Report on

EPOXY

NOVEMBER 9, 2014

Contents
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1. INTRODUCTION
Definition: An adhesive, plastic, or other material made from a class of synthetic
thermosetting polymers containing epoxide groups.
Manufacturing process: Most common epoxy resins are produced from a reaction between
epichlorohydrin (ECH) and bisphenol-A (BPA), though the latter may be replaced by other raw
materials (such as aliphatic glycols, phenol and o-cresol novolacs) to produce specialty resins.
The epoxy resins can be obtained in either liquid or solid states. The two processes are similar.
Firstly ECH and BPA are charged into a reactor. A solution of 20-40% caustic soda is added to
the reaction vessel as the solution is brought to the boiling point. After the evaporation of
unreacted ECH, the two phases are separated by adding an inert solvent such as
methylisobutylketone (MIBK). The resin is then washed with water and the solvent is removed
by vacuum distillation. The producers will add the specific additives to create a formula that
lend special properties such as flexibility, viscosity, colour, adhesiveness, and faster curing,
depending on a particular application.
In order to convert epoxy resins into a hard, infusible, and rigid material, it is necessary to cure
the resin with hardener. Epoxy resins can cure at practically any temperature from 5-150oC
depending on the choice of curing agent. Primary and secondary amines are widely used to
cure epoxy resins.
Advantages:
Epoxy adhesive has proven to be useful for emergency repairs.
Many epoxy adhesives are not affected by the presence of moisture, thus can be used
to make emergency repairs to swimming pools, boats or equipment in a marine
environment.
As an engineering adhesive, epoxy-based materials are commonly used to bond one
surface to another, thus limiting movement between the joints and dampening
sound.
Epoxy adhesive is used as structural adhesive to glue fixtures in place in locations
where driving a nail might cause issues. An example of this epoxy application might
include setting tack strip for carpeting on a concrete floor with sub-floor heating
system. Epoxy adhesives makes it possible to adhere the fixture to a surface in a
permanent or semi-permanent manner without the risks associated with driving nails
into the surface.
2. Different types of Epoxy products used in Construction and Repair works:
1) Nitomortar S (FOSROC)
Description
High strength abrsasion resistance epoxy reinstatement mortar
Principal Use
Nitomortar S is used for the fast and permanent reinstatement of concrete,
particularly where high strength abrashion resistance and resistance to chemicals is
required.

Key Properties
Compressive Strength
Tensile strength
Flexural strength
Pot Life at 35C

60N/mm
10N/mm
20N/mm
20mins

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 highly impermeable to
water
Typically twice as strong as good quality concrete
Pre-weighed components ensure consistency
Specification
Nitomortar S is based on a high quality solvent-free epoxy resin system. The special
silica aggregates provide high strength and excellent abrasion resistance. Nitomortar
S is a three - component material supplied in pre-weighed quantities ready for onsite mixing and use.
2) SiKadur-31
Sikadur-31 is a solvent-free, moisture tolerant, thixotropic, two part structural
adhesive and repair mortar, based on epoxy resins and special fillers, designed for
use at temperatures between +10C and +40C.
USAGE
As a structural adhesive for:
Concrete elements
Hard natural stone
Ceramics, fibre cement
Mortar, Bricks, Blocks, Masonry etc.
Steel, Iron, Aluminium
Wood
Polyester, Epoxy
Glass
As a fast setting repair mortar for:
Corners and edges
Hole and void filling
Joint arrises
Joint filling and crack sealing:
Rigid joint filling
Crack filling and sealing (non moving)
CHARACTERISTICS
Sikadur-31 has the following advantages:
Easy to mix and apply
Suitable for dry and damp concrete surfaces
Very good adhesion to most construction materials
High strength adhesive
Thixotropic: non-sag and suitable for vertical and overhead application
Solvent free
Hardens without shrinkage
Different coloured components (for mixing control)
No primer needed
High initial and ultimate strengths

 Good abrasion resistance

Adhesive and filler in one
Impermeable to liquids and water vapour
Good chemical resistance
COLOR
Part A: white
Part B: black
Part A+B mixed: concrete grey
PACKAGING
3 kg (A+B) Pre-batched unit
Part A: 2.00 kg plastic container
Part B: 1.00 kg plastic container
3. Epoxy flooring systems
Advantages of epoxy flooring systems are,
High-traffic finishes with industrial-strength chemical and abrasion
resistance.
Perfect for heavy and frequent foot and cart traffic.
Quick turnover, fast-curing systems available.
Easy to maintainno waxing or re-polishing required.
Antimicrobial protection available.
Moisture vapor mitigation floors.
Skid-resistant options that do not interfere with aesthetics.
Pattern and flooring design options, ideal for designating traffic lanes and
dividing floor space.
a) Protect1000-CR-HB-FS-ST
Universal Epoxy Coating System
Protect 1000 is a two-component, universal, 100% solids, epoxy resin coating system
that can be applied as a clear or pigmented coating or primer. Protect 1000 is supplied
with a choice of curing agents to achieve specific cure rates, chemical resistance
requirements and final aesthetics. This product produces a gloss finish. Protect 1000
may be used as a primer, build coat, broadcast, grout filler and top coat simply by
selecting and mixing with the correct curing agent.
b) Protect1000-Thixo
Thixotropic-Epoxy-System
Protect 1000 Thixo is a two or three-component, 100% solids, low odor, epoxy resin
system. Protect 1000 Thixo is primarily designed to grout Protect epoxy mortar
systems. This product exhibits a higher degree of body and thixotropy when
compared with Protect 1000 Grout. Protect 1000 Thixo may also be used as the binder
in combination with decorative quartz and silica sand aggregate for vertical cove
applications. Protect 1000 Thixo may also be used alone or in combination with
Protect Trowel Power for fine crack filling, patching or use as a cinder block wall filler.
This product is supplied with a choice of curing agents to achieve specific cure rates,
chemical resistance requirements, utility and final aesthetics.

c) Protect 1000 Grout

Epoxy Grout & Coating System
Protect 1000 Grout is a two or three-component, 100% solids, low odor, epoxy resin
coating system. Protect 1000 Grout is primarily designed to grout Protect epoxy
mortar systems. This product may also be used as a finish or basecoat when an orange
peel or slightly stippled finish is desired. Protect 1000 Grout is supplied with a choice
of curing agents to achieve specific cure rates, chemical resistance requirements and
final aesthetics.
d) Protect 1200 WR
Water-Reducible Epoxy System
Protect 1200 WR is an economical, two-component, water-reducible epoxy coating.
Protect 1200 WR is to be applied as an epoxy primer or an epoxy topcoat. This product
produces a gloss finish. Protect 1200 WR is suited for applications where a "no odor"
general use coating is desired, such as office areas, schools, display area floors and
light duty industrial work areas.
e) Protect-1500-SB
Solvent-Borne-Epoxy-System
Protect 1500 SB is a three-component, chemical-resistant, solvent borne epoxy
pigmented coating. Protect 1500 SB can be used as a topcoat on an epoxy mortar, as
a recoat on an existing epoxy floor, or as a concrete primer. This product produces a
gloss, orange peel finish. Protect 1500 SB is suited for direct-to-metal and concrete
applications where a chemical-resistant epoxy pre-solvated coating is desired for use
and installation in industrial work areas.
f)

Protect-1750-Novalac
Novalac-Epoxy-System
Protect 1750 Novalac is a three-component, highly chemical-resistant, novalac epoxy
pigmented coating. Protect 1750 Novalac is applied as a top coat or used to recoat an
existing epoxy floor. This product produces a semi-gloss finish. Target areas of use for
Protect 1750 Novalac include battery charging, chemical processing and other
chemical exposure areas. This product is designed to withstand a wide array of
chemical contact including strong acids, caustics and solvents.

g) Protect 1800 Flex

Flexible Epoxy Resin System
Protect 1800 Flex is a three-component flexible epoxy and urethane hybrid
coating. Protect 1800 Flex is applied as a membrane and/or broadcast with aggregate
to form a flexible impact resistant wear course. Target areas of use for Protect 1800
Flex include liquid processing and elevated areas requiring a flexible membrane.

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References:
1. http://resources.alibaba.com/topic/800050983/BriefHistoryofepoxyresin.htm
2. http://www.protectiveindustrialpolymers.com/epoxy-floor-coating.aspx
3.