Fosroc Expocrete EC
A three-component, solvent-free epoxy repair concrete that reinstates horizontal surfaces with abrasion, impact and chemical resistance conventional mortar cannot match.
What is it?
A solvent-free, three-part epoxy repair concrete (resin base, hardener and graded fine filler) that is combined on site with 10 mm-down graded aggregate to rebuild worn or damaged horizontal concrete.
Where is it used?
Industrial floors, loading bays, expansion and construction joints in highways, bridge decks, dam surfaces, foundations, runways and machine bedding where mechanical and chemical loads are severe.
Why use it?
It cures unaffected by humidity, hardens fast even at low temperatures and develops far higher compressive, abrasion and impact strength than a cementitious patch, cutting downtime on trafficked areas.
How is it applied?
Prepare and prime the substrate with Nitoprime 25, blend base and hardener, fold in fine filler and coarse aggregate to a trowellable mix, then place min. 20 mm thick and steel-trowel to finish.
About Fosroc Expocrete EC
Expocrete EC is Fosroc’s high-strength epoxy repair concrete for horizontal reinstatement where an ordinary sand-cement or polymer-modified patch simply will not survive. It arrives as a three-component system, a liquid resin base, a liquid hardener and a pre-graded fine filler, to which the applicator adds 10 mm-down graded granite aggregate at site in a fixed weight ratio. Blended together, these produce a dense, trowellable concrete that bonds tenaciously to a primed substrate and sets into a monolithic repair capable of taking forklift, HGV and impact loading almost immediately. Contractors who worked with the older Fosroc catalogue will recognise it as the product formerly sold as Nitocrete EC.
What sets an epoxy concrete apart from a cement repair is the binder. Because the matrix is a thermosetting epoxy rather than hydrated cement, curing does not depend on moisture and is not derailed by damp substrates or humid site conditions, a genuine advantage during the Indian monsoon or inside wash-down areas. The hardened material is dimensionally stable, non-flammable and highly resistant to abrasion, oils and a broad range of chemicals. Space Arc supplies Expocrete EC as an authorised Fosroc distributor and applicator across Delhi NCR and Pan-India, and can advise on primer selection, aggregate sourcing and thickness build-up for your specific floor or joint detail.
The technical insight
The performance comes from load-sharing between a rigid epoxy binder and a high proportion of graded aggregate. The base-to-hardener-to-filler-to-coarse ratio (roughly 4.5 : 2.1 : 20.8 : 30 by weight) is deliberately aggregate-heavy so the cured mass behaves like a resin-bound concrete rather than a resin mortar: the aggregate skeleton carries compression while the epoxy locks it together and grips the substrate. That structure is why Expocrete EC reaches 45 N/mm2 in just one day and climbs to 90 N/mm2 by seven days, roughly double a good structural concrete, with 20 N/mm2 flexural strength and a 3 N/mm2 bond to the parent concrete. Priming with Nitoprime 25 is not optional: the primer wets the substrate and is overlaid while still tacky, so the epoxy concrete keys chemically into the primer film instead of merely resting on the surface. Applied at a minimum 20 mm per layer on a horizontal plane, it develops the confined thickness the binder needs to build strength and resist point loads.
Where it is used
- Deep reinstatement of spalled or worn industrial and warehouse floor slabs
- Repair of construction and expansion joint arrises in highways and pavements
- Rebuilding damaged bridge deck and dam surface concrete
- Foundation and plinth repairs subject to impact and vibration
- Concrete runway and hardstanding reinstatement
- High-strength bedding material for machine bases and rail sections
- Restoration of loading-bay and ramp edges taking forklift and HGV traffic
- Patch repair of chemically attacked floors in process and wash-down areas
Key advantages
- Solvent-free formulation, safe for enclosed and food-adjacent areas
- Very high compressive strength, 90 N/mm2 at 7 days
- Curing unaffected by humidity, works on damp or dry surfaces
- Rapid hardening even at low ambient temperatures
- Excellent abrasion, impact and chemical resistance
- Dimensionally stable hardening with minimal shrinkage
- Fast return to traffic, 45 N/mm2 already at one day
- Non-flammable in the cured and mixed state
Limitations & considerations
- Designed for horizontal work only, not for vertical or overhead surfaces
- Requires a minimum 20 mm layer thickness, unsuitable for thin feather-edging
- Short 30-minute pot life at 35 degrees C demands disciplined batching
- Coarse aggregate is added on site, so mix quality depends on aggregate grading and workmanship
- Mandatory Nitoprime 25 priming adds a step and cure-window constraint
- Epoxy binder makes it a higher-cost option than cementitious repair concrete
Selection & best practice
Clean the substrate back to sound, laitance-free concrete by light scabbling or grit blasting, and remove all oil and grease by steam cleaning or degreaser. Prime with Nitoprime 25, scrubbed well in with no puddling, and place the Expocrete EC while the primer is still tacky, normally 30 minutes to 4 hours after priming. Stir base and hardener separately to disperse settlement, combine and mix for about 3 minutes, then add fine and coarse aggregate slowly using a forced-action mixer or slow-speed heavy-duty drill until fully homogeneous. Because pot life is only about 30 minutes at 35 degrees C, batch to what the crew can place, and lay in layers of at least 20 mm. Trowel firmly into the tacky primer, finish with a steel trowel, and do not overwork the surface. Clean tools immediately with Nitoflor Sol.
Specifications
| Product type | Three-component solvent-free epoxy repair concrete |
| Components | Base + Hardener + graded fine filler; 10 mm-down coarse aggregate added at site |
| Compressive strength | 45 N/mm2 (1 day), 70 N/mm2 (3 days), 90 N/mm2 (7 days) |
| Flexural strength | 20 N/mm2 at 7 days |
| Bond strength to concrete | 3 N/mm2 |
| Density of epoxy concrete | 2.20-2.40 kg/litre |
| Pot life | Approx. 30 minutes at 35 degrees C |
| Recommended thickness | Minimum 20 mm per layer (horizontal only) |
| Packaging | 13.5 litre pack (without coarse aggregate); 12-month shelf life below 35 degrees C |
Industry use cases
Warehousing & Logistics
Rebuilds spalled slab sections and loading-bay edges so forklift and HGV traffic can resume within a day rather than waiting on cement cure.
Highways & Bridges
Reinstates joint arrises, deck defects and pavement edges that face constant impact and abrasion, with curing that ignores wet weather.
Manufacturing & Process Plants
Patches chemically attacked and oil-soaked floors with a non-porous epoxy matrix that resists solvents, fuels and dilute acids.
Infrastructure & Power
Repairs dam surfaces, foundations and machine bedding where high compressive strength and dimensional stability are essential.
Frequently asked questions
Can Expocrete EC be used on vertical or overhead concrete?
How strong does it get and how fast?
Do I have to use a primer?
Is the coarse aggregate supplied in the pack?
What is the minimum thickness I can apply?
Does damp concrete or humid weather affect curing?
How we position Fosroc Expocrete EC
Expocrete EC is Fosroc’s answer for deep, high-strength horizontal reinstatement where the repair must take heavy traffic and chemical exposure. Because it is horizontal-only and needs a minimum 20 mm build, pair it with the right partner products from the Fosroc family: prime with Nitoprime 25 and clean tools with Nitoflor Sol, both specified in its own method statement. Where the damage is on vertical faces, overhead soffits or in thin sections, move to Fosroc Nitomortar S, the structural epoxy repair mortar, or to the cementitious Renderoc HB for large hand-applied reprofiling without formwork. For fluid-consistency deep repairs and machine grouting, a flowable epoxy grout such as Conbextra EP series is the more suitable choice. Across our other brands, Space Arc can also match equivalent epoxy repair systems from Sika and MC-Bauchemie when a project specification calls for them.
Related Concrete Repair products
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