STP ShaliFix EM
A 100% solids, three-component epoxy mortar that patches concrete back to a surface tougher than the slab it repairs.
What is it?
A solvent-free, three-component epoxy repair mortar (resin, hardener and graded filler) from STP that cures to a dense, chemical-resistant surface far harder than concrete.
Where is it used?
Horizontal industrial floors and slabs that take heavy load or chemical attack: airport aprons, car parks, warehouses, dairies, food and beverage plants, chemical and fertiliser units.
Why use it?
It reaches 40-50 MPa in a single day and 70-80 MPa in a week, so a bay can be back in service fast while the patch outperforms the parent concrete.
How is it applied?
Trowel-applied in a minimum 10 mm section over a sound, dry, prepared substrate (primed with ShaliPrime 2E where the concrete is porous), built up in coats.
About STP ShaliFix EM
STP’s ShaliFix EM is a 100% solids, solvent-free epoxy mortar built for one job that ordinary cementitious repairs struggle with: restoring worn, spalled or chemically attacked concrete to something stronger than it ever was. It arrives as three pre-weighed parts, an epoxy resin, a hardener and a selected graded filler, that are combined on site into a stiff, non-slumping mortar. Once cured it behaves less like a patch and more like a purpose-built industrial surface, dense, non-absorbent and dust-free, which is exactly what a plant floor or a machine base needs. The product conforms to ASTM C395-01 (2012), the standard method covering chemical-resistant resin mortars, so its performance claims sit on a recognised test basis rather than marketing language.
For engineers and contractors in Delhi NCR and across India, the appeal is the combination of speed and toughness. ShaliFix EM dries hard enough for foot traffic in about eight hours and develops 40-50 MPa of compressive strength within a single day, letting a repaired bay return to service quickly instead of waiting on a long cement cure. It is genuinely versatile too, working as a repair mortar, a bedding mortar for machinery and an adhesive mortar, so a single product covers several tasks on a shutdown. Space Arc Engineering supplies it as an authorised STP distributor and applicator, with technical support on surface prep and system build-up so the mortar actually delivers the strength the datasheet promises.
The technical insight
The strength comes from chemistry, not cement hydration. In a cementitious mortar, strength depends on water reacting with cement over days to weeks, and the paste stays comparatively porous. ShaliFix EM instead relies on the epoxy resin and hardener cross-linking into a rigid, three-dimensional polymer network that locks the graded filler in place. Because that reaction needs no water and gives off no solvent, the mortar is 100% solids: there is nothing to evaporate and leave voids, which is why the cured mass is dense, non-absorbent and reaches 70-80 MPa. The graded filler carries compressive load while the resin matrix bonds tenaciously to the prepared substrate and resists acids, alkalis and oils. The non-slumping consistency means it holds a 10 mm-plus section on a floor without sagging, and the thixotropic sister grade, ShaliFix EM 51, carries the same chemistry up onto vertical and overhead surfaces. This is also why surface preparation is decisive; the polymer bonds to what it touches, so laitance, dust or moisture above 5% will cap the achievable adhesion no matter how good the mortar itself is.
Where it is used
- Reinstating spalled or worn industrial floor slabs in plants and workshops
- Structural patch repair of load-bearing concrete stronger than the parent slab
- Bedding and grouting machine bases and equipment foundations
- Chemical- and oil-exposed floors in fertiliser, chemical and metal-treating plants
- Airport apron and taxiway repair where fast return to service matters
- Warehouse and car-park floors subject to heavy wheeled traffic
- Dairy, food and beverage production floors needing a hygienic, non-dusting surface
- Use as an adhesive or bedding mortar for setting components and fixtures
Key advantages
- 100% solids and solvent-free, so no odour during application and no shrinkage from evaporation
- High strength: 40-50 MPa at 1 day and 70-80 MPa at 7 days, exceeding typical concrete
- Reaches foot-traffic hardness in about eight hours for fast turnaround
- Dense, non-absorbent, non-dusting surface that resists a wide range of acids, alkalis and oils
- Non-slumping trowel consistency holds a 10 mm-plus section cleanly
- Conforms to ASTM C395-01 (2012) for chemical-resistant resin mortar
- Multipurpose: repair mortar, bedding mortar and adhesive mortar in one product
- Slip-resistant textured finishes available to suit different floor conditions
Limitations & considerations
- Minimum applied thickness is 10 mm, so it is not suited to feather-edging or very thin skims
- Substrate must be dry (moisture below 5%) and at least 28 days old; damp or green concrete will fail the bond
- Working time is only 30-40 minutes at 30°C, so mixed material must be placed promptly and in workable batches
- Not a wear-and-tear economy option; for large plain areas a cementitious repair is far cheaper
- Fuel and oil resistance is general only; a ShaliUrethane TC topcoat is advised where hydrocarbon penetration must be fully excluded
- The base grade is formulated for horizontal work; vertical and overhead repairs need the thixotropic ShaliFix EM 51 grade
Selection & best practice
Success is set by preparation. On new concrete, confirm it is at least 28 days old with moisture below 5%, then remove laitance, dust and contaminants and strip oil or grease by acid etching or burning off. On old floors, mechanically scabble, grind or grit-blast back to sound, clean substrate. Priming is not usually needed on sound, non-porous concrete, but where any doubt exists on quality or porosity, prime with two-part ShaliPrime 2E and let it reach tack-free before laying. Mix the pre-weighed hardener fully into the resin with a drill and paddle, then add the entire filler and mix a further two minutes until every aggregate particle is coated. Lay a first coat around 5 mm with trowel or squeegee for continuous coverage, then the second coat after a 12-hour initial cure at 27°C, keeping total thickness at 10 mm or more. For anti-slip floors, draw a metallic broom across the fresh topcoat to texture it. Carry existing expansion joints through the topping and seal them with ShaliSeal EMS. Clean tools immediately with xylene before the mortar hardens.
Specifications
| Composition | 3-component (A resin + B hardener + C graded filler), 100% solids, solvent-free |
| Standard | Conforms to ASTM C395-01 (2012) |
| Compressive strength | 40-50 MPa at 1 day; 70-80 MPa at 7 days |
| Flexural strength | 25-27 MPa |
| Tensile strength | 14-16 MPa |
| Working time | 30-40 minutes at 30°C |
| Mix density | 2 ± 0.05 g/cc |
| Coverage / thickness | 20 ± 0.5 kg/m² at 10 mm; minimum 10 mm section |
| Pack size | 20 kg combo (A 2.90 kg + B 0.50 kg + C 16.60 kg); shelf life 12 months |
Industry use cases
Airports & Logistics
Aprons, taxi areas, warehouse and loading floors where a repaired bay must carry heavy load and return to traffic within hours, not days.
Food, Dairy & Beverage
Hygienic, non-dusting, non-absorbent floor repairs that resist wash-down chemicals, lactic and citric acids without harbouring contamination.
Chemical & Fertiliser Plants
Reinstating floors and bunds attacked by acids and alkalis, with a coat of ShaliUrethane TC where fuel or oil exposure must be sealed out.
Heavy Manufacturing
Bedding and grouting machine bases and equipment foundations, and patching structural concrete back stronger than the surrounding slab.
Metal Treating & Workshops
Durable, chemical-resistant floors in car parks and treatment shops that shrug off spillage and abrasion from wheeled traffic.
Frequently asked questions
How strong is ShaliFix EM compared to concrete?
What is the minimum thickness I can apply?
Can it be used on walls, columns or soffits?
How soon can the floor take traffic?
Does it resist chemicals and oils?
What pack size does it come in and how much area does it cover?
How we position STP ShaliFix EM
ShaliFix EM is the workhorse for horizontal, load-bearing epoxy repair; for vertical, overhead or non-sag work up to 30 mm per layer, move within the same STP family to ShaliFix EM 51, which shares the chemistry and is primed with ShaliBond 41. Pair either with ShaliPrime 2E on porous substrates, seal carried-through expansion joints with ShaliSeal EMS, and topcoat with ShaliUrethane TC where fuel or oil ingress must be blocked. Where the repair is shallow, large-area or budget-driven, a cementitious micro-concrete such as STP ShaliFix MC is the more economical route. Space Arc also stocks equivalent epoxy mortars from other brands, so specifiers can match an approved-vendor list; on a Fosroc-specified job, Nitomortar S is the direct counterpart.
Fosroc Nitomortar S — Choose Nitomortar S when the project or client approved-vendor list specifies Fosroc; it is the equivalent solvent-free three-component epoxy reinstatement mortar for horizontal industrial repairs, carrying an EN 1504-3 declaration.
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