Fosroc Expocrete EC
A solvent-free, three-part epoxy concrete for fast, permanent horizontal reinstatement where high strength, abrasion and chemical resistance decide the job.
What is it?
A solvent-free, epoxy-based repair concrete supplied as a three-component pack (base, hardener, graded filler) with 10 mm coarse aggregate added on site.
Where is it used?
Horizontal surfaces carrying heavy traffic or impact: bridge decks, dam surfaces, foundations, slabs, highway and runway joints, and as a high-strength bedding material.
Why use it?
It hardens without shrinkage, cures even in damp or cold conditions, and develops far higher abrasion, impact and chemical resistance than a cementitious mortar.
How is it applied?
Prime the substrate with Nitoprime 25, then trowel the mixed epoxy concrete firmly into place while the primer is still tacky and finish with a steel trowel.
About Fosroc Expocrete EC
Fosroc Expocrete EC (formerly Nitocrete EC) is the material engineers reach for when an ordinary sand-cement or polymer-modified mortar simply will not survive the service conditions. It is a solvent-free epoxy concrete, delivered as three factory-proportioned parts — a liquid base, a liquid hardener and a graded fine filler — to which 10 mm down-graded granite aggregate is added on site. The result is a dense, trowellable concrete that behaves like a structural material rather than a patching compound, which is why it is written into repair specifications for bridges, dams, foundations, industrial slabs and the joints of highways and runways.
What sets it apart on an Indian site is its indifference to conditions that defeat cementitious repairs. It hardens without dimensional change, so patches do not lift or debond, and its cure is unaffected by humidity — it will set on a damp deck or in a cold early-morning pour where a water-based mortar would struggle. For contractors working to tight commissioning windows, that reliability, combined with rapid early strength, is the whole point: the repair goes back into service quickly and stays put under abrasion, impact and chemical attack.
The technical insight
The performance comes from the binder, not from water and cement. In a conventional repair the aggregate is glued together by hydrated cement, which shrinks as it dries and is vulnerable to acids and abrasion. Expocrete EC replaces that matrix with a cured epoxy resin: the base and hardener cross-link into a tough, chemically inert polymer that grips every aggregate particle. Because there is no water of convenience to evaporate, the material is dimensionally stable as it hardens, and because epoxy cure is a chemical reaction rather than hydration, ambient humidity and low temperature do not stall it. The graded filler and 10 mm aggregate give the mix the packing density and load-spreading skeleton of a concrete, so it carries wheel and impact loads, while the epoxy envelope is what delivers the 90 N/mm compressive strength at 7 days, the 20 N/mm flexural strength and the 3 N/mm bond to the parent concrete. The Nitoprime 25 primer is the other half of the mechanism — it seals the substrate and creates the resin-to-concrete bond that stops the repair delaminating under repeated loading.
Where it is used
- Reinstating spalled or defective concrete on bridge decks and abutments
- Repairing abraded and impact-damaged dam surfaces and spillways
- Rebuilding load-bearing machine foundations and equipment plinths
- Patching heavy-duty industrial and warehouse floor slabs
- Reinstating joints in highways, concrete pavements and runways
- High-strength bedding for rails, bearings and heavy fixings
- Localised repairs in areas exposed to chemical spillage or aggressive traffic
- Reinstatement work on damp or low-temperature substrates where cementitious mortars are unreliable
Key advantages
- Solvent-free formulation, suitable for enclosed and occupied structures with adequate ventilation
- Hardens without shrinkage, so repairs stay bonded and level under load
- Cure is unaffected by humidity and works on both damp and dry surfaces
- Develops strength rapidly, including at low temperatures, for fast return to service
- High compressive strength of 90 N/mm at 7 days, well above typical repair mortars
- Excellent abrasion and impact resistance for heavy-traffic horizontal surfaces
- Strong 3 N/mm bond to concrete when used with the Nitoprime 25 primer
- Non-flammable in the cured and mixed state
Limitations & considerations
- Designed for horizontal applications only; not intended for vertical or overhead patching
- Minimum layer thickness is 20 mm, so it is uneconomical for thin feather-edge repairs
- Short pot life of about 30 minutes at 35C demands disciplined batching and quick placement
- Requires site addition of 10 mm graded granite aggregate and correct weigh-batching to perform as specified
- Substrate must be primed with Nitoprime 25 and the concrete placed while the primer is still tacky
- Epoxy cost per unit is high relative to cementitious repair mortars, so it is best reserved for demanding conditions
Selection & best practice
Success with Expocrete EC is about preparation and timing. Clean the surface back to sound, roughened concrete by light scabbling or grit blasting, and remove all oil, grease, laitance and corrosion deposits; steam-clean or degrease oily areas. Prime with Nitoprime 25 mixed in the supplied proportions for a full three minutes, scrubbed well in without puddling, and re-coat absorbent substrates. Batch the base and hardener accurately, mix for about three minutes, then add the fine filler and 10 mm aggregate slowly using a forced-action mixer or slow-speed heavy-duty drill until fully homogeneous. Place while the primer is still tacky — normally 30 minutes to 4 hours after priming — trowel firmly into place at a minimum 20 mm thickness, and finish with a steel trowel without overworking. Respect the 30-minute pot life at 35C by mixing only what the crew can lay, and clean all tools immediately with Nitoflor Sol.
Specifications
| Product type | Solvent-free epoxy repair concrete (three-component + site aggregate) |
| Compressive strength | 45 N/mm (1 day), 70 N/mm (3 days), 90 N/mm (7 days) |
| Flexural strength | 20 N/mm at 7 days |
| Bond strength to concrete | 3 N/mm |
| Density of epoxy concrete | 2.20 – 2.40 kg/litre |
| Pot life | Approx. 30 minutes at 35C |
| Minimum thickness per layer | 20 mm |
| Coarse aggregate | 10 mm down-graded granite, added on site |
| Primer / pack / shelf life | Nitoprime 25; 13.5 L pack (without aggregate); 12 months below 35C |
Industry use cases
Bridges & Infrastructure
Reinstating spalled bridge decks, expansion-joint nosings and abutments that must carry traffic loads and resist abrasion immediately after repair.
Dams & Water Structures
Rebuilding eroded and cavitation-damaged concrete on spillways and dam faces, where humidity and damp substrates rule out cementitious mortars.
Highways & Airports
Repairing joints and defective concrete in pavements and runways, giving high early strength for short overnight or weekend possession windows.
Heavy Industry
Rebuilding machine foundations, equipment plinths and impact-loaded factory floors where chemical spillage and heavy traffic are routine.
Precision Bedding
High-strength bedding for rails, crane beams and heavy fixings that need a dimensionally stable, load-bearing seat.
Frequently asked questions
Is Expocrete EC the same as the old Nitocrete EC?
What compressive strength does it reach and how quickly?
Can I use it on a vertical wall or overhead soffit?
Does the pack include the aggregate?
Do I have to prime the concrete first?
What is the working time once mixed?
How we position Fosroc Expocrete EC
Expocrete EC is Space Arc’s specification-grade answer for horizontal concrete repair that must take punishment — heavy traffic, impact, abrasion or chemical exposure. Where the damage is on a vertical or overhead surface, or where a cementitious repair is more economical and adequate, we would steer you to the Fosroc Renderoc mortar family instead. Where the task is precision grouting under baseplates or machinery rather than surface reinstatement, the right Fosroc products are the Conbextra epoxy grouts (such as Conbextra EP10). Substrate priming here is done with Nitoprime 25 and tool cleaning with Nitoflor Sol, both of which we supply alongside. As an authorised Fosroc distributor and applicator across Delhi NCR and Pan-India, we can also cross-check the epoxy-repair route against comparable systems from Sika, MC-Bauchemie and Dr. Fixit when a project’s approved-vendor list calls for it.
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Authorised distribution, technical advice & professional application across Delhi NCR and Pan-India.