Nitofill LV: Low Viscosity Epoxy Crack Injection System

Product Overview

Nitofill LV is a high-strength, low viscosity dual cartridge epoxy crack-injection system manufactured by Fosroc, specifically designed for injecting cracks in concrete and masonry. The system is engineered to consolidate structures and exclude water and air from contact with reinforcement, making it ideal for structural crack repairs in both insitu and precast concrete elements.

Key Features and Advantages

Nitofill LV offers several distinctive advantages for concrete crack repair applications:

• Low viscosity design enables penetration into the finest cracks (down to 0.1 mm internally and 0.2 mm at substrate surface)
• Non-shrink formulation adheres with no loss of bond after curing
• High strength provides excellent structural performance
• Cost-effective and efficient crack repair solution
• Convenient disposable cartridge pack contains both base and hardener in the correct proportions
• System completeness includes all necessary components for crack injection
• Excellent bond to both concrete and masonry surfaces
• Ideal for small-scale on-site repairs and suitable for structural applications

Technical Specifications

Physical Properties

Nitofill LV exhibits temperature-dependent viscosity characteristics critical for application performance:

Property	Value
Colour	Clear/amber (when mixed)
Viscosity @ 10°C	250–450 cps
Viscosity @ 20°C	150–200 cps
Viscosity @ 30°C	50–100 cps
VOC Content	31 g/litre

Mechanical Properties

The cured Nitofill LV epoxy demonstrates strong structural performance:

Property	Value
Compressive Strength @ 1 day	57 MPa
Compressive Strength @ 3 days	66 MPa
Compressive Strength @ 7 days	83 MPa
Tensile Strength	>25 MPa
Flexural Strength	>50 MPa
Adhesion to Concrete	>2.5 MPa

Pot Life (Working Time)

Mixed Nitofill LV has limited working time that is temperature-dependent:

Temperature	Pot Life
10°C	40 minutes
20°C	20 minutes
30°C	10 minutes

Chemical Resistance

Cured Nitofill LV epoxy provides excellent chemical resistance to:

• Oil, grease, and fats
• Most chemicals
• Mild acids and alkalis
• Fresh and sea water

For applications involving solvents or concentrated chemicals, consultation with Fosroc is recommended.

Crack Suitability and Design Criteria

Nitofill LV is specifically designed for fine crack repair applications:

• Minimum crack width capacity: 0.1 mm (internal cracks)
• Maximum crack width capacity: 0.2 mm at substrate surface
• Suitable for: Structural crack repairs in concrete and masonry
• Not suitable for: Cracks where continued movement is expected; flexible sealant should be considered as an alternative

Standards Compliance

Nitofill LV complies with AS 4020-2018 at an exposure level of 9,000 mm² per litre, as documented in AWQC Report 326461. Copies of the compliance report are available on the Fosroc website.

Application Requirements

Substrate Conditions

• Must be dry or saturated surface dry (SSD) concrete or masonry
• Cannot be injected into voids containing free water
• Any free water in cracks must be removed or allowed to dry before injection
• Surface preparation must remove oil, grease, free standing water, and loosely adherent material

Surface Preparation

• Light grinding of surfaces adjacent to cracks removes contamination and assists adhesion
• All dust must be removed
• Ideally, cracks should be ground to 5 mm depth to accept surface seal epoxy and assist Nitofill LV penetration

System Components and Product Codes

Primary Supply Formats

Component	Product Code
Nitofill LV (450ml twin cartridge)	FC344220-450ML
Nitofill LV Base (10 litre)	FC344214-10L
Nitofill LV Hardener (5 litre)	FC344216-5L
Nitomortar AP Base (2 litre)	FC320467-2L
Nitomortar AP Hardener (1 litre)	FC320468-1L
Fosroc Solvent 10 (4 litre)	FC600800-4L

Accessory Items

Accessory	Product Code
Nitofill LV Gun	FC344221-UNIT
Nitofill LV Flange	FC344222-UNIT
Nitofill LV Adaptor	FC344223-UNIT
Nitofill LV Static Mixer/Hose	FC344224-UNIT

Application Methods

Nitofill LV can be applied using three distinct methods:

1. Cartridge Gun Method

The most common approach for surface-mounted flanges, using the disposable 450ml dual cartridge pack with the hand-operated cartridge gun system.

2. Hand Pump Application

Alternative method using hand-operated (grease-gun type) pumps with small quantities mixed in correct 2:1 base-to-hardener ratio by volume, requiring a spiral type mixer for 3 minutes.

3. Proportioning Pump Application

Mechanical proportioning pumps deliver both components in the correct 2:1 ratio automatically. Nitofill LV is supplied in 15 litre kits (10 litres base & 5 litres hardener) for this application method.

Injection Procedure Overview

The Nitofill LV injection process involves:

1. Surface seal application: Nitomortar AP bonds injection flanges to substrate and seals crack faces
2. Flange installation: Positioned 200–500 mm apart depending on crack size
3. Resin injection: Injected through flanges until resin flows from adjacent flanges
4. Pressure release: Controlled via thumb release plate on cartridge gun
5. Through-wall cracks: Injected through alternate flanges on both sides where access permits
6. Slab cracks: Underside injection takes precedence over top-side injection

Mixing Ratio

Nitofill LV components are supplied in a 2:1 ratio by volume (base to hardener), ensuring proper chemical balance and performance when mixed correctly.

Storage and Shelf Life

• Shelf life: 3 years for the 450ml cartridge pack
• Storage conditions: Cool, dry environment in original, unopened packaging
• Temperature sensitivity: Shelf life may be reduced if stored at high temperatures and/or high humidity

Important Limitations

• Temperature rise: All epoxy systems develop exothermic reactions; mixed product must be applied immediately without bulk storage or resealing
• Movement restrictions: Should not be used for cracks where movement is expected to continue
• Water restriction: Must not be injected into voids containing free water
• Substrate requirement: Only for dry or saturated surface dry concrete and masonry

Cleaning and Safety

• All tools and equipment must be cleaned immediately after use with Fosroc Solvent 10
• A Safety Data Sheet (SDS) is available from the Fosroc website and should be read carefully prior to use
• Emergency contact: Contact any Poisons Information Centre or a doctor for advice

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References

• [1] Fosroc_Nitofill_LV_TDS.pdf
• [2] Fosroc_Nitomortar_AP_TDS.pdf
• [3] Fosroc_Conbextra_EP10_TDS.pdf