Nitocote EP500: Chemical and Abrasion Resistant Epoxy Liner System

Overview

Nitocote EP500 is a spray-applied, two-component epoxy mortar lining system designed specifically for providing maximum chemical and abrasion resistance to concrete and similar substrates. It represents a modern generation epoxy lining technology incorporating the latest epoxy resins and advanced chemical formulations, making it ideal for rehabilitation of challenging infrastructure applications.

Key Applications

Nitocote EP500 is particularly suited for:

• Manhole rehabilitation: Can be used in brick, block, and precast concrete manholes to provide a permanent impermeable, high-strength, monolithic lining to interior manhole walls
• Sewer and outfall lining: Protection of sewerage systems and similar structures exposed to aggressive chemical environments
• Wastewater environments: Specifically formulated to resist sulphuric acid found in waste water

Distinctive Advantages

The product offers several key benefits that distinguish it from alternative repair systems:

• Enhanced chemical resistance: The formulation provides increased resistance to a wide range of acids and alkalis, with specific emphasis on sulphuric acid resistance in wastewater environments
• 100% solids content: Contains no solvent, which is advantageous for spray application and environmental performance
• No priming required: Superior chemical and physical bond to virtually all substrates (dry or damp) eliminates the need for priming concrete surfaces, reducing labour costs and minimizing bad priming risks
• Resistant to biological attack: Protects against biodegradation in challenging environments
• Unaffected by freeze-thaw: Eliminates problems often encountered with conventional water-based materials
• Monolithic waterproof barrier: Cured material provides long-lasting protection

Technical Composition

Nitocote EP500 is formulated as a new generation epoxy lining mortar based on the latest epoxy resins with a high epoxy content and fine graded fillers. This composition ensures:

• Enhanced hydrophobic properties: The chemical resistance is significantly enhanced through improved water-repellent characteristics
• Tortuous path for acid penetration: The fine graded fillers create a complex pathway that resists sulphuric acid penetration
• Easy spray application: The material formulation facilitates efficient spraying while maintaining protective properties

Performance Properties

Physical and Mechanical Properties

Property	Specification
Compressive Strength	40 MPa @ 28 days
Pot Life	1 hour @ 25°C
Initial Hardness	4 hours @ 25°C
Back to Service Time	6 hours @ 25°C (minimum)
Full Cure	7 days @ 25°C
Adhesion to Concrete	>1 MPa substrate failure
Minimum Application Temperature	5°C

Note: Cure times will increase by a factor of 2 for each 10°C reduction in temperature.

Chemical Resistance Performance

Nitocote EP500 demonstrates excellent chemical resistance to a comprehensive range of substances when tested through continuous immersion at 23°C for 28 days:

Chemical	Concentration	Rating
Bleach	—	Excellent
Detergent	—	Excellent
Sodium Hydroxide	25%	Excellent
Diesel Fuel/Petrol	100%	Excellent
Sulphuric Acid	50%	Excellent
Nitric Acid	25%	Excellent (Colour Change)
Phosphoric Acid	25%	Excellent
Hydrochloric Acid	25%	Excellent
Toluene	100%	Excellent
Kerosene	100%	Excellent

Abrasion Resistance

Nitocote EP500 exhibits excellent resistance to abrasion and impact, providing durability against physical wear and mechanical stresses on the coating surface.

Supply Specifications

Pack Size and Composition

Nitocote EP500 is supplied in 16-litre packs with the following component specifications:

Component	Size	Product Code
Base Component	9.5L	FC836688-9.5L
Hardener Component	6.5L	FC836699-6.5L

The product is made to order and supplied in multiples of 55 × 16 litre packs with a lead time of 21 to 28 days.

Coverage Rates

Application Thickness	Coverage
2mm thick	8.0 m² per 16 litre pack
5mm thick	3.2 m² per 16 litre pack

Important Note: Coverage figures are theoretical. Due to wastage factors and the variety of possible substrates, practical coverage figures will be reduced.

Application Instructions

Design Criteria

Nitocote EP500 is spray applied generally in layers between 2mm and 5mm per layer, with a minimum total thickness of 2mm. To avoid sagging on overhead surfaces, do not apply greater than 5mm per layer.

Surface Preparation

Comprehensive surface preparation is essential:

• Clean the surface and remove dust, unsound concrete, oil, paint, grease, corrosion deposits, and algae
• Roughen the surface and remove laitance by light scabbling or grit-blasting
• Saw cut or cut back repair location extremities to a depth of 3mm to avoid featheredging and provide square edges
• Prior to application, all active hydrostatic leaks must be stopped using Vandex Plug, a rapid-setting mortar

Mixing Requirements

• Forced-action mixer is essential
• Mix at slow speed (400–500 rpm) in a suitably sized drum
• Recommended equipment: Ransom 140 × 600 M14 Helical mixing paddle with a heavy-duty 1600W mixer
• Mix continuously for approximately 3 minutes until uniform consistency is reached
• Do not thin components as solvents will prevent proper cure and result in blisters
• Do not attempt to mix part packs as incorrect proportioning severely affects cured properties

Spray Application

• Nitocote EP500 is spray-applied using specialized equipment
• Contractors are strongly advised to carry out trials prior to proceeding
• Technical guidance is provided in the "Spraying Nitocote EP500 Application Guidelines" document available on request from Fosroc
• Apply only when substrate temperature and ambient temperature are above 5°C

Post-Application Considerations

• If the coating becomes wet through immersion, rain, or dew, the surface must be mechanically prepared prior to subsequent overcoating
• Nitocote EP500 will continue to cure after application and subsequent immersion
• The coating must be protected from "wash-out"/flowing water until it hardens (6 to 8 hours)
• If a smooth surface is required, close the surface with a steel trowel

Cleaning

Nitocote EP500 should be removed from tools, equipment, and mixers with Fosroc Solvent 10 immediately after use.

Storage and Shelf Life

Nitocote EP500 should be kept in a dry store below 35°C in original, unopened packs. High temperatures may reduce shelf life.

Limitations and Restrictions

• Should not be used when temperature is below 5°C and falling
• Do not mix part packs under any circumstances
• Ambient and substrate temperatures will affect spray application and product film build characteristics
• If doubts arise concerning temperature or substrate conditions, consult Fosroc

Related Products

Nitocote EP500 is available as a spray-applied alternative to hand-applied Nitomortar EL-HB for lining concrete structures, providing contractors with flexible application options.

Safety and Documentation

A Safety Data Sheet (SDS) is available from the Fosroc website. In emergencies, contact any Poisons Information Centre (phone 13 11 26 within Australia) or consult a doctor for advice.

References

• [1] Fosroc_Nitocote_EP500_TDS.pdf
• [3] Fosroc_Nitomortar_EL-HB_TDS.pdf