Fosroc Nitomortar S constructive solutions

High strength, abrasion-resistant epoxy reinstatement

mortar

Uses Properties

For fast and permanent patch repair of concrete, particularly The following results were obtained at a temperature of 20°C
where high strength, abrasion and chemical resistance is unless otherwise specified.
required. It is ideally suited for:
Test method Typical result
 Sewage tanks Compressive strength : 70 N/mm2 @ 7 days
(BS 6319, Pt 2)
 Sea walls
Flexural strength : 20 N/mm2 @ 7 days
 Industrial floors (BS 6319, Pt 3)
Tensile strength : 10 N/mm2 @ 7 days
 Use as a bedding mortar
(BS 6319, Pt 7)
 Joint arris repairs Water absorption : 0.2% (concrete - 2.0 to 2.5%)
BRE Impact Resistance
Advantages BS 8204 Part 1: 1987 : Category A
20°C 35°C
 High ultimate strength - suitable for structural use.
Pot Life : 45 mins 20 mins
 Early development of strength minimises disruption. Initial hardness : 24 hours 16 hours
Full cure : 7 days 4 days
 Abrasion-resistance: suitable for heavily trafficked areas.
Fresh wet density : Approximately 2000 kg/m3
 Highly resistant to a wide range of chemicals. (fully compacted)

 Will cure under damp conditions - cured product is highly Fully cured blocks of Nitomortar S were continually im-
impermeable to water. mersed at 20°C in a wide range of aggressive chemicals
found in industrial environments. Tests were performed by
 Pre-weighed components ensure consistency.
constant immersion over a set period, followed by visual
inspection and testing for Shore D hardness.
Description
Acids (m/v)
Nitomortar S is a three-component material supplied in
Citric acid 10% : Resistant
pre-weighed quantities ready for on-site mixing and use. It is
Tartaric acid 10% : Resistant
based on a high quality, solvent-free, epoxy resin system;
Hydrochloric acid 25% : Resistant
with special aggregates to provide high strength and excel-
Sulphuric acid 10% : Resistant
lent abrasion resistance.
Phosphoric acid 50% : Resistant
Lactic acid 10% : Resistant
Specification
Nitric acid 10% : Resistant
High strength epoxy repair mortar
Alkalis (m/v)
The high strength repair mortar shall be Nitomortar S, a Sodium Hydroxide 50%: Resistant
three-component epoxy resin. The cured mortar shall
Solvents & organics
achieve a compressive strength of 70 N/mm2, a flexural
Diesel fuel/petrol 100% : Resistant
strength of 20 N/mm2 and a tensile strength of 10 N/mm2
Hydrocarbons 100% : Resistant
when tested at 28 days. The water absorption of the cured
mortar shall not exceed 0.2%. Aqueous solutions
Sugar 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
Nitomortar S

housekeeping practice.
Fosroc Nitomortar S

Instructions for use The mixed primer should be scrubbed well into the prepared
substrate, taking care that all imperfections in the surface are
Design criteria
properly coated and avoiding ‘ponding’ in depressions. If the
Nitomortar S can be applied in sections up to 50 mm thick- primer is absorbed within 30 minutes, a second coat should
ness in horizontal locations, and 12 mm in vertical locations, be applied before continuing. Nitomortar S can be applied as
in a single application and without the use of form work, soon as the primer has started to gel but still has surface
dependent upon the repair geometry. ‘tack’. This is normally between 30 minutes and 4 hours
dependent on the ambient and substrate temperatures. If the
Nitomortar S can be used for emergency repairs where fast
primer cures hard, a second application must be made before
strength gain is important. When properly compacted, the
application of Nitomortar S. The usable life of the mixed
mortar is highly impermeable.
primer is approximately 60 minutes at 20°C or 30 minutes at
In certain instances, Nitomortar S can be used on metal 35°C.
substrates. Contact the local Fosroc office for advice in this
Mixing
respect.
Care should be taken to ensure that Nitomortar S is thorough-
For fast repairs in vertical and overhead locations where a
ly mixed to produce a fully homogeneous, trowellable mortar.
higher-build, lightweight formulation is required, the use of
Nitomortar HB*† is recommended. Nitomortar S must be mixed mechanically. The ‘hardener’
and ‘base’ components should be stirred thoroughly in order
Preparation
to disperse any settlement before mixing them together. The
Clean the surface and remove any dust, unsound material, entire contents of the ‘ hardener’ container should then be
plaster, oil, paint, grease, corrosion deposits or algae. Rough- emptied into the ‘base’ container and manually mixed for 3
en the surface and remove any laitence by light scabbling or minutes, then emptied into a forced action mixer of adequate
grit-blasting. Saw cut or cut back the extremities of the repair capacity (e.g. Cretangle or Pennine). Add the aggregate
locations to a depth of at least 5 mm to avoid feather-edging slowly with the mixer running and continue for 2 to 3 minutes
and to provide a square edge. Break out the complete repair until all the components are thoroughly blended. Under no
area to a minimum depth of 5 mm up to the sawn edge. circumstances should part packs be used.

Oil and grease deposits should be removed by steam clean- Application

ing, detergent scrubbing or the use of a proprietary degreaser.
Apply the mixed Nitomortar S to the prepared substrate by
The effectiveness of decontamination should then be as-
wood float, pressing firmly into place to ensure positive
sessed by a pull-off test.
adhesion and full compaction. Thoroughly compact the
Expose fully any corroded steel in the repair area and remove mortar around any exposed reinforcement. In restricted
all loose scale and corrosion deposits. Steel should be location, or where exposed reinforcing steel is present,
cleaned to a bright condition paying particular attention to the application by gloved hands is an acceptable alternative but,
back of exposed steel bars. Grit-blasting is recommended for in all cases, the product must be finished to a tight surface
this process. with a steel trowel.

Substrate priming Nitomortar S can be applied in sections up to 50 mm thick-

ness in horizontal locations or up to 12 mm thickness in
Horizontal substrates should be primed using Nitoprime 25*.
vertical locations in a single application and without the use of
Predominantly vertical and metal substrates should be primed
form work. Thicker vertical sections may sometimes be
using Nitocote Primer Sealer*. In both cases, the primer
possible dependent on the profile of the substrate and the
should be mixed in the proportions supplied, adding the entire
volume of exposed reinforcing steel but should generally be
contents of the ‘hardener’ tin to the ‘base’ tin. The two compo-
built up in layers.
nents should be thoroughly mixed together by hand for 3
minutes. When larger areas are being rendered, a chequer board
application technique is recommended.

Note: the minimum applied thickness of Nitomortar S is 5 mm.

Nitomortar S - Page 2 of 4
Fosroc Nitomortar S

Build-up Estimating

Additional build-up can be achieved by application of multiple Supply

layers. Exposed steel reinforcing bars should be firmly Nitomortar S : 10 litre packs
secured to avoid movement during the application process as Nitoprime 25 : 1 & 4 litre packs
this will affect mortar compaction, build and bond. Nitocote Primer Sealer : 1 & 4 litre packs
Fosroc Solvent 102 : 5 litre cans
Where thicker sections are required, the surface of the
intermediate applications should be scratch-keyed to provide a
Coverage
suitable surface for subsequent layers. The application of
Nitoprime 25 : 4.0 - 5.0 m2/litre
additional layers should follow between 8 and 24 hours (@
Nitocote Primer Sealer : 4.0 - 5.0 m2/litre
20°C) after the first application. This time should be reduced
at higher temperatures. Re-priming and a further application Note : The coverage figures for Nitoprime 25 and Nito-
of Nitomortar S may then proceed. cote Primer Sealer are theoretical - due to wastage
factors and the variety and nature of possible
If sagging occurs during application, the Nitomortar S should
substrates, practical figures will be reduced.
be completely removed and reapplied at a reduced thickness
on to the correctly re-primed substrate.
Storage
Finishing
Shelf life
Nitomortar S is finished by the use of a wood float and closed
All products have a shelf life of 12 months at 20°C if kept in a
with a steel trowel. The completed surface should not be
dry store in the original, unopened bags or packs.
overworked.
Storage conditions
High temperature working
Store in dry conditions in the original, unopened bags or
At ambient temperatures above 35°C, Nitoprime 25, Nitocote
packs. If stored at high temperatures, the shelf life may be
Primer Sealer and Nitomortar S will have shorter pot lives and
reduced to 4 to 6 months.
open working time. The materials should be stored in the
shade or in an air-conditioned environment and should not be
Limitations
applied in direct sunlight.
Nitomortar S should not be used when the temperature is
Curing
below 5°C and falling. Do not mix part packs under any
Curing protection is not necessary for Nitomortar S. circumstances. Nitomortar S should not be exposed to
moving water during application. Exposure to heavy rainfall
Cleaning
prior to the final set may result in surface scour. If any doubts
Nitoprime 25, Nitocote Primer Sealer and Nitomortar S should arise concerning temperature or substrate conditions, consult
be removed from tools, equipment and mixers with Fosroc the local Fosroc office.
Solvent 102* immediately after use.
The material should not be applied at less than 5 mm
thickness. Greater thicknesses than those specified above
Technical support
can be achieved by the application of subsequent layers.
Fosroc offers a comprehensive technical support service to Larger areas should be applied in a ‘chequer board’ fashion.
specifiers, end users and contractors. It is also able to offer
For higher build characteristics to vertical locations, or for
on-site technical assistance, an AutoCAD facility and dedicat-
overhead application, Nitomortar HB is recommended.
ed specification assistance in locations all over the world.

Nitomortar S - Page 3 of 4
Fosroc Nitomortar S

Precautions Additional Information

Health and safety Overcoating with protective/decorative finishes

Nitoprime 25, Nitocote Primer Sealer, Nitomortar S and Nitomortar S is extremely durable and resistant to a wide
Fosroc Solvent 102 should not come in contact with skin or range of acids, alkalis and industrial chemicals and will
eyes, or be swallowed. Ensure adequate ventilation and provide excellent protection to the concrete and embedded
avoid inhalation of vapours. Some people are sensitive to steel reinforcement within the repaired location. The
resins, hardeners and solvents. Wear suitable protective surrounding parts of the structure may benefit from the
clothing, gloves and eye protection. If working in confined application of a protective coating, thus bringing them up to
areas, suitable respiratory protective equipment must be the same protective standard as the repair itself. Fosroc
used. recommends use of the Nitocote range of epoxy resin,
chemical-resistant, protective coatings.
The use of barrier creams provide additional skin protection.
In case of contact with skin, remove immediately with resin For surrounding areas not subjected to chemical attack or
removing cream followed by washing with soap and water. physical wear, Fosroc recommend the use of the Dekguard
Do not use solvent. In case of contact with eyes, rinse range of anti-carbonation, anti-chloride protective coatings.
immediately with plenty of clean water and seek medical These products provide a decorative and uniform appear-
advice. If swallowed, seek medical attention immediately - ance as well as protecting areas of the structure which might
do not induce vomiting. otherwise be at risk from the environment.

Fire Nitocote epoxy resin protective coatings should be applied

within 24 hours. Dekguard products should not be applied
Nitomortar S and Nitocote Primer Sealer are non-flammable.
until the Nitomortar S is at least 3 days old. For further
Nitoprime 25 and Fosroc Solvent 102 are flammable. Keep advice, consult the local Fosroc office.
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 25 : 39°C
Fosroc Solvent 102 : 33°C

For further information, refer to the Product Material Safety

Data Sheet.

* Denotes the trademark of Fosroc International Limited

†
See separate data sheet

Important note
Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply of
Goods and Service. All Fosroc datasheets are updated on a regular basis. It is the user’s responsibility to obtain the latest version.

Head Office
telephone: (+9714) 2039699 fax: (+9714) 2859649 email: agf@fosroc.com
Al Gurg Fosroc LLC
Regional offices
Post Box 657, Dubai Abu Dhabi, Al Gurg Fosroc telephone: 673 1779 fax: 673 1449 email: abudhabi@fosroc.com
Bahrain, YBA Kanoo telephone: 17738200 fax: 17732828 email: bahrain@fosroc.com
United Arab Emirates Kuwait, Boodai telephone: 4817618 fax: 4832124 email: kuwait@fosroc.com
Oman, Al Amana telephone: 24815080 fax: 24817554 email: oman@fosroc.com
www.fosroc.com

UAE/0269/01/C