Fosroc Nitofill EPLV
Two-part, solvent-free low-viscosity epoxy resin for pressure-injecting and structurally re-bonding cracks 0.25-9 mm wide in concrete and masonry, formulated for India’s hot climate.
What is it?
A two-part, solvent-free, low-viscosity epoxy resin injection grout (liquid base plus hardener) used to fill, seal and structurally re-bond cracks and fine voids in concrete and masonry. It is a crack-injection resin, not a movement-joint sealant or waterstop.
Where is it used?
Structural concrete repair on bridges, water-retaining structures, RCC slabs, columns, beams, basements, foundations and masonry where dormant (non-moving) cracks 0.25-9 mm wide need to be re-bonded.
Why use it?
Its low viscosity penetrates fine cracks that thicker pastes cannot reach, and once cured it bonds both crack faces together, restoring monolithic strength and sealing the path against water and chemical ingress.
How is it applied?
Surface ports/nipples are fixed along the crack and the crack face is sealed; the mixed two-part resin is then pressure-injected port-to-port using a manual or pneumatic injection pump until refusal.
About Fosroc Nitofill EPLV
Fosroc Nitofill EPLV is a two-pack, solvent-free, low-viscosity epoxy resin system engineered for the structural repair of cracked concrete and masonry by the pressure-injection process. Supplied as a liquid base and a hardener that are blended on site in the supplied proportions, it cures to a rigid, high-strength solid that knits the two faces of a crack back together. The “LV” denotes low viscosity, the property that lets the resin travel deep into hairline and fine cracks where a thixotropic paste would stall at the surface. It is part of Fosroc’s well-established Nitofill family of injection resins, sitting alongside the gun-grade Nitofill LV and the thixotropic Nitofill TH. A point worth clarifying up front: although Nitofill EPLV is sometimes catalogued under joint-treatment and waterproofing chemicals by Indian distributors, it is not an elastomeric movement-joint sealant and not a waterstop. It is a structural crack-bonding adhesive grout. It is intended for dormant cracks that are not expected to move further; live, cyclically moving joints must instead be treated with a flexible sealant such as Fosroc Nitoseal or Thioflex. Understanding that distinction is the single most important specification decision when this product is being considered.
The technical insight
The performance of Nitofill EPLV rests on two competing requirements that the formulation balances. First, viscosity must be low enough for the resin to wick into cracks as narrow as 0.25 mm under modest injection pressure, yet the cured polymer must still develop full structural strength. The Fosroc India datasheet reports compressive strengths of 45, 60 and 70 N/mm2 at 1, 3 and 7 days respectively (BS 6319 Part 2), a 7-day tensile strength of 18 N/mm2 (BS 6319 Part 7) and a 7-day flexural strength of 55 N/mm2 (BS 6319 Part 4) at 30C, with a hardened density of about 1100 kg/m3. Because the bonded resin is stronger than the surrounding concrete matrix, a correctly executed repair typically fails monolithically through the parent concrete rather than along the glue line. Second, the system is formulated for hot climates: pot life is a generous 60 minutes at 20C but drops to 30 minutes at 30C, reflecting the accelerating exotherm of epoxy chemistry as ambient temperature rises. Every epoxy generates heat on mixing, and that exotherm is amplified by larger mixed volumes and high site temperatures, so on a hot Indian afternoon mixing should be done in small batches and injected promptly. The resin bonds reliably to both dry and damp substrates and, once cured, resists most chemicals, mild acids and alkalis, fresh water and sea water; concentrated chemical or solvent exposure should be referred to Fosroc. The UK sister grade is third-party certified to EN 1504-5 (concrete injection), giving the chemistry a recognised structural-injection pedigree.
Where it is used
- Pressure-injection of dormant structural cracks 0.25-9 mm wide in RCC beams, columns, slabs and walls
- Re-bonding cracks in water-retaining structures such as tanks, reservoirs, STPs and treatment plants
- Sealing and bonding cracks in basements, retaining walls and foundations against water seepage
- Filling honeycombs, voids and cavities in concrete left by poor compaction or formwork defects
- Crack repair in load-bearing masonry and brickwork
- Restoring monolithic action in cracked bridge decks, piers and abutments
- Repair of cracks in industrial floors, ramps and machine foundations subject to chemical splashes
Key advantages
- Low viscosity allows the resin to penetrate fine cracks down to roughly 0.25 mm, reaching the full crack depth
- Solvent-free system with no shrinkage on cure, so no loss of bond or surface contact
- High mechanical strength: cured resin is stronger than the parent concrete, giving monolithic repairs
- Bonds reliably to both dry and damp/wet substrates
- Formulated for hot climates with early strength gain (45 N/mm2 compressive in 24 hours)
- Good chemical resistance to mild acids, alkalis, fresh water and sea water
- Simple two-part mix in pre-measured proportions, suited to standard manual or pneumatic injection equipment
- Restores structural integrity and seals the water path in a single operation
Limitations & considerations
- Not a movement-joint sealant or waterstop: it is rigid and must only be used on dormant, non-moving cracks; live joints will re-crack the cured resin
- Maximum injectable crack width is about 9 mm; wider gaps or large voids need a different grout (e.g. Conbextra epoxy grouts)
- Pot life shortens sharply with temperature (60 min at 20C, 30 min at 30C), demanding small batches and quick placement in Indian summer conditions
- Requires skilled labour, surface crack sealing and proper injection equipment; not a brush- or trowel-applied product
- Crack faces and ports must be thoroughly cleaned of dust, laitance, grease and standing water for the bond to develop
- Epoxy exotherm can be significant in large mixed volumes or hot ambient conditions
- Once mixed it cannot be paused; gelled resin in the pump must be discarded and equipment flushed before set
Selection & best practice
Confirm first that the crack is dormant, not a moving joint; if there is any cyclic movement, switch to a flexible sealant (Nitoseal/Thioflex) instead. Clean the crack line and drill or fix injection ports (nipples) along it, typically spaced at roughly the wall/member thickness, then surface-seal the crack between ports with an epoxy paste such as Nitomortar or a Nitofill capping resin so the low-viscosity resin cannot drain or leak out during injection. Blow out all dust and loose material with oil-free compressed air. Mix the full base and hardener in the supplied ratio (do not split packs by eye) using a slow-speed drill paddle, and inject in small batches you can place within the pot life for the site temperature, working from the lowest port upward on vertical cracks and one end to the other on horizontal cracks, moving to the next port only when resin flows from it. In hot weather, store packs in the shade, mix smaller batches and inject promptly to manage the exotherm and 30-minute pot life. Flush equipment with Fosroc Solvent 102 before the resin gels. Damp substrates are acceptable, but free-flowing water should be stopped or diverted first.
Specifications
| Product type | Two-part, solvent-free low-viscosity epoxy resin injection grout |
| Components | Liquid epoxy base + hardener (pre-proportioned) |
| Function | Structural crack injection / re-bonding (not a movement-joint sealant or waterstop) |
| Injectable crack width | 0.25 mm to 9 mm |
| Hardened density | approx. 1100 kg/m3 |
| Compressive strength (BS 6319 Pt 2) | 45 / 60 / 70 N/mm2 at 1 / 3 / 7 days (30C) |
| Tensile strength (BS 6319 Pt 7) | 18 N/mm2 at 7 days |
| Flexural strength (BS 6319 Pt 4) | 55 N/mm2 at 7 days |
| Pot life | 60 minutes at 20C; 30 minutes at 30C |
| Substrate condition | Bonds to dry or damp concrete and masonry |
| Chemical resistance | Mild acids and alkalis, fresh and sea water; refer Fosroc for solvents/concentrated chemicals |
| Cure type | Ambient-cure two-part epoxy (exothermic) |
| Application method | Pressure injection via ports using manual/pneumatic pump |
| Equipment cleaning | Fosroc Solvent 102 before resin gels |
| Reference standard | BS 6319 (India TDS); EN 1504-5 for UK Nitofill LV grade |
Industry use cases
Water & Wastewater
Re-bonding and sealing cracks in RCC water tanks, sumps, reservoirs and sewage treatment plant walls where leakage must be stopped while restoring structural strength; cured resin tolerates fresh and sea water exposure.
Infrastructure & Bridges
Injecting flexural and shrinkage cracks in bridge decks, piers, abutments and box girders to restore monolithic load transfer, with 24-hour strength gain allowing quicker return to service.
Commercial & High-Rise Buildings
Structural crack repair in columns, beams, shear walls and slabs after settlement, overload or early thermal cracking, common in fast-track Delhi NCR construction.
Basements & Below-Grade
Sealing seepage cracks in basement retaining walls, raft foundations and lift pits where damp-substrate bonding is essential.
Industrial & Power
Repairing cracks and honeycombs in machine foundations, equipment plinths and industrial floors subject to chemical splash and dynamic-but-dormant loading.
Frequently asked questions
Is Fosroc Nitofill EPLV a joint sealant or a waterstop?
What crack widths can Nitofill EPLV fill?
Can it be used on damp or wet concrete?
What is the pot life in Indian summer conditions?
How strong is the cured repair?
Is a primer needed before injection?
How we position Fosroc Nitofill EPLV
Within Fosroc’s repair portfolio, Nitofill EPLV is the low-viscosity, hot-climate crack-injection grade. It complements rather than competes with the gun-grade Fosroc Nitofill LV and the thixotropic Nitofill TH used for open-ended or overhead cracks. It is important not to confuse it with Fosroc’s actual joint sealants: Nitoseal (polyurethane/silicone gun-grade movement-joint sealants), Thioflex 600 (polysulphide) and Colpor 200PF (pourable joint sealant for pavements) are the correct choices for live, moving joints, whereas EPLV is strictly for dormant cracks. Where the project genuinely needs flexible joint sealing or waterstopping, those products or a hydrophilic/PVC waterstop should be specified instead. As an authorised Fosroc distributor and applicator, Space Arc Engineering recommends Nitofill EPLV specifically for structural crack re-bonding. Credible equivalent injection resins from other manufacturers include Sika Sikadur-52 (low-viscosity epoxy injection), MBS/Master Builders MasterInject 1380 and the STP (Pidilite) epoxy injection range; for flexible joints the comparable alternatives are Sika Sikaflex, MBS MasterSeal and STP sealants. Selecting between them should be driven by whether the defect is a dead crack (use EPLV) or a moving joint (use a flexible sealant), the substrate moisture condition, and the site temperature governing pot life.
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