Lightweight Reinstatement Mortar.

epidermix 510 is a solvent-free, three component, epoxy mortar, formulated to be used in overhead and vertical applications where its lightweight fillers give the material its thixotropic characteristics

For repairs: 

  • To concrete, especially in vertical and overhead locations.
  • Where good chemical resistance is important in those areas.
  • Emergency repairs where rapid re-instatement is required.
  • Where an impermeable mortar is required.
Advantages
  • Use of lightweight fillers allows high build repairs in overhead and vertical applications.
  • High early strength ensures rapid reinstatement to be carried out.
  • Good chemical resistance to a range of corrosive materials.
  • Low permeability offers excellent protection to re-bar.
Surface Preparation

The existing concrete surfaces must be clean and mechanically sound. They must be free of dust, laitance and any foreign matter as well as cracked or loose stone.

Maximum bond strength is only achieved if main aggregate of existing concrete is exposed. This may be done by scabbling, grinding, abrasive blasting or manual chipping. All cracked or loose aggregate must be removed.

In repairing spalls all loose and friable material must be broken away. If damage has exposed reinforcing, this should be undercut and hammered back into position, if so directed by the engineer. If exposed reinforcing has rusted badly it should be cleaned by abrasive blasting. The existing concrete surface should ideally be dry. epidermix 344 will bond to green concrete. It will not, however, penetrate free water on the surface of any concrete.

Bonding / Priming

All epoxied re-bar is to be coated with dura.®rep ZR primer first which provides an unbroken finish.

The dura.®rep ZR primer is allowed to dry in accordance with the specific product datasheet.

Horizontal and vertical substrates should be primed using epidermix 326, a two-component epoxy primer.

The base and activator components need to be thoroughly mixed for 3 to 5 minutes to achieve uniform colour and consistency.

The mixed primer must be thoroughly applied to the substrate in its horizontal application to avoid puddles of material forming. The primer should be allowed to dry for 30 minutes to release its solvent. The primed surface should be tacky when applying theepidermix 510.

Typical Physical Properties
Compressive strength ASTM C109 38 Mpa at 7 days
Flexural strength 15 Mpa at 7 days
Tensile strengths ASTM C307 5 Mpa at 7 days
Pot life (at 20°C) 40 minutes
Pot life (at 35°C) 20 minutes
Initial cure 24 hours
Full cure 7 days
Relative density 1,16

Chemical Resistance

(Performance of epidermix 510 continually immersed at 20°C)
Citric acid 10% Very High
Tartaric acid 10% Very High
Hydrochloric acid 25% Very High
Sodium hydroxide 50% Very High
Diesel fuel/petrol 100% Very High
Sulphuric acid 10% High
Sugar solutions Saturated High
Lactic acid 10% High
Hydrocarbons 100% High
Phosphoric acid 10% High
Nitric acid 10% Medium
Acetic acid 5% Low
Mixing

Add the entire contents of the activator tin to the base component and, without splashing, stir with a flat paddle until an even streak-free mixture results.

This takes at least five minutes by hand. Once liquid components have been thoroughly mixed, the aggregate may be added. When using a mechanical mixer, place premixed aggregate, mixing until an evenly coated, wetted mortar results.

Use this method also if manual mixing is carried out in a drum. If manually mixing on a board, make a heap of the mixed aggregate, form a saucer in the centre of the heap; add the mixed liquid to the saucer. Fold the aggregate into the liquid taking care that no binder is lost. Mix the product following standard cement mortar mixing practice. All lumps must be broken down and an evenly wetted mortar obtained

Coverage

1 litre/m2/1mm thickness.

Application

Tightly pack the mixed epidermix 510 behind any exposed steel with a gloved hand. All other areas have to be applied with a wood float pressing the mortar firmly into place. A smooth finish can be achieved using a wetted steel float.

epidermix 510 can be applied 50 mm thick in a single application in overhead and vertical sections without using formwork.

Thicker sections can be built up in layers by scratching the surface of the first layer and applying a second layer some 8 to 24 hours later at an operating temperature of 20ºC dependant on the surface hardness.

Should the epidermix 510 begin sagging, it should be immediately removed and a thinner layer applied.

Re-prime with epidermix 326 between applications of epidermix 510.

Minimum application of the epidermix 510 is 10 mm. Never feather edge the product.

Cleaning

Uncured epidermix 510 can be removed from tools with abe® super brush cleaner immediately after use before the material has had time to cure. Hardened material can only be cleaned by mechanical means.

Model Specification

Three-component, high-build epoxy mortar for fast reinstatement of concrete in vertical and overhead applications where chemical resistance is required. 

The repair mortar will be epidermix 510, a three-component, high-build, epoxy mortar applied in accordance with the recommendations of a.b.e.® Construction Chemicals, including dura.®rep ZR primer for steel or epidermix 326 for concrete. The mortar will have a compressive strength of 38 MPa in seven days.

Temperature

As with all epoxies, the mixture may not be applied to substrates at a temperature lower than 5ºC. At ambient temperatures above 35ºC, working time and pot life will be drastically shortened.

Packaging

epidermix 510 is supplied in 7 litre yield kits.

Handling & Storage

This product has a shelf life of 24 months if kept in a dry cool place in the original packaging. In more extreme conditions this period might be shortened.

Health & Safety

Product safety information required for safe use is not included. Before handling, read product and safety data sheets and container labels for safe use, physical and health hazard information. The safety data sheet is available from your local a.b.e.® Construction Chemicals’ sales representative.

Important Note

This data sheet is issued as a guide to the use of the product(s) concerned. Whilst a.b.e.® Construction Chemicals endeavors to ensure that any advice, recommendation, specification or information is accurate and correct, the company cannot – because a.b.e.® has no direct or continuous control over where and how a.b.e.® products are applied – accept any liability either directly or indirectly arising from the use of a.b.e.® products, whether or not in accordance with any advice, specification, recommendation, or information given by the company.

Further Information

Where other products are to be used in conjunction with this material, the relevant technical data sheets should be consulted to determine total requirements. a.b.e.® Construction Chemicals has a wealth of technical and practical experience built up over years in the company’s pursuit of excellence in building and construction technology.

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