Fosroc Conbextra EP80E
A solvent-free, three-component free-flow epoxy resin grout engineered for high-strength, dynamically loaded baseplate and machinery grouting in 10-80mm gaps.
What is it?
A solvent-free, three-component (base resin + hardener + graded filler) free-flow epoxy resin grout from Fosroc’s Conbextra range, designed for filling gaps from roughly 10mm to 80mm under static and dynamic loads.
Where is it used?
Under machine baseplates, high-speed turbines, centrifuges, reciprocating and forging equipment, heavy crane and transporter rails, and for anchoring holding-down bolts – especially where vibration, impact or chemical spillage is present.
Why use it?
It delivers high compressive, tensile and flexural strength with early load-bearing capacity, low creep under sustained load, fatigue resistance against repetitive dynamic loads, non-shrink performance for full baseplate contact, and good resistance to oils, fuels, mild acids and alkalis.
How is it applied?
Surfaces are cleaned and primed (steel shot-blasted), leakproof formwork with a feeding hopper is set, the hardener is blended into the base, the graded filler is added and mixed to a uniform free-flowing consistency, then poured continuously from one side with a hydrostatic head to fill the gap without air entrapment.
About Fosroc Conbextra EP80E
Fosroc Conbextra EP80E is a member of the Conbextra EP family of solvent-free epoxy resin grouts, positioned as the free-flow grade for medium-to-deep gaps of approximately 10mm up to 80mm. Unlike cementitious grouts such as Conbextra GP, which rely on a Portland-cement matrix and develop strength through hydration, EP80E cures through an epoxy reaction. This gives it a denser, lower-porosity matrix with markedly higher tensile and flexural strength, far better fatigue endurance under repetitive dynamic loading, and broad resistance to oils, fuels, mild acids and alkalis – properties that ordinary cementitious grouts cannot match. It is supplied as a pre-weighed, three-component system comprising a base resin, a liquid hardener and a specially graded inert filler, all proportioned for whole-pack site mixing so that no additional aggregate or water is introduced. For Indian contractors, consultants and EPC plant teams, EP80E sits in the gap between the small-pour anchoring grades (such as the Conbextra EP10 family) and the deepest large-volume pours (EP120, EP150), making it a practical default for the kind of heavy rotating and reciprocating equipment foundations common across power, steel, cement, refining and process industries. Because it is non-shrink and free flowing, it ensures effectively complete contact between a machine baseplate and its foundation, which is essential for transmitting load uniformly and avoiding the localised stress concentrations that lead to baseplate rocking, bolt fatigue and premature foundation distress.
The technical insight
The engineering value of EP80E lies in its combination of high modulus, low creep and dynamic fatigue resistance. For vibrating machinery the grout is not merely a void filler – it is a structural load path that must carry cyclic stress for years without relaxing. Across the Conbextra EP free-flow range, hardened grout typically reaches around 78-82 N/mm2 compressive strength at one day and 95-105 N/mm2 by seven days (tested to ASTM C579), with tensile strength of the order of 15-16 N/mm2 (ASTM C307) and flexural strength around 25-30 N/mm2 (ASTM C580). The relatively high elastic modulus (roughly 10-12 kN/mm2 by ASTM C580 on the EP150 grade) keeps deflection low under load, while documented low-creep behaviour prevents progressive settlement of the baseplate. A practical caution applies to all epoxy grouts including EP80E: the resin’s coefficient of thermal expansion (on the order of 40 x 10-6 mm/mm/degC, several times that of concrete and steel) means deep, unrestrained or thermally cycled pours must be detailed with care – using shoulders, restraint and controlled lift thickness – to avoid differential-movement cracking. Exotherm and pot life are also temperature-sensitive; in Indian summer conditions, material should be stored cool, mixed in the planned pour quantity, and placed within its working time, which shortens significantly as ambient temperature rises.
Where it is used
- Precision grouting under high-speed turbine, compressor and generator baseplates
- Foundations for centrifuges, drop forges, presses and reciprocating machinery subject to vibration
- Bedding of heavy crane rails, transporter rails and gantry tracks
- Anchoring and encapsulating holding-down bolts and starter bars under dynamic load
- Grouting of machine bases in steelworks, refineries, electroplating and chemical plants where chemical spillage is likely
- Structural baseplate grouting where high early strength and rapid return to service are required
- Filling gaps of approximately 10-80mm where a free-flowing, pourable epoxy is needed for full contact
Key advantages
- High compressive, tensile and flexural strength with early strength gain for fast return to service
- Non-shrink, free-flowing formulation that ensures near-complete baseplate-to-foundation contact
- Excellent resistance to repetitive dynamic and impact loads with low creep under sustained loading
- Strong adhesion to both prepared concrete and steel substrates
- Good chemical resistance to oils, greases, fuels, fresh and sea water, and mild acids and alkalis
- Supplied as pre-weighed components for whole-pack mixing, reducing site batching errors
- Solvent-free system suitable for confined and indoor plant environments
Limitations & considerations
- High coefficient of thermal expansion versus concrete and steel; deep or thermally cycled pours need careful restraint and detailing to avoid cracking
- Must not be placed in unrestrained situations such as free-standing plinth edges without shoulders
- Pot life and exotherm are highly temperature-dependent and shorten sharply in hot Indian conditions
- More expensive than cementitious grouts, so best reserved for genuinely dynamic, chemical or high-strength duties
- Requires thorough surface preparation – shot-blasted steel and sound, clean, dust-free concrete – and leakproof formwork with a hydrostatic head
- Single-pour volume and lift thickness should be controlled; very deep sections may require multiple lifts or a deeper-gap grade
- Cure slows below about 15-20 degC and effectively stops below 5 degC; exact EP80E figures should be confirmed against the current Fosroc India TDS before specification
Selection & best practice
Always design EP80E pours to be restrained: provide shoulders or formwork edges so the grout is confined, and keep lift thickness within the manufacturer’s limit, using multiple lifts for deeper sections rather than one massive pour. Prepare substrates rigorously – cut concrete back to a sound, clean, oil-free base and shot-blast steel free of rust and mill scale, priming exposed steel as recommended. Build leakproof formwork with a feeding hopper to maintain a hydrostatic head, pour continuously from one side only to expel air, and have enough mixed material and operatives ready to complete the pour within pot life. In hot weather, store components in the shade, keep mixing equipment cool, and avoid midday placement. Treat the published strength and physical values as grade-typical for the Conbextra EP free-flow range and confirm the exact figures against the current Fosroc India technical data sheet for EP80E, or contact Space Arc Engineering, before finalising any structural specification.
Specifications
| Product type | Solvent-free, free-flow epoxy resin grout (three-component: base resin + hardener + graded filler) |
| Gap / section thickness | Approx. 10mm to 80mm |
| Compressive strength (grade-typical, ASTM C579) | ~78-82 N/mm2 at 1 day; ~95-105 N/mm2 at 7 days |
| Tensile strength (grade-typical, ASTM C307) | ~15-16 N/mm2 at 7 days |
| Flexural strength (grade-typical, ASTM C580) | ~25-30 N/mm2 at 7 days |
| Modulus of elasticity (grade-typical, ASTM C580) | ~10-12 kN/mm2 |
| Coefficient of thermal expansion (grade-typical, ASTM C531) | ~40 x 10-6 mm/mm/degC |
| Density of mixed grout (grade-typical) | ~2000-2050 kg/m3 |
| Pot life | Temperature-dependent; reduces significantly as ambient temperature rises (typically 1-2.5 hours) |
| Substrates | Prepared concrete and shot-blasted steel |
| Chemical resistance | Oils, greases, fuels, fresh and sea water, mild acids and alkalis |
| Mixing | Whole-pack site mixing with slow-speed power mixer; no added water or aggregate |
| Note on values | Strength/physical figures are typical for the Conbextra EP free-flow range; confirm EP80E-specific values against the current Fosroc India TDS |
Industry use cases
Power generation
Precision grouting beneath turbine, generator and BFP baseplates in thermal and combined-cycle plants, where vibration resistance and low creep keep alignment stable over long service intervals.
Steel and heavy industry
Bedding of crane rails, transporter tracks, drop-forge and press foundations in steelworks and rolling mills, where impact and repetitive dynamic loads demand fatigue-resistant epoxy grout.
Oil, gas and petrochemical
Grouting of pump, compressor and reciprocating-machinery skids in refineries and process plants, taking advantage of EP80E’s chemical resistance to spilled hydrocarbons and mild chemicals.
Cement and minerals
Foundations for crushers, mills, fans and centrifuges subject to continuous vibration, where non-shrink contact ensures uniform load transfer to the foundation.
Infrastructure and ports
Anchoring of holding-down bolts and baseplates for gantry cranes and material-handling equipment, where high early strength shortens downtime and speeds commissioning.
Frequently asked questions
Is Conbextra EP80E an epoxy or a cementitious grout?
What gap or thickness can EP80E be poured into?
What strengths does EP80E achieve?
Why choose EP80E over a cementitious grout for machinery foundations?
What surface preparation does EP80E need?
Where can I buy Fosroc Conbextra EP80E in India?
How we position Fosroc Conbextra EP80E
Within Space Arc Engineering’s Fosroc grouts and anchors portfolio, Conbextra EP80E occupies the mid-range of the free-flow epoxy grout ladder. It steps up from the small-pour anchoring grades such as Fosroc Conbextra EP10 (M) and sits below the deep-gap, large-volume grades Conbextra EP120 and EP150, while the cementitious Conbextra GP and high-flow Conbextra HF cover non-dynamic, more cost-sensitive baseplate and void-filling work. Choose EP80E when the duty is genuinely dynamic, chemically exposed or high-strength and the gap falls in the 10-80mm band; choose a cementitious grade when load is largely static and budget is the priority. Among credible alternatives available in India, comparable free-flow epoxy machinery grouts include Sika’s SikaGrout epoxy range and Master Builders Solutions (formerly BASF) MasterFlow epoxy grouts; for cementitious duties, Dr. Fixit (Pidilite) and STP (Shalimar) offer non-shrink precision grouts. Space Arc’s role is to specify and supply the correct Fosroc grade for the actual load case, gap and environment rather than defaulting to a single product, and to back it with application guidance and on-site support.
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