Epoxymortar

Epoxymortar is a cementitious repair and bonding material in which an epoxy resin system is used as part of the binder. It combines a two-component epoxy resin (resin and hardener) with cementitious powder and often graded aggregates to form a dense, high‑strength mortar. Epoxymortar offers improved adhesion, chemical resistance, and low porosity compared with conventional Portland cement mortars.

Composition and forms: Typical formulations use a two-component epoxy system mixed with Portland cement or lime and quartz sand or other aggregates. Some products are epoxy-modified cement mortars in which epoxy is integrated into a cementitious matrix. Epoxymortar products are used as tile adhesives, repair mortars, grout, or overlays, and may be supplied as ready-to-use compounds or as systems requiring on-site mixing.

Properties and curing: Epoxymortars exhibit high bond strength to concrete, brick, and steel; chemical and moisture resistance; low shrinkage; and good abrasion resistance. They generally cure at ambient temperatures, with cure times and pot life depending on the specific system and conditions. Proper surface preparation is crucial for achieving the intended bond.

Applications: Common applications include concrete repair and resurfacing, structural overlays, anchoring and grouting in industrial floors, chemical plants, and marine environments, as well as tile installations in wet or chemically aggressive areas.

Advantages and limitations: The principal advantages are superior adhesion, durability, chemical resistance, and reduced permeability. Limitations include higher material cost, more intensive surface preparation, potential health and safety considerations related to epoxy components, and the need for trained installers to ensure proper mixing and curing.

Safety and standards: Handling and mixing require appropriate personal protective equipment and ventilation. Epoxymortars should be used in accordance with manufacturer instructions and relevant national or international standards for epoxy resins and cementitious mortars.