4 - dpf brochure

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DPF Brochure




Material Data Sheet



constructive solutionsNitomortar FC*

Uses

Nitomortar FC is designed for application to minor

imperfections in concrete surfaces. It is suitable for

application from a feather-edge to 3 mm, and can be used inthe following situations :

! Filling pinholes prior to overcoating with Nitocote*† or

Nitoflor*† products.

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

! Sealing of surface cracks in preparation for crack injection.

!General purpose bedding mortar and adhesive

Advantages

! Cost effective - reduces usage of subsequent coatings

! High performance - excellent chemical resistance, strong

adhesion to concrete substrate

! User friendly - easy to apply and finish, manufactured to

meet local conditions

Description

Nitomortar FC is a two component thixotropic, solvent free,

compound based on epoxy resins, graded fillers and

thixotropic 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 hardener black to ease identification of uniform mixing.

Design criteria

Nitomortar FC is designed for filling pinholes and surface

irregularities in concrete prior to the application of subsequent

Properties

Solids by weight : 100% @ 25ºC

Compressive strength : 70 N/mm2 @ 7 days

Pot life : 1 hour 40 mins @ 25ºC1 hour @ 35ºC

Drying time : 10 hours @ 25ºC

4 hours @ 35ºC

Overcoating time : After 24 hour curing period

Colour : 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 is

thoroughly mixed to produce a fully homogeneous paste.

The hardener' and 'base' components should be stirred

thoroughly in order to disperse any settlement before mixing

them together. The entire contents of the 'hardener' should be

emptied into the 'base' container and the components mixed

together using a Fosroc mixing paddle attached to a slow-

speed (400/500rpm) heavy duty drill, until a uniform grey colour

and consistency is obtained. Mixing of 1kg packs can be

done by hand but care must be taken to ensure homogenus

mixing. Under no circumstances should part packs be used,

or part mixing be attempted.

High strength trowel grade, epoxy resin fairing coat,

repair mortar, bedding and adhesive



Nitomortar FC*

Cleaning

Nitomortar FC should be removed from tools, equipment and

mixers with Fosroc Solvent 102*† immediately after use.

Hardened material can only be removed mechanically.

Estimating

Supply

Nitomortar FC : 1.0 and 4.0 litre packs

Fosroc Solvent 102 : 5 and 25 litre cans

Coverage and yield:

Coverage of Nitomortar FC is wholly dependant upon surface

conditions, site trials are therefore recommended to ascertain

actual usage on uneven substrates. As a guideline when

applied at 200 microns dft coverage is approximately 5m2/litre.

Storage

Shelf life

12 months if kept in unopened tins and stored in a dry place

away 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 to

4 to 6 months.

Limitations

- Do not mix part packs under any circumstances.

- Nitomortar FC should not be exposed to moving water

during application.

- Exposure to heavy rainfall prior to final set may result in

surface scour.

Precautions

Health and safety

Nitomortar FC and Fosroc Solvent 102 should not come in

contact with skin or eyes, or be swallowed. Ensure adequate

ventilation and avoid inhalation of vapours. Some people are

sensitive to resins, hardeners and solvents. Wear suitableprotective clothing, gloves and eye/face protection.

If working in confined areas, suitable respiratory protective

equipment must be used. The use of barrier creams provides

additional skin protection. Should accidental skin contact

occur, remove immediately with a resin removing cream

followed by soap and water. Do not use solvent. In case of

contact with eye, rinse immediately with plenty of clean water

and seek medical advice. If swallowed seek medical

attention immediately - do not induce vomiting.

Fire

Nitomortar FC is non-flammable.

Fosroc Solvent 102 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 points

Fosroc Solvent 102 : 33ºC

For further information, refer to the product materials safety

data sheet.

Additional information

Fosroc manufactures a wide range of products specifically

designed for the repair and refurbishment of damaged

reinforced concrete. These include hand-placed and spray

grade repair mortars, fluid micro-concretes, chemical-

resistant epoxy mortars and a comprehensive package of

protective coatings.



constructive solutionsNitobond SBR*

Polymer bonding aid and additive for mortars, screeds and

renders

Uses

For improving the physical properties of cementitious mixes.

Typical uses include, but are not limited to, the following :

! Bonding concrete repair mortars

! Floor toppings and screeds

! Waterproof renders and cementitious slurries

! Bonding agent for slip bricks, ceramic tiles, etc.

Advantages

! Single component liquid can be easily gauged as required

! Improves cohesion and workability

! Improves mortars to provide waterproof repairs, renders

and toppings which are highly resistant to freeze/thaw

cycling

! Improved tensile and flexural properties allow thin

applications

! Excellent bond to concrete, masonry, stonework, plaster and blockboard

! Contains no chloride admixtures

Specification

Polymer bonding aid and mortar additive

The polymer bonding aid and site-batched mortar shall be

modified by the use of Nitobond SBR, a single component

styrene butadiene rubber emulsion.

Description

Nitobond SBR is a modified styrene butadiene rubber

l i hi h i li d d hi li id I

Properties

The results listed below were achieved by assessing the

mechanical properties of a 3:1 sand:cement mortar containing

Nitobond SBR in the proportions 10 litres per 50 kg cementagainst a 3:1 sand:cement control mortar. The test methods

used were in full accordance with BS 6319 at 28 days - air

cured.

Test method Typical result Control

Compressive strength

(BS 6319, Pt 2) : 35 N/mm2 28 N/mm2

Tensile strength

(ASTM C-190) : 5.5 N/mm2 2.7 N/mm2

Flexural strength

(BS 6319, Pt 3) : 11.5 N/mm2 7.9 N/mm2

Slant shear bond

(BS 6319, Pt 4) : 18 N/mm2 2.6 N/mm2

Chemical resistance : Cementitious materials

have limited chemical

resistance. The addition of

Nitobond SBR to cement

mortars reduces

permeability and therefore

helps reduce the rate of

attack by aggressive

chemicals, acid gases and

water.

Design criteria

The application parameters for mortars modified by the use

of Nitobond SBR will differ depending on the actual mix design

used, but should always be subject to a minimum applied

thickness of 6 mm.



Nitobond SBR*


Preparation

Form the extremities of the application area to a depth of at

least 10 mm to avoid feather-edging and to provide a square

edge. Ensure a minimum depth of 6 mm is observed in the

remaining area, up to the previously formed edge.

Clean the surface and remove any dust, unsound or

contaminated material, plaster, oil, paint, grease, corrosion

deposits or algae. Oil and grease deposits should be removed

by steam cleaning, detergent scrubbing or the use of a

proprietary degreaser.

Where breaking out is not required, roughen the surface and

remove any laitance by light scabbling or grit-blasting. Theeffectiveness of decontamination should then be assessed

by a pull-off test.

Substrate priming

The substrate should be thoroughly soaked with clean water

and any excess removed prior to commencement. A slurry

primer should be prepared consisting of 1 volume Nitobond

SBR to 1 volume clean water to 3 volumes fresh cement. Toobtain a smooth consistency, the cement should be blended

slowly into the premixed liquids. The slurry primer should be

stirred frequently during use to offset settlement.

The slurry primer should be scrubbed well into the surface of

the substrate, being careful to avoid ‘ponding’. The repair

mortar, topping or render must be applied on to the wet slurry

primer. If the slurry primer dries before application of the mortar,

it must be removed and the area reprimed before continuing.

Preparation of reinforcement (repairs only)

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

Mix designs

A wide range of mix designs is achievable using Nitobond

SBR. For typical designs, please refer to Mix Design Sheet

FOS/SBR/05/02.

Mixing

Care should be taken to ensure that Nitobond SBR mortars

are thoroughly mixed. A forced-action mixer is essential for

large volume applications. Mixing in a suitably sized drum

using an approved spiral paddle in a slow speed (400/500

rpm) heavy-duty drill is acceptable for minor areas.

Weigh the cement, sand and, where required, aggregate into

the mixer and dry blend together for one minute. With the

machine in operation, add the pre-mixed Nitobond SBR andclean water. Continue mixing for 3 minutes to ensure complete

dispersal into the sand and cement.

Make any small adjustment to the quantity of clean water but

do not significantly exceed the literage shown above, additional

water should be kept to a minimum.

Continue mixing up to a maximum of 5 minutes until a smooth

and fully homogeneous consistency is achieved with therequired workability and application properties. It is critical

that allowance is made for the moisture content of the sand

and aggregate, particularly where stored on site.

Application

For application to all surfaces, Nitobond SBR mortars,

toppings and renders must be well-compacted on to the

primed substrate by trowel. It is frequently beneficial to work a

thin layer of the mortar into the slurry primer and then build the

mortar on to this layer. Exposed steel reinforcement should

be completely encapsulated by the mortar.

Nitobond SBR mortars can be applied at a minimum thickness

of 6 mm and up to 40 mm thickness, dependent on the location



Nitobond SBR*

Finishing

Nitobond SBR mortars can be finished with a steel, plastic or

wood float, or by a damp sponge technique, to achieve the

desired surface texture. The completed surface should not be

overworked.

Low temperature working

In cold conditions down to 5oC, the use of warm water (up to

30oC) is advisable to accelerate strength development. Normal

precautions for winter working with cementitious materials

should then be adopted.

High temperature working

At ambient temperatures above 35oC, the material should be

stored in the shade and cool water used for mixing.

Curing

Nitobond SBR mortars, toppings and renders are cement-

based. In common with all cementitious materials, they must

be cured immediately after finishing in accordance with good

concrete practice.

The use of Nitobond AR or Concure RB90, sprayed on to thesurface of the finished mortar in a continuous film, is

recommended. In harsh drying conditions, supplementary

curing with polythene sheeting must be used.

Overcoating with protective decorative finishes

Nitobond SBR mortar repairs are extremely durable and will

provide excellent protection to the embedded steel reinforcement

within the repaired locations.

The surrounding parts of the structure will generally benefit

from the application of a barrier/decorative coating to limit the

advance of chlorides and carbon dioxide, thus bringing them

up to the same protective standard as the repair itself.

F d th f th D k d f t ti

Cleaning

Nitobond SBR and Nitobond AR should be removed from tools,

equipment and mixers with clean water immediately after use.

Cured material can only be removed mechanically.

Equipment used with Nitoprime Zincrich and Concure RB90

should be cleaned using Fosroc Solvent 102.

Limitations

- Nitobond SBR mortars, toppings and renders should not

be applied when the temperature is below 5oC and falling.

- Nitobond SBR mortars should not be exposed to moving

water during application. Exposure to heavy rainfall prior

to the final set may result in surface scour.

- If any doubts arise concerning temperature or substrate

conditions, consult the local Fosroc office.

Technical support

Fosroc offers a comprehensive technical support service to

specifiers, end users and contractors. It is also able to offer

on-site technical assistance, an AutoCAD facility and dedicatedspecification assistance in locations all over the world.

Estimating

Supply

Nitobond SBR : 25 and 200 litre drums

Nitoprime Zincrich : 1 litre cans

Nitobond AR : 1 & 5 litre cans

Concure RB90 : 25 and 200 litre drums

Fosroc Solvent 102 : 5 litre cans

Coverage

Nitobond SBR : Refer to mix designs



Nitobond SBR*

Storage

Shelf life

All products have a shelf life of 6 months if kept in a dry store in

the original, unopened bags or packs.

Storage conditions

Store in dry conditions in the original packs. If stored at high

temperatures and/or high humidity conditions the shelf life

may be reduced. Nitobond SBR and Nitobond AR should be

protected from frost.

Precautions

Health and safety

Cementitious mortars and slurries modified with Nitobond SBR

contain cement powders which, when mixed or become damp,

release alkalis which can be harmful to the skin. During use,

avoid inhalation of dust and contact with skin and eyes. Wear

suitable protective clothing, gloves, eye protection and

respiratory protective equipment. The use of barrier creams

provide additional skin protection. In case of contact with skin,

rinse with plenty of clean water, then cleanse with soap and

water. 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.

Nitoprime Zincrich, Nitobond products, Concure RB90 and

Fosroc Solvent 102 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 protectiveclothing, gloves and eye protection. If working in confined areas,

suitable respiratory protective equipment must be used. The

use of barrier creams provide additional skin protection.

In case of skin contact with Nitoprime Zincrich and Concure

RB90, 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

Nitobond SBR and Nitobond AR are non-flammable.

Nitoprime Zincrich, and Fosroc Solvent 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

Nitoprime Zincrich : 16o

CFosroc Solvent 102 : 33oC

For further information, refer to the Product Material Safety

Data Sheet.



constructive solutionsNitocote ET402*

Coal tar extended epoxy resin coating

Uses

Provides chemical and abrasion resistance to prevent

corrosion of concrete surfaces for applications such as :

! Seawater tanks, channels and intakes.

! Manhole linings.

! Sewage works and effluent plants.

! Chemical processing.

! Foundation waterproofing.

!

Jetties, piers and docks.

Advantages

! Low cost service life - excellent chemical and abrasion

resistance, does not support bacterial growth.

! Cost saving - primerless system.

! Added value system - acts as an impermeable waterproof

coating.

! Versatile usage - can be applied to green concrete by

brush, roller or spray.

Description

Nitocote ET402 is based on solvent-free epoxy resins,

modified with coal tar. It is supplied as a two pack material in

pre-weighed quantities ready for on-site mixing and use.

Nitocote ET402 is applied as a two coat application. It is

generally applied at a wet film thickness of 200 micron per

coat, but can be applied at greater thicknesses to suit

exposure conditions.

Properties

Colour : Black/Brown

Solids by weight : 100%

Pot life :at 25°C 75 minutes

at 40°C 40 minutes

Tack free time : 4 to 5 hours @ 23°C

Overcoating time : 6 hours at 35°C

3 hours at 45°C

Full cure : 4 days at 35°C

Curing Efficiency : 93%

(BS 7542)Water Absorption : <0.01%

(ASTM D570)

Bond Strength : Min 1N/mm²

(BS 1881 Pt 207)

Water Permeability : Nil 100% reduction in

(DIN 1048 P5) coated specimens.

Sea water immersion

resistance : Resistant

Chemical resistance :

Tests were carried out in accordance with ASTM D1308. Test

was conducted at room temperature of 23°C and specimens

were soaked in the solution for a period of 7 days.

Acids (m/v)*

Hydrochloric acid 18% : ExcellentSulphuric acid 25% : Very good

Nitric acid 10% : Very good

Phosphoric acid 10% : Very good

Alkalis (m/v)*

Ammonia 15% : Excellent



Nitocote ET402*


Preparation

All surfaces to be treated with Nitocote ET402 must be clean

and free from dust or loose material.

Concrete surfaces

All laitance must be removed by grit blasting, or other suitable

removal methods. The general standard of surface preparation

should be in accordance with ACI 503R-89, Chapter 5,

Paragraph 5.4.

Following the preparation of a concrete surface, care should

be taken to ensure that any surface irregularities are filled with

Nitomortar FC*† or Nitomortar FC(B)*†.

Metal surfaces

Any metal surfaces should be grit blasted to a bright finish,

meeting the requirements of Swedish Standard SA 2½ or equal.

Priming

Concrete surfaces

Priming is not required on properly prepared concrete surfaces

- see Preparation section.

Metal surfaces

Al l meta l surfaces should be coated immediately af ter

preparation. If this is not possible and to eliminate formation

of rust, prime the metal surfaces using Nitoprime 25*.

Mixing

The contents of the resin can should be thoroughly stirred to

disperse any possible settlement.

The entire contents of both the hardener and resin cans should

be poured into a suitable sized mixing vessel.

It i d d th t th t t i d t th

Application

A minimum 2 coat application is generally recommended to

ensure a full, unbroken coating is achieved.

Brush application

Once mixed, the material should be immediately applied,

ensuring that a continuous coating is obtained. The first coat

is applied to achieve a uniform coating with a wet film thickness

not less than 200 microns, and should be allowed to dry for at

least 6 hours at 35°C before the application of the second

coat.

The second coat should be applied between 6 hours and 4

days (at 35°C) after the application of the first coat, at 45°C

this will be reduced to 3 hours. The second coat should be

applied as above again achieving a wet film thickness not

less than 200 microns.

Spray application

Where large areas are to be coated, it is advisable to consider

spray application. Consult the local Fosroc office for further

details and recommendations.

Cleaning

Tools and equipment should be cleaned with Fosroc Solvent

102* immediately after use.

Hot weather working practices

Whilst the performance properties of Nitocote ET402 at

elevated temperatures are assured, application under such

conditions can sometimes be difficult. It is therefore suggested

that, for temperatures above 35°C, the following guidelines

are adopted as a prudent working regime:

(i) Store unmixed materials in a cool (preferably temperature

controlled) environment, avoiding exposure to direct

sunlight.



Nitocote ET402*

Repairing and overcoating

Any applications of Nitocote ET402 which have become

damaged can be readily overcoated.

The existing surface should well abraded, using a stiff wire

brush, or similar, to ensure that a good mechanical bond will

be achieved between the two layers.

Overcoating works can then proceed as for new work, always

ensuring that the prepared substrate is free from any moisture.

Limitations

- Nitocote ET402 should not be applied over other existing

coatings, but can be applied on top of itself (see above).

- For cold weather working (down to 5°C), it is recommendedthat materials are stored in a heated building and only

removed immediately before use. Accelerated heating

methods are not to be utilised under any circumstances.

- In contact with moisture/high humidity during cure, the colour

of the coatings will change to brown/red.

Technical support

Fosroc offers a comprehensive technical support service to

specifiers, end users and contractors. It is also able to offer on-

site technical assistance, an AutoCAD facility and dedicated

specification assistance in locations all over the world.

Estimating

Supply

Nitocote ET402 : 10 litre packs

Nitoprime 25 : 1 and 4 litre packs

Fosroc Solvent 102 : 5 litre packs

Coverage

Ni ET402 0 2/li @ 200 i f

Storage

Nitocote ET402 has a shelf life of 12 months, when stored in

warehouse conditions below 35°C.

Precautions

Health and safety

Nitocote ET402, Nitoprime 25 and Fosroc Solvent 102 should

not come in contact with skin or eyes, nor should they be

swallowed. Avoid inhalation of vapours and ensure adequate

ventilation.

Some people are sensitive to resins, hardeners and solvents.

Wear suitable protective clothing, gloves and eye/face

protection. Barrier creams such as Kerodex Antisolvent or

Rozalex Antipaint provide additional skin protection.

Should accidental skin contact occur, remove immediately with

a resin removing cream such as Kerocleanse Standard Grade

Skin Cleanser or Rozaklens Industrial Skin Cleanser, followed

by washing with soap and water - do not use solvent.

In case of contact with eyes, rinse immediately with plenty of

water and seek medical advice.

If swallowed seek medical attention immediately - do not

induce vomiting.

For further information, please consult the Material Safety Data

Sheet for Nitocote ET402.

Fire

Nitocote ET402 and Nitomortar FC are non-flammable.

Nitoprime 25 and Fosroc Solvent 102 are flammable. Do not

use near a naked flame.

Flash points

Nitoprime 25 : 55°C

F S l t 102 33°C



Nitocote ET402*

Additional Information

Fosroc manufactures a wide range of complementary

products which include :

! waterproofing membranes & waterstops

! joint sealants & filler boards

! cementitious & epoxy grouts

! specialised flooring materials

Fosroc additionally offers a comprehensive package of

products specifically designed for the repair and

refurbishment of damaged concrete. Fosroc’s ‘Systematic

Approach’ 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 consult

your local Fosroc office - as below.




Mix Design




Drawing

4 - dpf brochure

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