Epoxy Mortar Installation

June 19, 2019

Epoxy.com Mortar Systems can be used to make permanent repairs that no other kind of product can make. The purpose of this blog is to give you an overview of what you can use and how to use it.

  1. Product Selection –  The following are a list of Epoxy.com Products that make excellent epoxy mortars  All the products listed below are zero (0) VOC, so it meets even the strictest low VOC requirements, and meets Indoor Environmental Quality/Air Quality (LEED IEQ 4.2 Indoor Emitting Materials Credit). See the individual product component technical data sheets and MSDS for further information.
    • First and foremost is good surface preparation.  Good surface preparation is necessary for most if not all patches to have long term success: www.epoxy.com/surfaceprep.aspx.
    • Prime the bottom of the whole with some of the neat mortar resin. Neat mortar resin is the liquid (A&B) mixed at the proper mix ratio and stirring in a way to insure a completely mixed product.  This will typically take about 3 minutes.
    • Mix some of the neat epoxy into the Epoxy.com Mortar Blend Aggregate #82 or other appropriate dry clean silica sand gradation.
    • The amount of sand aggregate depends on the aggregate used. 
      • Typically, the Epoxy.com Product #82 Mortar aggregate can be added at a rate of 18 to 27 lbs. of #82 per 1.5 Qt of mixed resin (1Quart of A to ½ Quart of B).
      • You will need to recalculate the sand above when using a different sized batch. This is doubly true if using one of or 4:1 mix ratio material.
      • Shallow patches tend to be a smaller amount of sand filler.
      • Deeper patches tend to be on the higher side.
      • If you get a lot of resin to the surface your mix is too wet.  If your mixture after it hardens is porous, or weak then you have added too much aggregate.
      • For a better finish in very deep pours do it in 2 lifts. 
        • Fill all but the last ¼ inch plus or minus with your dryer mix. Allow to cure hard (typically overnight).Fill with a wetter mix on top of that after the first one has cured.
        • To ensure proper adhesion between layers never wait more than 24 hours between layers.
      • It is always better to have your patch slightly higher rather than to low.  If you are slightly high you can grind the patch back to level. If to low you will need to fill again. 
    • For very shallow fills (1/32 or so) where the sand particles are to large you can use any of the following:

As always, when in doubt contact me at Epoxy.com Technical Support with your questions.


Epoxy Stone Maintenance.

May 16, 2019
Picture of Epoxy.com stone
Epoxy.com Epoxy Stone

A customer asks, “I have a patio with Chattahoochee or Chattahoochee like stone glued together with epoxy. It is no longer shinny and the stone is starting to come loose. What is causing this and what should I do about it?”

It sounds like you have a stone that was installed with Epoxy.com Product #17 – www.epoxy.com/17.aspx – or some other brand of stone adhesive. We tell all of our customers that install epoxied stone that they need to maintain by re-glazing it periodically. Unfortunately, not everyone is as forthright as us in telling their customers this.

We recommend you take these steps every spring and fall so you can enjoy your epoxied stone year-round.

1. Look at you epoxy stone and look determine if it needs maintenance. If it is still shinny and you don’t have loose stone, then you are done. Come back and do this step again in 6 months.

2. Clean your stone to remove algae, mold, oil, grease and any other contaminants from it. Typically, contamination is just algae and mold and can be removed with a weak Clorox and water combination with a thorough rinse with a hose or gentle pressure wash. Allow your stone to dry completely before proceeding.

3. Determine if it has only lost its shine or if you have loose stone. Decide if sections of the stone are so loose that they need to be reinstalled with Product #17 (4 below) or if there are just a few to no loose stones and you just want to re-glaze it (5 below).

4. If stone needs to be picked up and reinstalled in areas do that with Epoxy.com Product #17. Contact Epoxy.com Technical support for the amount of product you need. We can also go over the reinstallation of these areas with you. If the stone is sound or has just a few stones that you are not worried about replacing you can proceed to 4 below.

5. Apply 1-2 coats of Epoxy.com Product #15 (depending on how bad the stone has weathered) to the top of your clean dry stone. This will give you back your original shine and strengthen the interface (bond line) between the stones. Product #15 is the best product to do this with as experience has shown it lasts 1.5 to 2 times longer than convention epoxies used for this application.

6. CAUTION: You can find single component so called “Chattahoochee” . These sealers add shine to your epoxy stone but do not strengthen the interface between the stone. Using this kind of sealer can ruin your epoxy stone. Once these inexpensive sealers are on they are difficult to impossible to remove. Making it optionally impossible to ever re-glaze the epoxy stone properly again.

As always when in doubt contact Epoxy.com Technical support at info@epoxy.com or by calling 352-533-2167.

Epoxy on 316 Stainless

November 16, 2018

A customer writes:

“I’m an architect with a project under construction…

“There is a hazardous materials room in the building where various corrosive products will be stored. The materials are stored in the middle of the room on a large collection pan and the entire floor below that is constructed of stainless steel bar grating – held up off the concrete slab.

“Per the direction of the engineers we have required the contractor to essentially coat all the surfaces in the inside the room with your epoxy Novolac 633

“Now a question has come up about whether or not the 633 will adhere to stainless steel bar grating made from 316 stainless?

“Could you address that for us?”

My Answer:

That is an excellent question.  316 Stainless is very hard to bond to.  Many of our customers have had excellent luck with the following procedure however.

  1. If possible sandblast the stainless to get a profile.  If that is impossible grind/sand it the very best you can to create small scratches everywhere and remove the shine.
  2. Coat with Epoxy.com Product #660 Aluminum Filled Primer – www.epoxy.com/660.aspx . Allow to cure hard to the touch
  3. Apply 2 coats of Epoxy.com #633 or. 633W (Wall Grade).

For more information Contact:

Norm Lambert

or visit www.epoxy.com 

Epoxy Injection – Part 4

November 6, 2018

This is the 4th and final in this series on Epoxy Injection.

Part One is  Introduction to Epoxy Injection.  Part 2 is Crack Analysis Before Epoxy Injection. Part 3 is Port setting and Preparation. Part 4

If your have not read that yet you may want to go back and read it before you proceed with reading this.

In this blog we will deal with the actual product and injection procedure, and will include the summary

Epoxy Resin Properties Epoxy.com Product #301

Mix Ratio 2:1 By Volume
Viscosity 400-450 cps
Initial Cure 6 – 8 hours (with normal cure hardener)
Final Cure 24 hours
Pot life 30-40 minute (with regular cure hardner)
Packaging (unit size) 3 gal unit, 15 gal unit, 165 gallon unit
Standard Colors clear
Colors Clear – Can be pigmented at an additional charge to make it easier to see when pumping.
Elongation (ASTM D-638) Greater than 10%
Compressive Strength (ASTM D-695) 10,000 PSI (min)
Tensile Strength (ASTM D-790) 3,500 PSI
Concrete Bond Strength (ASTM C-882) 2,290 PSI
Shrinkage (ASTM C-883) Passed Test
Thermal Compatibility (ASTM C-884) Passed Test
Adhesion to Concrete (ACI Committee 403) 250 PSI (concrete fails)

Resin Injection

Epoxy resin injection with Epoxy.com Injection Gun  designed for Epoxy.com Injection resin is the only way of assuring quality installation. Single component caulking guns, pressure pots, or similar batching equipment are not suitable for injection.

Manual Epoxy Injection Gun

Limit pressures to 40 p.s.i for most applications. Excessive pressures can create additional stressing of Epoxy Concrete Injectionthe crack. It can also cause hydraulic lifting, rupturing of the cracked substrate, or further elongation of the crack. Low pressures allow gradual resin flow into the crack for deeper penetration. On vertical cracks, injection is start at the lowest point, and continue upward on the crack area. While injecting the lowest port, resin will flow to and out of the next higher port.

When pure resin is flowing out the next port cap, plug the current injection portEpoxy Injection of Epoxy and move to the next port. Then injection continues in the port showing resin flow. This procedure continues until all ports are full.

Epoxy Injection Resin Systems should be of very low viscosity for most applications. That way it will flow in the smallest hair line cracks. Resin can travel several feet from the point of injection. It may take some time before reaching the next port or penetrating through pin holes in the surface. Coring samples have shown that epoxy injection effectively fills cracks including small voids and hairline cracks.

Injection During Extreme Weather

A cold substrate will cause an increase in the viscosity of the injection resin. This slows down the rate of injection. A hot substrate results in premature jelling of the resin with sequential loss of penetration. During extremely hot weather an open bridge deck may exceed temperatures as high as 140 Degrees F. Special precautions are necessary before injection work can be done in such weather.

The precaution may be shading the bridge, and water cooling. Always check substrate temperature. The injection machine and its hoses require isolation from extremes of temperature.

Epoxy injection undertaken during cold weather also requires special precautions.

When doing injection work in freezing conditions, determining if there is ice present in the crack is critical. Determining if a cracks inner surfaces are ice coated, is equally important. When injecting under theseClose up of epoxy inection port setting at the Hush House at the Vermont Air National Guard conditions, the resin will not bond to the substrate and no structural rebonding will result. It is usually safer to preheat the portion of the structure you are injecting.

When heating a structure do not overheat it. This closes the crack. When removing heat, the crack may rapidly open. This will rupture the resin before it has a chance to achieve final cure. In most cases, indirect heating is much more desirable than direct heating. Maintain heat for several hours before and after the injection application.


The color of the sealer material used in resin injection is concrete gray. They are difficult to remove. If aesthetics require complete cleaning, the sealing material can be removed by grinding. This is normally done at an additional charge to the OWNER.

Injection Against A Head of WaterEpoxy injection of the Hush House at the Vermont Air National Guard

Injection of Epoxy Injection Resin against a head of water requires a slightly different procedure than normal injection. If water is running from a crack, applying a hydraulic cement (fast setting) seals the cracks and sets the ports. Epoxy pastes will not set up under this type of wet condition. The hydraulic cement seals the cracks and diverts all water flow through the injection ports.

Hydraulic cement is fast setting, but it does not have the strength needed for an Injection Sealer. Epoxy Concrete Bonder can have the strength to prevent blowouts or leaks while injecting. After the hydraulic cement cures applyingEpoxy Concrete Bonder. That solves this problem.

The injection process follows the procedures described before. The Injection resin forces the water out of the crack and through the adjacent ports. The resin has an amber color and does not look like water. Pure resin flows from the higher port before capping and moving on. The head of water will require increasing the injection pressure used.


Delamination of concrete structures is an area where injection can also offer selective repair. A prime example is bridge decks or other self supporting structures. The most common delamination is shearing of the concrete. This is commonly at the upper rebar mat.

Another common situation is hollow plane that develop when concrete bridge piers are resurfaced. Old piers are encased in new concrete. Hollow planes in this type of application are common, especially against smooth sections of the old pier. Cracking then occurs on the surface perpendicular to the hollow plane.

These delaminated area is subject to chemical penetration from the surface and moisture which may attack the reinforcing bar. If the delamination is not repaired, traffic will cause the area to pop-out by pounding on the delaminated upper concrete layer. Freeze-Thaw damage will also tear the concrete apart. The greater the number of freeze-thaws, the more water in the cracks during these free-thaws, the greater, and quicker the damage to the concrete.

Map delaminations by drag chain, hammer or sounding device. The damaged area requires no less than four (4) ports drilled for resin flow, depending on the size and shape of the delamination. This prevents the trapping of water that may be present.

The delamination is normally hollow planes that run along the reinforcing bar. When injecting the delamination, the resin will follow these hollow planed areas and can travel several feet in filling the voids.


Epoxy Injection Systems is very effective at repairing concrete cracks, delaminations, and hollow planes when used according to manufacturers recommendations. Job analysis and proper preparation are very important to insuring the maximum performance from the Epoxy Products, or any other concrete repair products. The right equipment is critical. Proper setup continuous mixing epoxy injection machines must always be used with no exception. Injection staff and management must have the training and experience to do the work right the first time. Epoxy injection has to be done right the first time. There is no second chance. So it is critical that your injection work be done by well trained and equipped, experienced personnel.

Epoxy.com Injection Products

Injection Resin

Product #301 Injection Resin, low Modulus – a 100% solids low viscosity epoxy adhesive used to restore cracked structural concrete by the pressure injection method and to grout cracks in a horizontal plane by gravity.

Product #301SC Slow Cure Injection Resin Low Mod is a longer Potlife version of Product #301

Product #301Cold Temperature Cured Epoxy Injection Resin a faster version of Product #301 typically used in Cold Temperature Cure applications, or where a very fast set is needed

Contact Epoxy.com Technical Support Department for more information on Injection and Binary Delivery Systems. 352-533-2167 info@epoxy.com

  • Manual Injection Pump
  • Injection Ports
  • Binary Tubes 75 ML
  • Binary Tubes 150 ML
  • Binary Tubes 300 ML
  • Static Mixing Tubes for Binary Tubes
  • Manual Gun for Binary Tubes
  • Pneumatic Gun

New Clear Methyl Methacrylate Top Coating.

October 31, 2018


Epoxy.com Product #6930

Methyl Methacrylate Technical Data Sheet


Epoxy.com #6930 MMA (methyl methacrylate) SEALER is a 100% reactive semi-flexible medium viscosity methyl methacrylate resin developed as a sealer/topcoat over various Epoxy.com MMA Systems.

Product #6930 MMA SEALER is a chemical resistant coating with improved UV light resistance specifically designed for exterior use such as vehicular parking decks, pedestrian decks, roof decks, pool decks, concrete and steel stairs, ramps, and interior freezer/cooler rooms.

Methyl Methacrylate Product #6930 MMA SEALER is suitable for use in numerous other applications, both indoors and outdoors.


  • Medium viscosity
  • Fast cure for rapid recoat and return to service
  • UV resistance; non-chalking
  • Semi-flexible for exterior use and freezers
  • Meets USGBC LEED criteria for low VOC
  • Chemical resistance
  • Meets USDA requirements
  • Use over wide temperature range even below freezing.

For a complete technical data sheet please see the technical data sheet or contact:
Epoxy.com Technical Support Department at 352-533-2167, 
email me (Norm Lambert) at norm@epoxy.com,
or visit our website at www.epoxy.com   


Epoxy Chip Floor Stays Clear

October 19, 2018


Here is the picture of the chip floor – www.epoxy.com/chips.aspx  that that was about 15 years old when the picture was take. It is in a Vermont Interstate Rest area.  It has never been waxed. You can still see the ceiling lights reflecting off the surface. Only maintenance has been to mop it.

Chip Floor install:

Links that will make your Chip Flooring installation better and easier:

Do with Epoxies

Don’ts with Epoxies

Surface Preparation


Chip Flooring Installation Guide

Job Supplies – for roller applications


Chip Flooring Tech data:

Tech data and installation:















Cove information:





Epoxy Chip Flooring

December 13, 2017

How to Install Chip Flooring

There are two easy ways to learn how to install our chip flooring.

  1. https://www.youtube.com/watch?v=geh61u3ChgI – the Youtube Video. Please view and like this video.
  2. You can find a version of this that you can print and have at the jobsite at: https://www.epoxy.com/ChipFlooringInstall.pdf

Please visit us at http://www.epoxy.com/ or call customer service at: support@epoxy.com or by calling 3520533-2167.

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