Fosroc Conbextra EP150E
Extended-working-time, free-flow epoxy resin grout for deep-pour machine foundations under heavy static and dynamic loading.
What is it?
A solvent-free, three-component epoxy resin grout (base resin, liquid hardener and graded inert filler) formulated for free-flow grouting of gaps from approximately 10 mm up to 150 mm. The ‘E’ denotes an extended-working-time grade built for large-volume pours, deep sections and hot Indian ambient conditions.
Where is it used?
Under the baseplates of reciprocating and rotating machinery, turbines, compressors, crane and transporter rails, presses and drop forges, and in chemically aggressive plant such as refineries, steelworks and electroplating units where cementitious grout would not survive.
Why use it?
It develops very high compressive, tensile and flexural strength, resists repetitive dynamic load and creep, is non-shrink for full baseplate contact, and tolerates oils, fats, mild acids/alkalis and chemical spillage that attack cementitious grouts.
How is it applied?
Whole-pack mixed on site (no site-batching of fillers), then placed by gravity free-flow from one side using a hopper or trough to maintain a hydrostatic head, eliminating air entrapment in deep gaps.
About Fosroc Conbextra EP150E
Fosroc Conbextra EP150E is the extended-pot-life member of the Conbextra EP150 free-flow epoxy grout family, engineered for situations where ordinary cementitious or fast-set epoxy grouts run out of working time before a deep or wide gap is filled. It is a solvent-free, three-component system: a base epoxy resin, a liquid hardener and a separately packed, specially graded inert filler. All three are supplied pre-proportioned for whole-pack mixing, so the installer never has to judge resin-to-filler ratios on site and nothing else should be added. Once combined, the material flows like a thick liquid and self-levels into the gap between a machine baseplate and its concrete foundation, producing a dense, non-shrink, load-bearing bedding layer.\n\nThe product occupies the deep-pour, heavy-load end of Fosroc’s grout portfolio. Where the thin-gap epoxy grade Conbextra EP10 is intended for joints and honeycombs in the 0.25-9 mm range, EP150E covers gaps from roughly 10 mm to 150 mm in a single pour. That makes it the natural choice for large dynamic machinery whose baseplates demand a thick, gap-filling bed rather than a skim. The ‘E’ suffix matters in the field: a longer working time lets a crew place a large batch, encourage lateral flow with chains in inaccessible widths, and complete the pour before the resin gels, even when site temperatures climb into the high thirties Celsius that are common across Delhi NCR, Gujarat and southern India for much of the year.\n\nFor a consultant or plant engineer, EP150E answers a specific brief: a grout that will not shrink away from the baseplate, will carry vibrating and reciprocating loads for the life of the plant, and will shrug off the oils, greases and mild chemical spillage found around compressors, presses and process equipment. Space Arc Engineering supplies it as an authorised Fosroc distributor and applicator, with technical support on substrate preparation, formwork and placement across Delhi NCR and Pan-India.
The technical insight
The defining engineering property of EP150E is not raw strength alone but its behaviour under sustained and cyclic load. Epoxy grouts in this family are specified for low creep under sustained loading and resistance to repetitive dynamic loads, which is precisely why they are bedded under reciprocating and rotating equipment rather than a cementitious grout that would micro-crack and lose preload over time. The cured matrix is effectively impermeable (water absorption below 0.30% to ASTM C413) and exhibits very low linear shrinkage (around 0.019%, well under the 0.03% ASTM C531 ceiling), so the baseplate stays in full, gap-free contact and bolt preload is retained. The trade-off engineers must design around is thermal: epoxy has a far higher coefficient of thermal expansion than steel or concrete and generates an exotherm on cure that grows with pour volume, so unrestrained shoulders and large exposed surfaces should be minimised and cyclic-temperature exposure managed to avoid cracking and peeling. This is the technical reason EP150E pours are detailed with restrained shutters and minimised exposed epoxy faces rather than left open.
Where it is used
- Free-flow grouting of baseplates under reciprocating machinery, compressors and pumps
- Bedding of high-speed turbines, centrifuges and rotating equipment subject to dynamic load
- Grouting of heavy crane rails, transporter rails and gantry track baseplates
- Anchoring of presses, drop forges and testing equipment with deep baseplate gaps (10-150 mm)
- Chemical-resistant machine foundations in refineries, petrochemical and process plants
- Equipment bedding in steelworks, electroplating and effluent areas exposed to spillage
- Large-volume and deep-section pours requiring extended working time in hot ambient conditions
Key advantages
- Non-shrink cure ensures complete, gap-free contact and bond beneath the baseplate
- Very high compressive (>100 N/mm2 at 7 days), tensile and flexural strength for heavily loaded foundations
- Low creep and high resistance to repetitive dynamic and vibrating loads
- Extended pot life suits large-volume pours, deep gaps and high site temperatures
- Free-flowing, self-levelling consistency reaches inaccessible sections without vibration
- Solvent-free three-part system pre-proportioned for simple whole-pack mixing
- Strong adhesion to both concrete and steel substrates
- Good resistance to oils, greases, fats, fresh and sea water, and mild acids/alkalis
Limitations & considerations
- Must not be placed in unrestrained situations (e.g. exposed plinth shoulders) or cracking may develop
- High coefficient of thermal expansion versus steel/concrete; cyclic temperature exposure can cause cracking or peeling of exposed faces
- Exotherm rises with pour volume, requiring care on very large single pours
- Cure rate slows below 20 C and needs ambient above 5 C to complete
- Significantly higher material cost than cementitious grouts such as Conbextra GP
- Requires shot-blasted, oil-free steel and a sound, clean, dry concrete substrate
- Whole-pack mixing only; partial-pack batching and addition of other materials are not permitted
- Solvent-based cleaner (Fosroc Solvent 102) is flammable and resins may cause skin sensitisation, demanding correct PPE
- 12-month shelf life when stored dry around 25 C
Selection & best practice
Cut concrete back to a sound base and remove all dust, oil and standing water; blow bolt pockets clean. Shot-blast steel baseplates free of rust and mill scale, priming cleaned steel with Nitoprime 28 where specified. Build leak-proof formwork and feed the mixed grout from one side only through a hopper or trough to maintain a continuous hydrostatic head, eliminating air pockets in deep gaps. Mix complete packs only with a slow-speed power mixer and pour each batch within the pot life, planning enough labour to finish large pours before gel. In temperatures above 35 C, store unmixed components in the shade, keep equipment cool, and avoid placing in direct midday sun. Minimise exposed epoxy shoulders and keep grout restrained to control thermal-movement cracking.
Specifications
| Product type | Free-flow epoxy resin grout (high strength, non-shrink) |
| Chemical system | Solvent-free, three-component: base resin + liquid hardener + graded inert filler |
| Mixing | Whole-pack only; no addition of other materials |
| Gap / section thickness | Approx. 10 mm to 150 mm |
| Compressive strength (ASTM C579) | >100 N/mm2 at 7 days (cured at 35 C) |
| Tensile strength (ASTM C307) | 16 N/mm2 at 7 days |
| Flexural strength (ASTM C580) | >26 N/mm2 at 7 days |
| Linear shrinkage (ASTM C531) | approx. 0.019% (<0.03%) |
| Water absorption (ASTM C413) | <0.30% |
| Pot life | approx. 150 min at 24 C / 105 min at 35 C |
| Yield | approx. 46 litres per 92 kg pack |
| Chemical resistance | Oils, greases, fats, fresh & sea water, mild acids/alkalis |
| Application temperature | 5 C to 25 C without special precautions; cure slows below 20 C |
| Shelf life / storage | 12 months in dry conditions at approx. 25 C |
Industry use cases
Power & process plants
Bedding turbine, compressor and pump baseplates where vibration and sustained load demand a low-creep, non-shrink epoxy bed rather than cementitious grout.
Heavy manufacturing & forging
Anchoring presses, drop forges and testing rigs with deep baseplate gaps that need an extended-pot-life pour to fill completely in one operation.
Refineries & petrochemicals
Machine foundations in oil- and chemical-laden environments where spillage resistance and adhesion to steel are critical.
Steel & metal finishing
Equipment bedding in steelworks and electroplating areas exposed to mild acids, alkalis and process water.
Material handling & ports
Grouting heavy crane rails and transporter track baseplates subject to repetitive dynamic loads.
Frequently asked questions
Is Conbextra EP150E a cementitious or epoxy grout?
What gap thickness can EP150E fill in one pour?
What does the ‘E’ mean compared with standard EP150?
How strong is the cured grout?
What is the pot life and how much does a pack yield?
Can it be used in chemically aggressive or wet environments?
How we position Fosroc Conbextra EP150E
Conbextra EP150E sits at the heavy-duty, deep-pour end of Fosroc’s grouting range. Within the Fosroc family it complements the thin-gap epoxy grade Conbextra EP10 (0.25-9 mm joints and honeycombs) and the general-purpose cementitious grout Conbextra GP, which remains the economical default for routine baseplate and pocket grouting where chemical attack and severe dynamic loading are not in play. Choose EP150E specifically when the foundation carries vibrating or reciprocating machinery, the gap is deep, the environment is chemically aggressive, or a long working time is needed for a large hot-weather pour; choose a cementitious grade when those drivers are absent and cost is the priority. Among competing brands an Indian specifier will credibly evaluate Sika (Sikadur-42 series epoxy grouts), MBCC/Master Builders Solutions (MasterFlow epoxy grouts), STP and Dr. Fixit for analogous high-strength epoxy bedding. As an authorised Fosroc distributor and applicator, Space Arc Engineering recommends EP150E where its dynamic-load, low-creep and chemical-resistance profile genuinely earns its premium, and will value-engineer to a cementitious or thin-gap alternative where the duty does not require a deep-pour epoxy.
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