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Nitomortar S constructive solutions

High strength, abrasion-resistant epoxy


reinstatement mortar

Uses Design criteria

For the fast and permanent reinstatement of concrete, Nitomortar S can be applied in section up to 50 mm
particularly where high strength, abrasion-resistance and thickness in horizontal locations and 12 mm in vertical
resistance to chemicals is required. The product is designed locations in a single application without the use of
for horizontal use but can be applied vertically, although formwork. The material should not be applied at less than
generally in thinner sections. It is ideally suited for acid tanks, 5 mm thickness. Greater thicknesses than those specified
sea walls, industrial floors and for use as a bedding mortar. above can be achieved by application of subsequent
Nitomortar S can be used for emergency repairs where fast layers. Larger areas should be applied in a ‘chequerboard’
strength gain is important. When properly compacted, the fashion. Consult the local Fosroc office for further
mortar is highly impermeable. information.

In certain instances, Nitomortar S can be used on metal For higher build characteristics to vertical or overhead
substrates. Contact the local Fosroc office for advice in this locations, Nitomortar HB is recommended.
respect.
Properties
For fast repairs in vertical and overhead locations where a
higher-build, lightweight formulation is required, the use of The following results were obtained at a temperature of
o
Nitomortar HB is recommended. 20 C unless otherwise specified.
Test method Typical result
Advantages Compressive strength:
2
(BS 6319, Part 2) 70 N/mm at 28 days
 High ultimate strength - suitable for structural use. Flexural strength:
2
(BS 6319, Part 3) 20 N/mm at 28 days
 Early development of strength minimises disruption. Tensile strength:
2
(ASTM C-307) 10 N/mm at 28 days
 Abrasion-resistance - suitable for heavily trafficked areas. Compressive modulus:
2
(ASTM C-469) 16.2 kN/mm at 28 days
Water absorption: 0.2% (concrete - 5.0%)
 Highly resistant to a wide range of chemicals. o
Pot life: 45 minutes at 20 C
o
20 minutes at 35 C
 Will cure under damp conditions - cured product is highly
Initial hardness: o
24 hours at 20 C
impermeable to water. o
16 hours at 35 C
o
Full cure: 7 days at 20 C
 Typically twice as strong as good quality concrete. o
4 days at 35 C
3
Fresh wet density: Approximately 2000 kg/m
 Pre-weighed components ensure consistency. (fully compacted)
Chemical resistance: The low permeability of
Description Nitomortar S retards
chemical attack in
Nitomortar S is based on high quality solvent-free epoxy resin aggressive environments.
system. The special silica aggregates provide high strength Performance of Nitomortar S
and excellent abrasion resistance. Nitomortar S is a three- blocks continually immersed
o
component material supplied in pre-weighed quantities ready at 20 C.
for on-site mixing and use. Citric acid 10% Excellent
Tartaric acid 10% Excellent
Technical support Hydrochloric acid 25% Excellent
Sodium hydroxide 50% Excellent
Fosroc offers a comprehensive range of high performance, Diesel fuel/petrol 100% Excellent
high quality construction products. In addition, the company Sulphuric acid 10% Very good
offers a technical support package to specifiers, end-users Sugar solutions Saturated Very good
and contractors, as well as on-site technical assistance in Lactic acid 10% Very good
locations all over the world. Hydrocarbons 100% Very good
Phosphoric acid 50% Very good
Nitric acid 10% Good
Acetic acid 5% Limited

Page 1
Nitomortar S
Specification clauses primer cures hard, a second application must be made
before application of Nitomortar S. The useable life of the
o
High strength epoxy repair mortar mixed primer is approximately 60 minutes at 20 C or 30
o
minutes at 35 C.
The high strength repair mortar shall be Nitomortar S, a three-
component epoxy resin with a density not greater than 2000 Mixing
3
kg/m . The cured mortar shall achieve a compressive strength
2 2 Care should be taken to ensure that Nitomortar S is
of 70 N/mm , a flexural strength of 20 N/mm and a tensile
2 thoroughly mixed to produce a fully homogeneous
strength of 10 N/mm when tested at 28 days. The water
absorption of the cured mortar shall not exceed 0.2%. trowellable mortar.

Nitomortar S must be mixed mechanically. The ‘hardener’


Application instructions and ‘base’ components must be stirred thoroughly to
disperse any settlement before mixing them together. The
Preparation entire contents of the ‘hardener’ container should then be
emptied into the ‘base’ container and thoroughly mixed for
Clean the surface and remove any dust, unsound or 3 minutes, then emptied into a forced action mixer of
contaminated material, plaster, oil, paint, grease, corrosion adequate capacity (e.g. Cretangle or Pennine). Add the
deposits or algae. aggregate slowly with the mixer running and continue for 2
to 3 minutes until all the components are thoroughly
Roughen the surface and remove any laitance by light blended. Under no circumstances should part packs be
scabbling or grit-blasting. Saw cut or cut back the extremities used.
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 A slow speed heavy duty drill fitted with a purpose mixer
complete repair area to a minimum depth of 5 mm up to the can be facilitated.
sawn edge.
Application
Oil and grease deposits should be removed by steam
cleaning, detergent scrubbing or the use of a proprietary Apply the mixed Nitomortar S to the prepared substrate by
degreaser. The effectiveness of decontamination should then wood float, pressing firmly into place to ensure positive
be assessed by a pull-off test. adhesion and full compaction. Thoroughly compact the
mortar around any exposed reinforcement. In restricted
Expose fully any corroded steel in the repair area and remove locations, or where exposed reinforcing steel is present,
all loose scale and corrosion deposits. Steel should be application by gloved hands is an acceptable alternative
cleaned to a bright conditions paying particular attention to the but, in all cases, the product must be finished to a tight
back of exposed steel bars. Grit-blasting is recommended for surface with a steel trowel. Nitomortar S can be applied in
this process. sections up to 50 mm thickness in horizontal locations or
up to 12 mm thickness in vertical locations in a single
Reinforcing steel priming application and without the use of formwork. Thicker
vertical sections may sometimes be possible dependent on
The cleaned steel should be coated within 3 hours. Apply one the profile of the substrate and the volume of exposed
full coat of Nitoprime Zinc Rich and allow to dry before reinforcing steel but should generally be built up in layers.
continuing. If any doubt exists about having achieved an When larger areas are being rendered, a chequerboard
unbroken coating, a second application should be made and, application technique is recommended.
again, allowed to dry before continuing.
Note: The minimum applied thickness of Nitomortar S is 5
Substrate priming mm.

Horizontal substrates should be primed using Nitoprime 25. Build-up


Predominantly vertical and metal substrates should be primed
using Nitoprime 28. In both cases, the primer should be mixed Additional build-up can be achieved by application of
in the proportions supplied, adding the entire contents of the multiple layers. Exposed steel reinforcing bars should be
‘hardener’ tin to the ‘base’ tin. The two components should be firmly secured to avoid movement during the application
thoroughly mixed together for 3 minutes. process as this will affect mortar compaction, build and
bond.
The mixed primer should be scrubbed well into the prepared
substrate, taking care that all imperfections in the surface are Where thicker sections are required, the surface of the
properly coated and avoiding ‘pudding’ in depressions. If the intermediate applications should be scratch-keyed to
primer is absorbed within 30 minutes, a second coat should be provide a suitable surface for subsequent layers. The
applied before continuing. Nitomortar S can be applied as application of additional layers should follows between 8
soon as the primer has started to gel but still has surface o
and 24 hours at 20 C after the first application. This time
‘tack’. This is normally between 30 minutes and 4 hours should be reduced at higher temperature. Re-priming and
dependent on the ambient and substrate temperatures. If the a further application of Nitomortar S may then proceed.

constructive solutions Page 2


Nitomortar S
Cleaning
If sagging occurs during application, the Nitomortar S should
be completely removed and reapplied at a reduced thickness Nitoprime Zinc Rich, Nitoprime 25, Nitoprime 28 and
on to the correctly re-primed substrate. Nitomortar S should be removed from tools, equipment
and mixers with Fosroc Solvent 102 immediately after use.
Finishing
Limitations
Nitomortar S is finished by the use of a wood float and closed
with a steel trowel. The completed surface should not be Nitomortar S should not be used when the temperature is
overworked. o
below 5 C and falling. Do not mix part packs under any
circumstances. Nitomortar S should not be used in
Low temperature working overhead locations – use Nitomortar HB for this purpose.
Nitomortar S should not be exposed to moving water
Nitoprime 25, Nitoprime 28 and Nitomortar S can be applied in during application. Expose to heavy rainfall prior to final
o
cold conditions down to 5 C. The materials should not be set may result in surface scour. If any doubt arises
o
applied when the substrate and/or air temperature is 5 C and concerning temperature or substrate condition, consult the
o o
falling. At 5 C static temperature or at 5 C and rising, the local Fosroc office.
application may proceed.

High temperature working Estimating


o
At ambient temperatures above 35 C Nitoprime 25, Nitoprime Supply
28 Nitomortar S and will have shorter pot lives and working
lives. The materials should be stored in the shade or in an air- Nitomortar S: 8 and 16 kg packs
conditioned environment and should not be applied in direct Nitoprime Zinc Rich: 1 litre cans, 2.5 litre packs
sunlight. Nitoprime 25: 1 kg and 5 kg packs
Nitoprime 28: 1 and 5 kg packs
Curing Fosroc Solvent 102: 4 and 25 litre cans

Curing protection is not necessary for Nitomortar S. Coverage and yield

Over-coating with protective/decorative finishes Nitomortar S: 4.0 litres per 8 kg pack


8.0 litres per 16 kg pack
2
Nitomortar S is extremely durable and resistant to a wide Nitoprime Zinc Rich: 7.4 m per litre
2
range of acids, alkalis and industrial chemicals and will provide Nitoprime 25: 5 m per kg
2
excellent protection to the concrete and embedded steel Nitoprime 28: 5 m per kg
reinforcement within the repaired locations. The surrounding
parts of the structure may benefit from the application of a Note: The coverage figures for Nitoprime Zinc Rich,
protective coating, thus bringing them up to the same Nitoprime 25 and Nitoprime 28 are theoretical due
protective standard as the repair itself. Fosroc recommend to wastage factors and the variety and nature of
the use of Nitocote range of epoxy resin, chemical-resistant, possible substrates, practical coverage figures will
protective coatings. be reduced.

For surrounding areas not subjected to chemical attack or UN packaging regulations


physical wear, Fosroc recommend the use of the Dekguard
range of anti-carbonation, anti-chloride protective coatings. To comply with current regulations, all product of a
These products provide a decorative and uniform appearance hazardous nature that are involved in a sea crossing as
as well as protecting areas of the structure which might part of the delivery requirements must be packed in United
otherwise be at risk from the environment. Nations Approved receptacles.

Nitocote epoxy resin protective coatings should be applied When a known sea crossing is involved, whether local to
within 24 hours. Dekguard products should not be applied the Saudi Arabia or for export worldwide, Fosroc will
until the Nitomortar S is at least 3 days old. For further advise, supply in the correct UN packaging. Where Fosroc are
consult the local Fosroc office. only requested to deliver within the Saudi Arabia mainland,
but the purchaser intends to ship on, it is incumbent on the
purchaser to specify that UN packaging is required at the
time of placing the order.

Otherwise, once delivery is received, the responsibility is


that of the purchaser. The use of UN packaging may
affect the selling price of products. Refer to the local
Fosroc office or representative.

constructive solutions Page 3


Nitomortar S
Storage Flash Points

Nitoprime Zinc Rich o


Shelf life 16 C
o
Nitoprime 25: 39 C
o o
All products have a shelf life of 12 months at 20 C if kept in Nitoprime 28: 27 C
a dry store in the original, unopened bags or packs. Fosroc Solvent 102: o
33 C
Storage conditions For further information, refer to the Product Material Safety
Data Sheet.
Store in dry conditions in the original, unopened bags or
packs. If stored at high temperatures and/or high humidity
conditions the shelf life may be reduced to 4 to 6 months. Additional information

Fosroc manufactures a wide range of products specifically


Precautions
designed for the repair and refurbishment of damaged
reinforced concrete. This includes hand-placed and spray
Health and safety grade repair mortars, fluid micro-concrete, chemical
resistant epoxy mortars and a comprehensive package of
Nitoprime Zinc Rich, Nitoprime 25, Nitoprime 28, Fosroc protective coatings. In addition, a wide range of
Solvent 102 and Nitomortar S should not come into contact complementary products is available.
with the skin, eyes or be swallowed. When using ensure
adequate ventilation and avoid inhalation of vapour. Some Fosroc has also produced several educational training
people are sensitive to resins, hardeners and solvent. Wear videos which provide more details about the mechanisms
suitable protective clothing, gloves, and eye protection. The which cause corrosion within reinforced concrete structures
use of barrier creams provides additional skin protection. In and the solutions which are available to arrest or retard
case of contact with eyes, rinse immediately with plenty of these destructive mechanisms.
clean water and seek medical attention immediately. If
swallowed seek medical attention immediately. Do not Further information is available from the publication.
induce vomiting. Concrete Repair and Protection. The ‘Systematic
Approach’, available in seven language formats.
Fire
For further information about products, training videos or
Nitomortar S is non-flammable. Nitoprime Zinc Rich, publications, contact the local Fosroc office.
Nitoprime 25, Nitoprime 28 and Fosroc Solvent 102 are
flammable. Keep away from sources of ignition. No
smoking. In the event of fire, extinguish with CO 2 or foam.
Do not use a water jet.

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 Services, copies of which may be obtained on request. Whilst Fosroc endeavours to ensure that
any advice, recommendation, specification of information it may give is accurate and correct, it cannot, because it has no direct
or continuous control over where or how its products are applied, accept any liability either directly or indirectly arising from the
use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.

Fosam Company Limited


Telephone: +966 2 637 5345 Fax: +966 2 637 5891 email: fosam@fosroc.com
Head Office
Post Box 11081 Regional Offices
Jeddah Sales Office Tel: (02) 608 0999 Fax: (02) 638 0693 Yanbu Tel: (04) 322 4280 Fax: (04) 391 2980
Jeddah – 21453
Jeddah Showroom Tel: (02) 665 0187 Fax: (02) 667 4844 Makkah Tel: (02) 542 0869 Fax: (02) 542 0869
Saudi Arabia Riyadh Tel: (01) 482 9303 Fax: (01) 482 7562 Medinah Tel: (04) 855 0091 Fax: (04) 855 0047
Dammam Tel: (03) 814 1282 Fax: (03) 814 1581 Jubail Tel: (03) 362 3904 Fax: (03) 362 3875

www.fosroc.com Khamis Mushayt Tel: (07) 250 0469 Fax: (07) 250 0469 CSD Tel: (02) 608 0999 Fax: (02) 638 0693

Registered Office: Industrial Area, Phase 4, Road No. 414, Street No. 407
Page 4 FO SA/NITOMORTAR S/05/A

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