MC-Bauchemie MC-Nafufill EP
A high-strength, chemical-resistant two-component epoxy repair mortar built for thin-section reinstatement on industrial floors and aggressive-exposure concrete where cementitious patches simply do not last.
What is it?
A two-component epoxy repair mortar (resin base plus hardener, blended with graded aggregate) for high-strength, low-shrinkage concrete reinstatement in thin sections.
Where is it used?
Industrial and warehouse floors, chemical and pharma plants, effluent and marine structures, and any spall or edge repair exposed to abrasion, acids, oils or fuels.
Why use it?
It bonds tenaciously, gains strength in hours not weeks, and shrugs off chemical attack far better than ordinary sand-cement or polymer-modified mortars.
How is it applied?
Prime the prepared substrate, mix Part A and Part B thoroughly, add the aggregate, then trowel firmly into the repair from about 5 mm depth and finish before the pot life expires.
About MC-Bauchemie MC-Nafufill EP
MC-Nafufill EP is a solvent-free epoxy repair system intended for the kind of concrete damage that keeps returning after cementitious repairs. On a busy factory floor, forklift traffic chips out joint arrises and spalls slab edges; in a chemical or effluent environment, acids and process spills eat away at cover concrete faster than any Portland-based mortar can hold up. This product is formulated for exactly those situations, where you need a repair that is hard, dense and chemically inert rather than one that merely matches the parent concrete cosmetically. Because it is filled with a specially graded aggregate, it can be laid in genuinely thin sections without the slumping or feather-edge failure that plagues bulk mortars.
For Space Arc’s engineering and contractor clients across Delhi NCR and Pan-India, the appeal is turnaround and durability under load. An epoxy mortar reaches walk-on and even light-traffic strength within hours, so a warehouse aisle or a plant floor can be handed back the same shift rather than being cordoned off for a week of cement cure. It also develops adhesion strong enough that, when tested, failure typically occurs in the parent concrete rather than at the bond line. That combination of fast return-to-service, near-zero water absorption and broad chemical resistance is why specifiers reach for an epoxy mortar in aggressive exposure classes where a standard EN 1504-3 cementitious repair would be over-attacked.
The technical insight
The performance comes from the cured epoxy matrix itself. When Part A (the epoxy resin) and Part B (the amine hardener) are combined, they cross-link into a dense, three-dimensional thermoset polymer with very little internal porosity. That tight network is what gives the mortar its high compressive and tensile figures and its resistance to acids, alkalis, oils and fuels, because there is almost no capillary structure for aggressive liquids to penetrate. The graded aggregate is not just filler; it carries the bulk of the compressive load and controls the exotherm and shrinkage, so the repair stays dimensionally stable as it cures. Adhesion is chemical as well as mechanical: the resin wets into the open pore structure of a properly prepared, primed substrate and keys directly to the aggregate and cement paste, which is why a correct application usually fails in the concrete rather than at the interface. The trade-off engineers must respect is that epoxy is a rigid, essentially non-breathable system with a different thermal movement to concrete, so it belongs in bonded thin-section repairs on sound substrates, not as a substitute for a flexible or vapour-permeable system.
Where it is used
- Reinstating chipped and spalled joint arrises on industrial and warehouse floors damaged by forklift and pallet-truck traffic
- Patch repair of spalls and potholes in floors exposed to acids, alkalis, solvents and process spills in chemical and pharmaceutical plants
- Structural concrete repair in aggressive exposure such as effluent treatment works, sugar mills, distilleries and coastal or marine structures
- Thin-section reinstatement of shallow defects from roughly 5 mm depth where sand-cement mortars feather-edge and debond
- Rebuilding abrasion-worn floor areas in loading bays, ramps and heavy-traffic aisles
- Regrouting and bedding of anchor bolts and base plates where the surrounding grout has chemically deteriorated
- Repairing bund walls, plinths and equipment foundations in chemically loaded plant rooms
- Localised reinstatement ahead of an epoxy or PU floor coating so the substrate is level, dense and coating-ready
Key advantages
- High compressive, tensile and flexural strength that comfortably exceeds the surrounding concrete
- Broad chemical resistance to dilute acids, alkalis, petroleum fuels and oils, suiting aggressive industrial exposure
- Fast strength gain giving walk-on and light-traffic use within hours, minimising plant and floor downtime
- Excellent adhesion to prepared concrete, with test failures typically occurring in the substrate not the bond line
- Dense, essentially non-porous matrix with very low water absorption for long-term durability
- Thin-section capability from around 5 mm without slumping or feather-edge failure
- Solvent-free formulation that is easier on applicators in enclosed plant areas
- Supplied as pre-proportioned components, reducing on-site batching error
Limitations & considerations
- Rigid and non-flexible: unsuitable for moving cracks or joints that require an elastomeric sealant or a flexible repair system
- Epoxy is essentially vapour-impermeable, so it should not be used where the substrate needs to breathe or where trapped moisture could drive it off
- Substrate-temperature sensitive: cure slows sharply in cold conditions and pot life shortens in heat, so working windows are tight
- Demands rigorous surface preparation and priming on a sound, dry substrate; it will not bond to laitance, oil-contaminated or damp concrete
- Not a bulk-fill economy mortar; for large-volume voids a cementitious or polyester system is usually more cost-effective
- Exact certified strengths, pack sizes and cure data must be confirmed against the current MC-Bauchemie product data sheet before specification, as epoxy formulations and grades vary
Selection & best practice
Success with an epoxy mortar is decided almost entirely by preparation. Break out all unsound and contaminated concrete back to a firm edge, ideally saw-cut the perimeter rather than feather-edging, and mechanically prepare the surface by grit-blasting or scabbling to expose a clean, sound, open texture. The substrate must be dry and free of oil, laitance and dust. Apply the recommended epoxy primer or bonding coat and work the mortar in while that primer is still tacky, so the two knit together. Mix Part A and Part B in the stated proportions with a slow-speed paddle until fully uniform, then blend in the aggregate; do not part-mix or eyeball the ratio, as under-dosed hardener never fully cures. Firmly compact the mortar into the repair to avoid voids, build up in the recommended lift thickness, and finish before the pot life ends. Watch ambient and substrate temperature closely: warm conditions cut your working time, cold conditions extend cure. Where the repair sits under a coating, respect the overcoating window and confirm the surface is fully cured first.
Specifications
| Product type | Two-component epoxy repair mortar (resin + hardener, aggregate-filled) |
| Components | Part A epoxy resin base; Part B hardener; graded aggregate filler |
| Mixing ratio | Pre-proportioned by weight per the product data sheet |
| Minimum application thickness | Approximately 5 mm (thin-section capable) |
| Compressive strength | Typical for structural epoxy mortars, on the order of 60-80 MPa at 7 days (confirm on TDS) |
| Adhesion to concrete | High; bond typically exceeds concrete tensile strength (failure in substrate) |
| Chemical resistance | Dilute acids, alkalis, petroleum fuels and oils |
| Water absorption | Very low (dense epoxy matrix) |
| Solvent content | Solvent-free |
Industry use cases
Warehousing & Logistics
Rebuilding forklift-damaged joint edges and worn aisle floors so racking bays return to full traffic within the same shift.
Chemical & Pharmaceutical Plants
Reinstating spalled floors, bunds and plinths in acid, solvent and process-spill zones where cementitious patches are quickly attacked.
Water & Effluent Treatment
Patch and edge repair on structures exposed to aggressive effluent and chemical dosing, where low absorption and chemical resistance are essential.
Food, Sugar & Distillery
Repairing floors and equipment bases exposed to organic acids and washdown in sugar mills, distilleries and food-processing facilities.
Marine & Coastal Structures
Localised reinstatement of concrete exposed to chloride, salt spray and abrasion where a dense, low-permeability repair is required.
Frequently asked questions
Is MC-Nafufill EP an epoxy or a cement-based mortar?
How thin can I apply it?
How soon can the repaired area take traffic?
Does it need a primer?
Can I use it to fill a moving crack or an expansion joint?
What surface preparation does it need?
How we position MC-Bauchemie MC-Nafufill EP
MC-Nafufill EP is the epoxy option to reach for when a repair has to survive chemical attack, abrasion and fast turnaround, rather than just match the parent concrete. Where the exposure is normal and a like-for-like cementitious reinstatement is enough, the wider MC-Bauchemie Nafufill family is the more economical and vapour-compatible choice: Nafufill KM 250 for structural R4 patch repair, Nafufill GSE as a fine finishing mortar, and the Nafufill SBR bonding agent as the primer/bond coat under cementitious work. For a genuinely equivalent structural epoxy mortar from another brand we stock, Fosroc Nitomortar S is the closest counterpart. As always, Space Arc can help match the right system to your exposure class, thickness and cure-time constraints.
Fosroc Nitomortar S — Choose Nitomortar S when the specifier wants a fully structural-grade epoxy repair mortar from the Fosroc system, particularly for heavy-duty industrial floor and aggressive-exposure reinstatement backed by a widely specified TDS.
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