Epoxy Resin Mortar: A Detailed Explanation of Material Composition, Construction Specifications and Application Scenarios
2025-07-22
What is epoxy resin made of ?
1. Epoxy resin: It is a binder that holds other components togethe and can be used in mortar mixer. It consists of epoxy resin and a curing agent, which undergo a chemical reaction (polymerization) to harden the material.
2. Curing agent: A curing agent is an essential component for the reactive curing of epoxy resin and must be added to mortar mixer for the resin in the specified weight ratio.
3. Filler: Fillers are added to impart certain mechanical properties to the mortar, such as application thickness or resistance. Common fillers include quartz sand, limestone powder, or other minerals.
4. Additives: These can be added to mortar mixer to improve certain properties of the mortar, such as flowability, adhesion, or chemical resistance.
Considerations for Processing Epoxy Resin
Epoxy resin-based construction materials are not low in cost. Therefore, careful preparation in the early stages of a project is crucial. The application of epoxy resin, such as in mortar mixer.
The surface to be treated must be dry and clean. In particular, concrete surfaces usually need to be mechanically treated by sandblasting or milling, followed by cleaning to ensure dust-free conditions. Other factors to consider and check include room temperature and humidity.
2. Working Equipment Required
★Electronic scales with digital displays - if components A and B need to be weighed; in most cases, these two components are already supplied in the correct proportion in separate containers just like mortar mixer to avoid dosage errors;
★Several sufficiently large and clean mixing buckets - if the materials cannot be mixed in the transport containers;
★Electric stirrers and suitable mixing paddles, and if necessary, automatic stirrers can be used in mortar mixer to handle larger quantities;
★Trowels, scrapers, rollers, brushes for applying the materials;
★Spiked shoes to step on the fresh coating;
★Spiked rollers for compacting and degassing the coating;
★Protective equipment: gloves and goggles must be worn to avoid skin contact with the resin. If a large amount is used in mortar mixer, it is recommended to wear a breathing mask;
★Suitable cleaning agents, brushes and paintbrushes for cleaning tools.
3. Basic Points to Note
★Mortar mixer for mixing: Before mixing the epoxy resin and sand mixture, the liquid resin must be properly mixed with the curing agent. The correct mixing ratio used in mortar mixer is specified by the manufacturer (e.g., 2:1 or 3:1). Accurate weighing is crucial because too much curing agent will accelerate the curing process, while too little will result in a sticky and unstable surface.
★Combination containers: Many manufacturers provide epoxy resin and hardener in pre-packaged containers to ensure proper mixing of epoxy resin in mortar mixer and avoid dosage errors.
★Pot life and processing: Once the epoxy resin is mixed in mortar mixer, the curing process begins. The pot life refers to the time during which the mixed material remains processable before starting to cure. The pot life varies with temperature - the higher the temperature, the shorter the processing time.
4. Mixing in mortar mixer
Typically, component A (resin) and component B need to be pre-mixed first. Synthetic resins are usually delivered in a liquid and viscous form. The two components should be thoroughly mixed through pre-mixing. Stir the liquid resin mixture with a low-speed stirrer (about 300 rpm) and a mixing paddle that can draw in a small amount of air in the mortar mixer. After pre-mixing, pour the resin mixture into another container (pot change) and mix again. This prevents unmixed components from remaining at the bottom or corners of the container. Depending on the intended use, add aggregates to the resin mixture and mix thoroughly again.
5. Pot Life
Pot life, also known as processing time or open time, refers to the period during which reactive resins remain processable after mixing the components until they start to cure in mortar mixer. During this period, the resin remains liquid and can be applied or shaped. Pot life is an important factor in the processing of reactive resins, and its duration varies depending on the resin type, ambient temperature and the amount of mixed material.
6. Processing
If you are processing coatings, use transportation equipment to transport the finished mixture from mortar mixer. This can protect your back. Pour out the material, spread it flat with a smoothing rake, and then compact it with a spiked roller. Always apply fresh material onto fresh material, otherwise undesirable bulges will appear on the surface.
Mortar is usually applied using a suitable trowel. If necessary, the surface to be treated must first be primed with a primer.
7. Curing
Allow the epoxy resin to fully cure in accordance with the manufacturer's instructions. The curing time may vary depending on the material and external influences.
Application Feilds of Epoxy Resin in Construction
Epoxy resin, also known as reactive resin, is widely used in the construction industry. They are mainly applied in scenarios where high requirements are placed on the mechanical properties or chemical resistance of components and surfaces. In daily life, epoxy resin is the material mixed by mortar mixer and also for surface protection, for serving as a coating in parking lots. It is also commonly used in traditional concrete renovation, such as filling cracks or reshaping components. In addition, some construction chemical products, such as reactive resin adhesives for ceramic tiles or mortar, also contain epoxy resin components to enhance adhesion or flexibility.
Epoxy resin mortar is favored in various fields due to its excellent performance. Here are some of the most common applications:
1. Industrial Flooring
★Epoxy resin mortar mixer has excellent chemical resistance and mechanical strength, making it an ideal choice for industrial floors that bear heavy loads. ★Epoxy resin also has moisture-proof performance, making it an ideal building material for basements and cellars.
2. Concrete Repair
Epoxy resin mortar mixer is an ideal choice for repairing and renovating damaged concrete components because of its strong adhesion, rapid curing, and almost no shrinkage effect. It has high-temperature resistance and can resist freezing even under frosty conditions (within certain limits). With its excellent adhesion, this mortar is very suitable for external renovation projects where the ground is exposed to extreme temperature differences.
3. Grouting
Epoxy resin mortar mixer can be used for grouting in high-stress areas such as laboratories, commercial kitchens, swimming pools, or industrial facilities. In addition to having excellent chemical resistance, resistance to temperature fluctuations, and moisture resistance, this material also features high resilience and high impermeability.
4. EP Coatings
They are used for surface protection, especially against mechanical and chemical impacts, such as in parking lots, shopping malls, and production or logistics areas. The addition of color pigments or binders can also provide a variety of design options.
5. Adhesives
Due to their strong adhesive properties, they are also used as adhesives in mortar mixer in the construction industry.
6. Decorative Applications
In living areas, they are also used for decorative floor coverings because they are available in a variety of colors and surface textures. Epoxy resin coatings are also often used in garages because they are easy to clean.
Avoiding Failures in the Production of Epoxy Resin Mixtures
1. Inadequate Substrate Preparation
An unclean surface—with dust or grease remaining—will impair the adhesion of the material.
2. Incorrect Proportioning
Improper mixing ratio of resin and curing agent. Too little curing agent will cause the surface to remain sticky and fail to cure. Too much curing agent will accelerate the reaction, causing the mixture to harden during processing in mortar mixer. Be sure to use a precision electronic scale and strictly follow the instructions provided by the material manufacturer. To avoid such errors, construction chemicals are supplied in pre-packaged form with the correct proportions.
3. Incorrect Mixing
Insufficient mixing or inadequate mixing time in mortar mixer will result in uneven blending of components. Typically, mixing must be performed at low speed for 3 minutes using the appropriate mixing paddle.
4. Failure to Transfer to a New Container
To ensure complete mixing of the mixture in mortar mixer, many material manufacturers recommend "transferring to a new container". This means that after the first mixing, the material is moved to another clean container and thoroughly mixed again. This prevents dry material from remaining at the bottom or edges of the bucket, thereby avoiding the formation of undissolved resin pockets.
5. Presence of Bubbles in the Mixture
This is particularly detrimental to liquid coatings. It may be caused by excessively high stirring speed or the use of an inappropriate mixing paddle. Bubbles may fail to dissipate during subsequent processing of mortar mixer, resulting in poor surface appearance.
6. Low Room Temperature
Curing is delayed, and the surface remains sticky. Ensure that the room temperature is within the specified range before starting construction. Ideally, the ambient temperature for epoxy resin application should be between 16 and 20°C. When the temperature is below 15°C, the curing time will be prolonged; when it exceeds 25°C, the curing time will be significantly shortened.
Proper Mixing Techniques for Epoxy Resin Bonding Materials
★Dual-shaft mortar mixer: These hand-held forced mixers, such as Xo33Rduo or Xo55Rduo, are ideal for quickly and evenly stirring epoxy resin-sand mixtures. The mortar mixer can achieve sufficient stirring in a short time to fully wet the aggregates. Meanwhile, the reverse rotation design of the mixing tool prevents the force of the material from acting on the operator, making it easier to stir even heavier mixtures.
★Basket paddles and disc paddles: The first step is to premix the thin epoxy resin and its hardener in mortar mixer. Depending on the quantity and delivery container, use an electric stirrer such as XQ1 or XQ4. For this purpose, use a stirring rod (of KR or AR type) that draws as little air as possible into the mixture. For smaller containers (up to 5 liters, you can also use a drill or a cordless screwdriver as a driver. Depending on the chemical composition of the resin, its consistency can be thicker, or color pigments can be added for surface coating. A stirring rod that moves the mixture from top to bottom is also suitable for this. LX-type paddles are particularly well-suited for this purpose. During the mixing process, it is essential to ensure that the paddle is completely immersed in the material in mortar mixer.
