Fosroc officefor further information.

High temperature working

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

(i) Store unmixed material in a cool (preferably temperaturecontrolled) environment, avoiding exposure to directsunlight.

(ii) Keep equipment cool, arranging shade protection ifnecessary. It is especially important to keep cool thosesurfaces of the equipment which will come into directcontact with the material itself.

(iii) Try to eliminate application during the hottest times of theday and in direct sunlight.

(iv) Make sufficient material, plant and labour available toensure that application is a continuous process.

(v) Water (below 20°C) should be used for mixing the groutprior to placement.

Nitomortar® PE

Curing

Curing protection is not necessary for Nitomortar PE products.

Cleaning

Nitomortar PE and Nitoprime Zincrich should be removed fromtools, brushes, equipments and mixers with Fosroc Solvent102 immediately after use.

Limitations

- Nitomortar PE products should not be used when thetemperature is below 0°C or if the substrate is contaminatedwith frost or ice.

- The products should not be applied to damp or wet surfaceswhere there is total reliance on bond nor should they beexposed to moving water during application.

- Exposure to heavy rainfall prior to the final set may result insurface scour. If any doubts arise concerning temperatureor substrate conditions, consult the local Fosroc office.

Technical support

Fosroc offers a comprehensive technical support service tospecifiers, end users and contractors. It is also able to offeron-site technical assistance, an AutoCAD facility and dedicatedspecification assistance in locations all over the world.

Estimating

SupplyNitomortar PE Mortar : 5 litre packsNitomortar PE Concrete : 5 litre packs

Coverage and yieldNitomortar PE Mortar : 5.0 litres/ packNitomortar PE Concrete : 15 to 27.5 litres/5 litre

pack (dependent onaggregate addition)

Note : Coverage figures for Nitoprime Zincrich are theoretical- due to wastage factors and the variety and nature ofpossible substrates, practical coverage figures will bereduced.

Storage

Nitomortar PE Mortar and Nitomortar PE Concrete have a shelflife 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 conditionsthe shelf life will be significantly reduced.

Precautions

Health and safety

Nitomortar PE products and Fosroc Solvents 102 and 105should not come in contact with the skin and eyes, or beswallowed. Ensure adequate ventilation and avoid inhalationof vapours. Some people are sensitive to resins, hardenersand solvents. Wear suitable protective clothing, gloves andeye protection. If working in confined areas, suitable respiratoryprotective equipment must be used. The use of barrier creamsprovide additional skin protection. In case of contact with skin,rinse with plenty of clean water, then cleanse with soap andwater. In case of skin contact, remove immediately with resinremoving cream followed by washing with soap and water. Donot use solvent. In case of contact with eyes, rinse immediatelywith plenty of clean water and seek medical advice. Ifswallowed, seek medical attention immediately - do not inducevomiting.

Fire

Nitomortar PE products and Fosroc Solvents 102 areflammable. Keep away from sources of ignition. No smoking.In the event of fire, extinguish with CO2 or foam. Do not use awater jet.

Flash pointsNitomortar PE resin : 29°CFosroc Solvent 102 : 33°C

Nitomortar® PE

INDIA/0410/B



++91 80-2334 3188 ++91 80-2334 3178 [email protected]





† See separate data sheet

Additional Information

Fosroc manufactures a wide range of complementaryproducts which include :

waterproofing membranes & waterstops

joint sealants & filler boards

cementitious & epoxy grouts

specialised flooring materials

Fosroc additionally offers a comprehensive package ofproducts specifically designed for the repair andrefurbishment of damaged concrete. Fosroc’s ‘SystematicApproach’ to concrete repair features the following :

hand-placed repair mortars

spray grade repair mortars

fluid micro-concretes

chemically resistant epoxy mortars

anti-carbonation/anti-chloride protective coatings

chemical and abrasion resistant coatings

For further information on any of the above, please consultyour local Fosroc office - as below.

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S

constructive solutionsNitomortar® S

High strength, abrasion - resistance epoxy reinstatementmortar

Uses

Nitomortar S is used for the fast and permanent reinstatementof concrete, particularly where high strength, abrasion -resistance and resistance to chemicals is required. Theproduct is designed for horizontal use but can be appliedvertically, although generally in thinner sections. It is ideallysuited for acid tanks, sea walls, industrial floors and for useas a bedding mortar. Nitomortar S can be used for emergencyrepairs where fast strength gain is important. When properlycompacted, the mortar is highly impermeable.

In certain instances, Nitomortar S can be used on metalsubstrates. Contact the local Fosroc office for advice in thisrespect.

Advantages

High ultimate strength - Suitable for structural use

Early development of strength Minimises disruption

Abrasion resistance - Suitable for heavy traffic areas

Highly resistant - To a wide range of chemicals

Will cure under damp conditions - Cured product is highlyimpermeable to water

Typically twice as strong as good quality concrete

Pre-weighed components ensure consistency

Description

Nitomortar S is based on a high quality solvent-free epoxyresin system. The special silica aggregates provide highstrength and excellent abrasion resistance. Nitomortar S isa three - component material supplied in pre-weighedquantities ready for on-site mixing and use.

Technical support

Fosroc offers a comprehensive range of high performance,high quality concrete repair and construction products. Inaddition, Fosroc offers a technical support package tospecifiers, end-users and contractors, as well as on-sitetechnical assistance in locations all over the country.

Design criteria

Nitomortar S can be applied in sections upto 50mm thicknessin horizontal locations and 12mm in vertical locations in asingle application and without the use of formwork. Thematerial should not be applied at less than 5mm thickness.

Greater thicknesses than those specified above can beachieved by the application of subsequent layers. Largerareas should be applied in a 'checker board' fashion. LocalFosroc office shall be contacted for further information.

Properties

The following results were obtained at a temperature of 300Cunless otherwise specified.

Test method Typical result

Compressive strength(BS 6319, Pt 2) 60N/mm2 @ 7 days

Flexural strength(BS 6319 Pt 3) 20N/mm2 @ 7 days

Tensile strength(ASTM C 307) 10N/mm2 @ 7 days

Pot life 20 mins @ 350C

Initial hardness 24 hours

Full cure 7 days

Fresh wet density Approximately 2000kg/m3 (fullycompacted)

Chemical resistance The low permeability ofNitomortar S retards chemicalattack in aggressiveenvironments.

Performance of Nitomortar S blocks continually immersed at200C.

Citric acid 10% ResistantTartaric acid 10% ResistantHydrochloric acid 18% ResistantSodium Hydroxide 50% ResistantDiesel fuel / Petrol 100% ResistantSulphuric acid 10% ResistantSugar solutions Saturated ResistantLactic acid 10% ResistantHydrocarbons 100% ResistantPhosphoric acid 50% ResistantNitric acid 10% ResistantAcetic acid 5% Resistant

Nitomortar® S

Specification clauses

High strength epoxy repair mortar

The high strength repair mortar shall be Nitomortar S, a threecomponent epoxy resin with a density not greater than 2000kg/m3. The cured mortar shall achieve a compressive strengthof 60 N/mm2, a flexural strength of 20N/mm2 and a tensilestrength of 10N/mm2 when tested at 7 days.

Application instructions

Preparation

Clean the surface and remove any dust, unsound material,plaster, oil, paint, grease, corrosion deposits or algae. Roughenthe surface and remove any laitance by light scabbling or gritblasting. Saw cut or cut back the extremities of the repairlocations to a depth of at least 5mm to avoid featheredgingand to provide a square edge. Break out the complete repairarea to a minimum depth of 5mm upto the sawn edge.

Oil and grease deposits should be removed by steam cleaning,detergent scrubbing or the use of a proprietary degreaser. Theeffectiveness of decontamination should then be assessedby a pull-off test.

Expose fully any corroded steel in the repair area and removeall loose scale and corrosion deposits. Steel should becleaned to a bright condition paying particular attention to theback of exposed steel bars. Grit blasting is recommended forthis purpose.

Reinforcing steel priming

The cleaned steel should be coated within 3 hours. Apply onefull coat of Nitozinc Primer and allow to dry before continuing. Ifany doubt exists about having achieved an unbroken coating,a second application should be made and, again. allowed todry before continuing.

Substrate priming

The substrate should be primed using Nitoprime 25. Theprimer should be mixed in the proportions supplied, addingthe entire contents of the 'hardener' tin to the 'base'tin. The twocomponents should be thoroughly mixed together, for 3minutes.

The mixed primer should be scrubbed well into the preparedsubstrate, taking care that all imperfections in the surface areproperly coated and avoiding 'puddling' in depressions. If theprimer is absorbed within 30 minutes, a second coat shouldbe applied before continuing. Nitomortar S can be applied assoon as the primer has started to gel but still has surface'tack'. This is normally between 30 minutes and 4 hoursdependent on the ambient and substrate temperatures. If theprimer cures hard, a second application must be made beforeapplication of Nitomortar S. The usable life of the mixed primeris approximately 60 minutes at 200C or 30 minutes at 350C.

Mixing

Care should be taken to ensure that Nitomortar S is thoroughlymixed to produce a fully homogenous, trowellable mortar.

The 'hardener' and 'base' components should be stirredthoroughly in order to disperse any settlement before mixingthem together. The entire contents of the 'hardener' containershould then be emptied into the 'base' container and thoroughlymixed for 3 minutes, then emptied into a forced action mixer ofadequate capacity. Add the aggregate slowly with the mixerrunning and continue for 2 to 3 minutes until all the componentsare thoroughly blended. Under no circumstances should partpacks be used.

Application

Apply the mixed Nitomortar S to the prepared substrate bywood float, pressing firmly into place to ensure positiveadhesion and full compaction. Thoroughly compact the mortararound any exposed reinforcement. In restricted locations, orwhere exposed reinforcing steel is present, application bygloved hands is an acceptable alternative but, in all cases, theproduct must be finished to a tight surface with a steel trowel.Nitomortar S mortar can be applied in sections upto 50mmthickness in horizontal locations or upto 12mm thickness invertical locations in a single application and without the use offormwork.

Nitomortar® S

Thicker vertical sections may sometimes be possibledependent on the profile of the substrate and the volume ofexposed reinforcing steel but should generally be built up inlayers, when larger areas are being rendered, a checkerboardapplication technique is recommended.

Note : The minimum applied thickness of Nitomortar S is5mm.

Buildup

If sagging occurs during application, the Nitomortar S shouldbe completely removed and reapplied at a reduced thicknesson to the correctly reprimed substrate.

Finishing

Nitomortar S is finished by the use of a wood float and closedwith a steel trowel. The completed surface should not beoverworked

Over coating with protective / decorative finishes

Nitomortar S is extremely durable and resistant to a wide rangeof acids, alkalis and industrial chemicals and will provideexcellent protection to the concrete and embedded steelreinforcement within the repaired locations. The surroundingparts of the structure may benefit from the application of aprotective coating, thus bringing them up to the same protectivestandard as the repair itself. Fosroc recommend the use ofthe Nitocote range of epoxy resin, chemical resistant, protectivecoatings.

For surrounding areas not subjected to chemical attack orphysical wear, Fosroc recommend the use of the Dekguardrange of anti-carbonation, anti-chloride protective coatings.These products provide a decorative and uniform appearanceas well as protecting areas of the structure which mightotherwise be at risk from the environment.

Nitocote epoxy resin protective coatings should be appliedwithin 24 hours. Dekguard products should not be applieduntil the Nitomortar S is at least 3 days old. For further advice,consult the local Fosroc office.

Cleaning

Nitozinc Primer, Nitoprime 25 and Nitomortar S should beremoved from tools and equipment with Nitoflor Solimmediately after use.

Estimating

Packaging & Coverage

Packaging Coverage

Nitomortar S 10 litre pack 2m2

@ 5 mm thickness

Nitoprime 25 1& 4 litre packs 5.5-6.5m2/litre

Nitoflor Sol 5 & 20 litre tins -

Note : The coverage figures given above are theoretical dueto wastage factors and the variety and nature of possiblesubstrates, practical coverage figures will be reduced.

Storage

Shelf life

All products have a shelf life of 12 months at 300C if kept in adry store in the original, unopened bags or packs.

Storage conditions

Store in dry conditions in the original. unopened bags or packs.If stored at high temperatures, the shelf life may be reduced to4 to 6 months.

Precautions

Health and Safety instructions

Nitozinc Primer, Nitoprime 25, Nitomortar S and Nitoflor Solshould not come in contact with skin or eyes, or be swallowed.Adequate ventilation shall be provided and inhalation ofvapours shall be avoided. Some people are sensitive toresins, hardeners and solvents. Suitable protective clothing,gloves and eye protection shall be worn. If working in confinedareas, suitable respiratory protective equipment must be used.The use of barrier creams provide additional skin protection.

Nitomortar® S

INDIA/0408/E



++91 80-2334 3188 ++91 80-2334 3178 [email protected]





In case of contact with skin, it shall be removed immediatelywith resin removing cream followed by washing with soapand water. Solvent should not be used. In case of contactwith eyes, it shall be rinsed immediately with plenty of cleanwater and medical advice shall be sought. If swallowed,medical attention shall be sought immediately - Vomitingshould not be used.

Fire

Nitomortar S mortar is nonflammable.

Nitozinc Primer, Nitoprime 25, Nitoflor Sol are flammable. Itshall be kept away from sources of ignition. Smoking isprohibited during handling / application of the product. In theevent of fire, use of fire extinguishers like carbon-dioxide orfoam, is suggested. Use of water jet is not suggested.

Flash points

Nitozinc Primer 160C

Nitoprime 25 250C

Nitoflor Sol 330C

Additional information

Fosroc have produced several educational training videoswhich provide more detail about the mechanisms whichcause corrosion within reinforced concrete structures andthe solutions which are available to arrest or retard thesedestructive mechanisms. Further information is availablefrom the publication 'Concrete Repair And Protection - TheSystematic Approach'.

For further information about products, training videos orpublications, contact the local Fosroc office.

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