Nitomortar EL-HB: Epoxy Repair Mortar System

Product Overview

Nitomortar EL-HB is a hand-applied, trowel-finished, high build epoxy repair mortar consisting of three components designed for protecting concrete and similar substrates. The product features epoxy resins without solvents combined with a special blend of chemical resistant fillers, making it an ideal material for long-lasting concrete rehabilitation.

Composition & System

Nitomortar EL-HB is supplied as a 3-component epoxy mortar system in 9 litre packs containing:

• Resin (Part A): FC342250-1.77L (1.77 litres)
• Hardener (Part B): FC342255-920ML (920 millilitres)
• Fillers: FC342260-10.4KG (10.4 kilograms)

The three-component formulation provides correct proportions for on-site mixing and should not be partially mixed, as incorrect proportioning can severely affect the cured properties of the product.

Key Advantages

• Chemical Resistance: Unaffected by a wide range of acids, alkalis and industrial chemicals
• Superior Bonding: Achieves superior chemical and physical bond to virtually all substrates, whether dry or damp
• Strength: Develops strengths in excess of the concrete to which material is applied
• Durability: Excellent resistance to abrasion and impact, unaffected by freeze-thaw attack
• Waterproofing: Cured material provides a long lasting waterproof barrier
• Safety: No harmful vapours present
• Consistency: Thixotropic consistency for easy hand placement when mixed
• Non-Sag Properties: Makes it suitable for overhead and vertical applications

Physical Properties

Property	Specification
Compressive Strength (7 days)	>45 MPa
Pot Life	45 minutes @ 20°C
Initial Hardness	4 hours @ 20°C
Full Cure	7 days @ 20°C
Minimum Application Temperature	5°C
Thixotropic Consistency	After ~5 minutes continuous mixing until gel-like consistency achieved

Design Criteria & Thickness Specifications

Horizontal Applications

Nitomortar EL-HB can be applied in sections up to 100mm thickness in horizontal locations.

Vertical Applications

The material should be "built-up" to a maximum thickness of 30mm in vertical applications.

Minimum Thickness

The material should not be applied at less than 5mm thickness.

Greater Thicknesses

Greater thicknesses than those specified above can be achieved by the application of subsequent layers. However, Nitomortar EL-HB is designed for small pocket type repairs only, with total build and volume dependent on the size and geometry of the repair.

Chemical Resistance Performance

When continually immersed at 23°C for 28 days, Nitomortar EL-HB demonstrates excellent resistance to:

• Bleach
• Detergent
• Sodium hydroxide (25%)
• Diesel fuel/petrol (100%)
• Sulphuric acid (25%)
• Phosphoric acid (25%)
• Hydrochloric acid (25%)
• Toluene (100%)
• Kerosene (100%)

Nitric acid (25%) shows colour change but remains excellent in performance.

Applications

Nitomortar EL-HB is ideal for:

• Patch repairs to manholes, sewers and general concrete structures
• Overhead patching and resurfacing
• Vertical patching and resurfacing
• Horizontal patching and resurfacing
• Protection of concrete and similar substrates
• Concrete rehabilitation

The product is suitable for both dry and damp surfaces.

Preparation Requirements

Surface Preparation

• Clean the surface and remove any dust, unsound material, plaster, oil, paint, grease, corrosion deposits or algae
• Roughen the surface and remove any laitance by light scabbling or gritblasting
• Saw cut or cut back the extremities of the repair locations to a depth of at least 5mm to avoid feather-edging
• Break out the complete repair area to a minimum depth of 5mm up to the sawn edge

Active Hydrostatic Leaks

Prior to application of Nitomortar EL-HB, all active hydrostatic leaks must be stopped using Vandex Plug, a rapid setting mortar.

Priming

Nitobond EP primer should be applied immediately after the mixing process has been completed by brush application to prepared surfaces. The primer can be applied on dry or damp (SSD) substrates. Nitomortar EL-HB must be applied to the primer-coated substrate within 90 minutes at 20°C while the Nitobond EP is still tacky. If the Nitobond EP primer is allowed to dry, a second coat will be required.

Mixing Instructions

The mixing process involves careful integration of all components:

1. Stir components separately: The hardener and base components should be stirred separately before mixing to disperse any settlement
2. Combine components: Pour the entire contents of the hardener tin into the base tin
3. Initial mixing: Mix using a suitable slow-speed electric drill and mixing paddle for 2 minutes until a fully uniform colour is obtained
4. Scrape sides: Scrape the sides of the tin
5. Continue mixing: Mix for a further 2 minutes
6. Add filler: Remove the filler component bag and thoroughly mix all contents of the resin (part A) and hardener (part B) in the original container
7. Achieve gel-like consistency: Mix continuously for approximately 5 minutes until a uniform colour and gel-like consistency has been reached
8. Add aggregate: Add the filler aggregate and continue mixing, ensuring that the aggregate is thoroughly wetted out with resin

Important: Do not attempt to mix part packs, as incorrect proportioning can severely affect the cured properties of the product.

Application Instructions

1. Timing: Apply Nitomortar EL-HB to the primer-coated substrate within 90 minutes at 20°C while the Nitobond EP is still tacky
2. Hand Placement: Apply with gloved hand and work the material firmly into the substrate surface
3. Build-up: Build up to the desired substrate level
4. Trowel Finishing: Finish off with a steel trowel
5. Surface Finish: To close the surface to a smooth finish, lubricate the trowel with water

Application Temperature Limitations

• Nitomortar EL-HB should be applied only when the substrate temperature and the ambient temperature is above 5°C
• Should not be used when the temperature is below 5°C and falling

Important Restrictions

• DO NOT thin components as solvents will prevent proper cure

Cleaning & Maintenance

Nitomortar EL-HB and Nitobond EP should be removed from tools, equipment and mixers with water or Fosroc Solvent 10 immediately after use.

Coverage Data

Product	Coverage
Nitomortar EL-HB	Each 9 litre pack covers approximately 0.9m² at 10mm thick
Nitobond EP	4-5 m²/litre

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

Storage & Shelf Life

Nitomortar EL-HB has a shelf life of 5 years if kept in cool, dry conditions in the original, unopened packs. If stored at high temperatures and/or high humidity conditions, the shelf life may be reduced.

Limitations & Restrictions

• Not for large areas: Nitomortar EL-HB is designed for small pocket type repairs only
• No partial packing: Do not mix part packs under any circumstances
• Temperature control: Should not be used when the temperature is below 5°C and falling
• Professional consultation: If any doubts arise concerning temperature or substrate conditions, contact Fosroc

Comparison with Other Products

Nitomortar EL-HB is recommended for repairs requiring thicknesses greater than those specified for Nitomortar 908. For concrete structures requiring lining with an epoxy mortar, Nitocote EP500 is available as a spray-applied alternative to hand-applied Nitomortar EL-HB.

Related Products in System

• Nitobond EP: Essential primer for substrate preparation (1.5 and 6.0 litre packs)
• Fosroc Solvent 10: For cleaning tools and equipment (4 and 20 litre pails)

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References

• [1] Fosroc_Expoband_F_TDS.pdf
• [2] Fosroc_Nitomortar_EL-HB_TDS.pdf
• [3] Fosroc_Nitomortar_908_TDS.pdf
• [5] Fosroc_Nitomortar_903_TDS.pdf