Fosroc Nitobond SBA
Two-component, solvent-free epoxy adhesive engineered for bonding match-cast precast concrete bridge segments into structural, watertight joints.
What is it?
A two-component, solvent-free epoxy paste adhesive (base resin plus a black hardener supplied in pre-weighed quantities) formulated as Fosroc’s dedicated segmental bridge adhesive (SBA).
Where is it used?
Precast segmental bridge and flyover construction, metro viaducts and box-girder erection, plus gap-filling and grouting of starter bars and holding-down bolts where a structural paste is needed.
Why use it?
It bonds hardened concrete to hardened concrete at match-cast joints, transferring shear and creating a waterproof seal, while tolerating damp substrates and offering a workable open time for segment alignment.
How is it applied?
The pre-measured base and hardener are site-mixed to a uniform black paste, applied by trowel/spatula to clean prepared faces of both segments at roughly 1 mm, then the segments are pulled together with temporary post-tensioning before the open time elapses.
About Fosroc Nitobond SBA
Fosroc Nitobond SBA is a purpose-built segmental bridge adhesive: a two-component, solvent-free epoxy resin system made up of a base resin and a black hardener delivered in pre-measured quantities so that the correct ratio is achieved simply by combining the two packs on site. The product is the current name for what Fosroc previously sold as Nitobond PCA, Nitobond PC and Nitobond ECP, consolidated under a single brand following the company’s product re-branding. Its core job is to bond precast concrete bridge segments to one another, forming a joint that is both structural and waterproof. Beyond bridge erection it is also used as a gap-filling paste and for grouting starter bars, holding-down bolts and fixing items such as wheel stoppers in car parks, wherever a high-strength epoxy paste of non-sag consistency is required. For Indian infrastructure contractors building elevated corridors, metro viaducts and balanced-cantilever or span-by-span flyovers, Nitobond SBA sits in the specialised category of match-cast joint adhesives rather than general concrete bonding aids. It is deliberately distinct from Fosroc’s water-based Nitobond SBR latex and the general-purpose Nitobond EP epoxy: SBA is engineered for the geometry control, squeezability and joint integrity that segmental construction demands. Space Arc Engineering supplies and supports Nitobond SBA across Delhi NCR and Pan-India, including grade selection for the prevailing site temperature.
The technical insight
The defining characteristic of Nitobond SBA is its temperature-graded formulation. Fosroc offers it in grades designated 10-30, 25-40 and 30-55 (the high-temperature grade is also expressed as 35-55), where the numbers correspond to the substrate and ambient temperature window in degrees Celsius over which that grade is designed to be applied and cured. This matters enormously on a bridge site: an epoxy that is correctly thixotropic and workable at 15 degC in a winter morning would cure far too quickly and lose open time at 45 degC in peak Indian summer, while a hot-grade resin applied in cool conditions would gel too slowly and risk an under-cured joint. Selecting the grade that brackets the expected concrete surface temperature at the time of jointing is therefore a specification decision, not an afterthought. Fosroc notes that for the high-temperature 35-55 grade a tolerance of plus or minus 5 degC at either end does not alter product performance, which gives sites some operational latitude. The adhesive is moisture tolerant and can be applied to damp (though not running-wet) surfaces, it is non-flammable, and it develops strength fast enough to allow the post-tensioning sequence to proceed. The black colour of the hardener is functional as well as a mixing indicator: a uniform black with no streaks confirms the two components are homogeneously blended before application.
Where it is used
- Bonding match-cast precast segments in span-by-span and balanced-cantilever bridge and flyover erection
- Metro and elevated-corridor box-girder viaduct segment jointing
- Creating structural, waterproof joints between hardened concrete bridge units
- Gap-filling paste where a high-strength epoxy of non-sag consistency is required
- Grouting of starter bars and holding-down bolts
- Fixing wheel stoppers and similar fixtures in car parks and decks
- General structural bonding of hardened concrete to hardened concrete
Key advantages
- Solvent-free, two-component epoxy with pre-measured packs that remove on-site ratio error
- Excellent adhesion to concrete, steel and most common construction substrates
- Moisture tolerant – can be applied to damp surfaces, useful in humid Indian conditions
- Non-sag paste consistency holds position on vertical match-cast faces at the recommended thickness
- Long pot life and open time relative to a fast-curing epoxy, giving time to align and post-tension segments
- Available in overlapping temperature grades (10-30, 25-40, 30-55) to suit cold, moderate and hot site conditions
- Forms a joint that is both load-transferring and watertight
- Non-flammable in the mixed product
Limitations & considerations
- A specialised segmental bridge adhesive, not a general-purpose bonding slurry – over-specified and uneconomic for routine repair or plaster keying
- Grade must match the substrate/ambient temperature window; using the wrong grade compromises open time and cure
- Epoxy resins and curing agents can cause dermatitis on prolonged skin contact – gloves, eye protection and barrier creams are required
- Solvents must not be used for skin cleaning; Fosroc Solvent 102 used for tool cleaning is flammable (flash point 33 degC)
- Surface preparation is essential – faces must be clean, sound and suitably profiled to develop full bond
- Pot life and open time shorten as temperature rises, demanding disciplined site logistics in hot weather
- Shelf life is limited to about 12 months and storage must be dry and below 25 degC
Selection & best practice
Confirm the concrete surface temperature expected at the time of jointing and order the matching grade (10-30, 25-40 or 30-55). Prepare both match-cast faces so they are clean, sound and free of laitance, dust, oil and curing-compound residue; remove standing water though the surface may remain damp. Mix the full base and hardener packs together – never split a pack – until a uniform streak-free black paste is obtained, and respect the pot life for the site temperature. Apply at roughly 1 mm thickness to give the rated coverage of about 1 m2 per litre, bring the segments together and apply temporary post-tensioning before the open time elapses so that adhesive squeezes out evenly across the full joint, confirming complete contact. Clean tools with Fosroc Solvent 102 with adequate ventilation and no naked flame. Wear gloves, eye protection and protective clothing throughout, and store unopened packs dry, below 25 degC, using within the 12-month shelf life.
Specifications
| Product type | Two-component, solvent-free epoxy resin segmental bridge adhesive (SBA) |
| Components | Base resin + black hardener, supplied in pre-measured quantities for site mixing |
| Temperature grades | 10-30, 25-40 and 30-55 (high-temp grade also expressed 35-55) – figures are application/cure temperature range in degC |
| High-temp grade tolerance | 35-55 grade: +/- 5 degC at each end does not alter performance |
| Coverage | Approx. 1 m2 per litre at 1 mm thickness |
| Recommended application thickness | Approx. 1 mm at the joint |
| Moisture tolerance | Tolerant of damp surfaces; can be applied to damp substrates |
| Consistency | Non-sag paste at recommended thickness |
| Flammability | Mixed product non-flammable; Fosroc Solvent 102 (cleaner) flammable, flash point 33 degC |
| Pack / supply size | 7 litres per grade (Nitobond SBA 10-30, 25-40 and 30-55) |
| Shelf life | At least 12 months in unopened containers |
| Storage | Store in a dry place below 25 degC |
| Tool cleaning | Fosroc Solvent 102 |
| Former product names | Previously marketed as Nitobond PCA, Nitobond PC and Nitobond ECP |
Industry use cases
Highways & expressways
Bonding precast segments in span-by-span and balanced-cantilever flyover and viaduct erection on national and state highway corridors, forming watertight structural joints in the deck.
Metro rail & urban transit
Jointing precast box-girder segments on elevated metro viaducts where match-cast geometry and rapid post-tensioning cycles demand a graded, controllable epoxy.
Bridges & grade separators
Erecting segmental bridges and grade separators where each joint must transfer shear and remain impermeable over the structure’s service life.
Precast & infrastructure contractors
Casting-yard and site teams use the pre-weighed packs and grade-by-temperature system to standardise joints across long production runs in varied climates.
Structural fixing & grouting
Grouting starter bars and holding-down bolts and fixing wheel stoppers in car parks and decks where a high-strength, non-sag epoxy paste is required.
Frequently asked questions
Is Nitobond SBA the same as Nitobond SBR?
What do the grade numbers 10-30, 25-40 and 30-55 mean?
Can Nitobond SBA be applied to damp concrete?
What pack size and coverage should I plan for?
How should it be stored and what is the shelf life?
What are credible alternatives to Nitobond SBA?
How we position Fosroc Nitobond SBA
Nitobond SBA occupies a specialised niche in Fosroc’s range – it is the segmental bridge adhesive, distinct from the general-purpose Nitobond EP epoxy bonding agent and the water-based Nitobond SBR latex, which serve everyday concrete bonding and cementitious repair. Where a project simply needs a bonding bridge between old and new concrete, Nitobond EP or Nitobond SBR is usually the right and more economical choice; SBA is reserved for match-cast segment jointing where joint shear transfer and watertightness are critical. It commonly sits alongside Fosroc’s post-tensioning grouts and Conbextra range on the same viaduct package. The most direct competitor in the Indian market is Sika’s Sikadur-31 SBA family, which is likewise temperature-graded (for example S-04 IN, S-02 IN and S-09 IN for cool, moderate and hot ranges) and widely specified on metro and highway segmental works. Other structural-epoxy suppliers operating in India – MBS, STP and Pidilite’s Dr. Fixit – offer epoxy adhesives, but for dedicated segmental bridge adhesive duty the realistic specified options are Fosroc Nitobond SBA and Sika Sikadur-31 SBA. As an authorised Fosroc distributor and applicator, Space Arc Engineering helps Delhi NCR and Pan-India contractors select the correct grade for site temperature and supply it to schedule.
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