20+ Years Experience
Specialist Epoxy Resin Flooring
When it comes to durable and long-lasting flooring and repair solutions, epoxy resin mortar stands out as a reliable choice.
With its exceptional strength, chemical resistance, and versatility, epoxy resin mortar has gained popularity in various industries, including construction, manufacturing, and automotive.
This article explores the benefits and applications of epoxy resin mortar, delving into its unique properties that make it an ideal solution for both new installations and repair projects.
From industrial floors to commercial spaces and even residential applications, epoxy resin mortar offers a range of advantages that contribute to its growing reputation as a go-to material for durable and aesthetically pleasing surfaces.
Join us as we delve into the world of epoxy resin mortar and discover its transformative potential in enhancing the performance and appearance of various surfaces.
Epoxy resin mortar is a polymer-based bonding paste composed of epoxy resins, solvents, binder, mineral fillers, and other components.
This powerful mix provides an impermeable environment and a barrier that safeguards the reinforcing steel against corrosion, making it the go-to material for concrete repairs.
But what makes epoxy resin mortar so effective? The answers lie in its two key components: epoxy mortars and curing agents.
Epoxy mortars, such as Epicrete, are fast-curing materials that boast remarkable strength, being five times stronger than concrete.
These mortars require no priming, making them a convenient and efficient option for concrete repair. With a coverage rate of 2kg per mm per m2, Epicrete ensures that your repair job is not only strong but also economical.
In addition to their impressive strength, epoxy mortars offer excellent adhesion to a wide range of materials, including concrete, cement, and masonry.
This makes them suitable for various applications, from repairing expansion joints and coatings to providing a long-lasting finish for your concrete repair projects.
A curing agent is a chemical compound employed to accelerate the curing process of epoxy resin mortar.
By facilitating the hardening of the epoxy resin mortar, curing agents increase the material’s durability and ensure a long-lasting repair. Common curing agents include epoxy-based, polyurethane-based, and acrylic-based compounds.
While curing agents do offer numerous benefits, it is important to consider the potential drawbacks. The cost of a curing agent and the necessary equipment for application may be a factor to consider.
Additionally, it is crucial to be aware of any toxicity that may be present in the curing agent and to take appropriate safety precautions.
An essential step in achieving a successful and durable repair is the proper preparation of the concrete surface.
This involves inspecting the surface for damage, cracks, or other irregularities, eliminating any loose or deteriorated concrete, and creating a rough profile for the epoxy resin mortar to adhere to.
To ensure optimal results, we will explore the tools and techniques needed for each of these steps in the following subsections.
The first step in preparing the surface for repair is cleaning. Wire brushing or sweeping is usually adequate for this task, ensuring that the surface is free of dirt, debris, and contaminants.
For grease and oil removal, Watco Bio-D degreaser is the recommended cleaning product. In case the surface is damp during surface preparation, Watco Tack Coat should be applied as a primer to properly prepare the surface.
Having an arsenal of appropriate cleaning tools not only ensures a thorough job, but also saves time and effort. From wire brushes and sweepers to degreasers and primers, investing in suitable cleaning tools is crucial for a successful concrete repair.
Identifying and removing loose material from the concrete surface is essential for the longevity of the repair. Cracks, chips, and other signs of damage should be inspected to detect any loose material.
The most effective approach for removing loose material from a concrete surface is to utilise a power washer or to break it up with a hammer and chisel.
Once the loose material has been removed, use a wire brush to eliminate any remaining particles, followed by a rinse of the surface with water.
After all loose material has been removed, it is crucial to inspect the surface to ensure it is even and smooth.
An improperly prepared surface may compromise the adhesion of the epoxy resin mortar, leading to weak spots and fractures in the repair.
Grit blasting, also known as abrasive blasting, is an effective method for surface preparation in concrete repairs.
It involves propelling a concentrated stream of abrasive material against the surface to remove contaminants, coatings, and impurities. Grit blasting not only cleans the surface, but also creates a rough texture that promotes better adhesion of the epoxy resin mortar.
Safety is paramount when using grit blasting. Be sure to wear protective clothing, such as a face shield, gloves, and a respirator.
Additionally, ensure that the area is well ventilated and that the abrasive material is disposed of in an appropriate manner.
By properly utilising grit blasting, you can achieve a surface that is optimally prepared for epoxy resin mortar application.
With the surface properly prepared, it’s time to move on to mixing and applying the epoxy resin mortar. Achieving the perfect mix and mastering the application techniques are essential for a successful repair.
In the following subsections, we will explore the mixing process and various application techniques that will help you create a durable and long-lasting repair.
To mix epoxy resin mortar, it is necessary to blend two components together, typically in a ratio of 1:1 to 5:1, depending on the epoxy used.
A low-speed drill with a mixing attachment is required for this task.
Mixing should be done for 2-3 minutes, ensuring that the components are combined thoroughly and that the mixture is free of any lumps.
Achieving the perfect blend is crucial for a successful repair. By following the recommended proportions and mixing process, you will create a homogenous mixture that will provide excellent adhesion and durability for your concrete repair project.
Epoxy resin mortar can be applied using a trowel, brush, or roller for optimal results. It is important to ensure that the mortar is applied evenly and that all air bubbles are eliminated.
The general applications of epoxy resin mortar include structural repair, filling voids, crevices, and vents in driveways, patios, and plazas.
Proper surface preparation is essential for successful application. By incorporating the cleaning and removal techniques discussed earlier, you will create a smooth and even surface for the epoxy resin mortar to bond with, ensuring a long-lasting and durable repair.
Low temperatures can pose a challenge when working with epoxy resin mortar. The liquid and gel periods of the material are prolonged in colder environments, making it crucial to adjust the pot life and ensure proper curing.
In the following subsections, we will discuss the adjustments necessary for working with epoxy resin mortar in low temperatures.
In low temperatures, the pot life of epoxy resin mortar must be adjusted to account for the slower curing process.
This can be achieved by incorporating a catalyst or accelerator into the resin to accelerate the curing process. Certain resin/hardener combinations, such as cold temperature cure epoxy resins, are formulated to cure at temperatures as low as 35°F.
By adjusting the pot life of epoxy resin mortar in cold temperatures, you can ensure that the material cures properly and maintains its durability, even in less-than-ideal conditions.
To ensure proper curing of epoxy resin mortar in cold temperatures, it is recommended to use a curing agent or a heat source to maintain warmth during the curing process. The optimal temperature range for curing epoxy resin mortar is between 50 and 85 degrees Fahrenheit.
If the temperature falls below 70°F, the cure time will increase proportionally for every 18°F decrease.
By taking appropriate measures to maintain warmth and using cure agents when necessary, you can ensure a successful repair even in cold environments.
Epoxy resin mortar surfaces can be enhanced by adding anti-slip properties, which can help prevent slips and falls, making the surface safer for pedestrian use.
To achieve this, a variety of anti-slip additives can be mixed into the epoxy resin mortar, such as kiln-dried silica sand, pumice, colored quartz, and polymer grit.
The anti-slip additive should be mixed into the epoxy resin mortar prior to application on the surface, with the quantity determined based on the degree of anti-slip properties required. By incorporating anti-slip additives, you can create a safer and more functional surface for your concrete repair projects.
A well-maintained epoxy resin mortar surface not only looks great, but also lasts longer. Regular cleaning and maintenance are key to preserving the appearance and durability of your repair.
In the following subsections, we will explore the best practices for regular maintenance and cleaning techniques for epoxy resin mortar surfaces.
To ensure the longevity of epoxy resin mortar surfaces, regular cleaning and rinsing with clean water is essential. Additionally, daily sweeping in high-traffic areas and weekly sweeping in lower-traffic areas of the home with a dust mop is recommended.
Proper maintenance not only keeps the surface looking its best, but also prevents the buildup of dirt and debris that can compromise the material’s integrity.
Wet vacuuming or squeegeeing the floor after rinsing is also recommended to eliminate any residue. By following these regular maintenance practices, you can ensure that your epoxy resin mortar surface remains in top condition for years to come.
Various cleaning techniques can be employed to maintain epoxy resin mortar surfaces. Undiluted stain remover can be applied to the surface with a brush or cloth and allowed to sit for a few minutes before being wiped off with a damp cloth.
Pressure washing and sweeping with water jetting and vacuuming equipment can also be effective, provided that the pressure is not too intense and the nozzle is kept at least 6 inches away from the surface.
Epoxy solvents such as acetone or denatured alcohol can also be employed to clean epoxy resin mortar surfaces. By incorporating these cleaning techniques into your maintenance routine, you can ensure that your epoxy resin mortar surface remains clean and well-preserved.
Listed below are the most common questions asked regarding Epoxy Resin Mortar:
Epoxy resin mortar is a strong and reliable bonding agent used in many construction applications. It is made up of a combination of epoxy resins, solvents, binder, mineral fillers, and additives.
This adhesive offers superior adhesion to both porous and non-porous surfaces, providing a secure and durable seal for all your construction needs.11 Jun 2021.
The key difference between mortar and epoxy mortar is that the former uses cement as its bonding agent, whereas epoxy mortar uses epoxy resin to create a more adhesive material. As a result, epoxy mortar forms a strong and durable bond between bricks and blocks, providing a better seal against air and moisture.
Overall, the use of epoxy mortar is associated with a longer process, higher material and installation costs, as well as more complicated preparation before application, making it a less attractive option for many projects.
However, epoxy mortar is still a viable option for certain projects due to its superior strength and durability. It is often used in areas where a high level of strength and durability is required, such as in industrial and commercial settings.
Epoxy mortar is designed with a mix of epoxy resins and finely ground minerals, making it highly durable and moisture resistant. This combination makes epoxy mortar waterproof, giving it greater protection than traditional mortar or grout.
Epoxy resin mortar is a game-changer in the world of concrete repair, offering superior strength, durability, and versatility.
By understanding its properties, mastering the preparation and application techniques, and diligently maintaining the surface, you can confidently tackle any concrete repair project.
Embrace the power of epoxy resin mortar and transform your repairs into long-lasting and beautiful surfaces that stand the test of time.
We Aim To Reply To All Enquiries With-in 24-Hours