Nitocote EP500: Chemical and Abrasion Resistant Epoxy Liner System

Overview

Nitocote EP500 is a spray-applied, two-component epoxy mortar lining system designed to provide maximum chemical and abrasion resistance for the protection of concrete and similar substrates. It represents a new generation epoxy lining mortar based on the latest epoxy resin formulations and chemical technology, specifically engineered for demanding industrial applications.

Key Uses and Applications

Nitocote EP500 is ideal for rehabilitation and protective lining applications, including:

• 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 sewage collection and discharge structures
• Concrete structure protection - General rehabilitation of concrete surfaces requiring enhanced chemical and abrasion resistance

The product is particularly valuable in wastewater environments where sulphuric acid exposure presents a significant degradation risk.

Distinctive Advantages

Nitocote EP500 offers several significant performance and practical benefits:

• Enhanced chemical formulation providing increased resistance to a wide range of acids and alkalis, specifically sulphuric acid found in wastewater environments
• Resistant to biological attack - Unaffected by freeze-thaw attack, eliminating problems encountered with conventional water-based materials
• Superior bonding - Superior chemical and physical bond to virtually all substrates, whether dry or damp
• Labour cost reduction - No need for priming concrete surfaces, reducing labour costs and eliminating the risk of bad priming
• 100% solids content - Contains no solvent, providing environmental and application advantages
• Exceptional strength - Strengths in excess of most concrete substrates to which material is applied, with excellent resistance to abrasion and impact
• Water impermeability - Cured material provides a long-lasting waterproof barrier
• Prepacked convenience - Supplied prepacked for ease of mixing

Product Description and Composition

Nitocote EP500 is based on the latest epoxy resins and chemical technology with a two-component system featuring:

• High epoxy content ensuring the material is easy to spray
• Fine-graded fillers ensuring optimal flow and application characteristics
• Hydrophobic properties meaning chemical resistance is significantly enhanced
• Tortuous path design for sulphuric acid penetration resistance - the fine graded fillers ensure a tortuous path that impedes acid migration through the coating

Technical Specifications and Properties

Physical Properties

Property	Value
Compressive Strength	40 MPa @ 28 days
Pot Life	1 hour @ 25°C
Initial Hardness	4 hours @ 25°C
Minimum Back to Service Time	6 hours @ 25°C
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 when blocks are continuously immersed at 23°C for 28 days against:

• Bleach
• Detergent
• Sodium hydroxide (25%)
• Diesel fuel/petrol (100%)
• Sulphuric acid (50%)
• Nitric acid (25%) - Excellent with colour change
• Phosphoric acid (25%)
• Hydrochloric acid (25%)
• Toluene (100%)
• Kerosene (100%)

The enhanced epoxy formulation provides exceptional chemical resistance as its primary protective property, with particular strength against sulphuric acid environments typical of wastewater treatment facilities.

Abrasion Resistance

Nitocote EP500 demonstrates excellent resistance to abrasion and impact, providing durability against physical wear as a key protective property. This characteristic makes it suitable for high-traffic or mechanically demanding environments.

Design and Application Criteria

Application Thickness

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, the product should not be applied greater than 5mm per layer.

Surface Finish

If a smooth surface is required, the applied surface can be closed with a steel trowel after application.

Mixing and Application Instructions

Mixing Requirements

• Forced-action mixer essential - Mixing at slow speed (400/500 rpm) in a suitably sized drum using appropriate equipment
• Mixing time - Approximately 3 minutes until uniform consistency is reached
• Correct proportions - Supplied in the correct proportions to facilitate easy on-site mixing
• No part-pack mixing - Do not attempt to mix part packs as incorrect proportioning can severely affect the cured properties of the product
• No thinning - Do not thin components as solvents will prevent proper cure and result in blisters in the coating

Application Method

• Spray application - Nitocote EP500 is spray applied using specialised equipment
• Contractor trials essential - Contractors are strongly advised to carry out trials prior to proceeding with any contract
• Technical guidance available - Advice on suitable application equipment and application method is contained in the Spraying Nitocote EP500 Application Guidelines document available on request from Fosroc
• Temperature requirements - Should be applied only when both substrate temperature and ambient temperature are above 5°C
• Curing with moisture protection - Will continue to cure after application and subsequent immersion; however, the coating must be protected from "wash-out"/flowing water until it hardens (6 to 8 hours)

Surface Preparation

Prior to application, surfaces must be properly prepared:

• Clean the surface and remove any dust, unsound concrete, 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 repair locations to a depth of 3mm to avoid featheredging and provide a square edge
• Stop active leaks first - All active hydrostatic leaks must be stopped by the use of Vandex Plug, a rapid-setting mortar, prior to Nitocote EP500 application

Cleaning

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

Supply and Packaging Information

Pack Composition

Nitocote EP500 is supplied in 16-liter packs containing:

• Base component: 9.5 liters (product code: FC836688-9.5L)
• Hardener component: 6.5 liters (product code: FC836699-6.5L)

Ordering Information

• Made to order - Supplied in multiples of 55 × 16-litre packs
• Lead time - 21 to 28 days

Storage

• Store in dry conditions below 35°C in original, unopened packs
• Reduced shelf life at high temperatures

Coverage Rates

Application Thickness	Coverage Rate
2mm	8.0 m²/16 litre pack
5mm	3.2 m²/16 litre pack

Important Note: The coverage figures for Nitocote EP500 are theoretical. Due to wastage factors and the variety and nature of possible substrates, practical coverage figures will be reduced.

Limitations and Restrictions

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

Safety and Documentation

A Safety Data Sheet (SDS) is available from the Fosroc website and should be read carefully prior to use as application or performance data may change. In emergency situations, contact any Poisons Information Centre (phone 13 11 26 within Australia) or a doctor for advice.

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References

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