FOX EPOFLOW® FC541 is an epoxy-based, three-component, solvent-free structural repair and filling mortar containing specially graded quartz aggregate. Compliant with EN 1504-3/R4 class, the product provides high mechanical strength across a wide range of applications, from the repair of reinforced concrete structural elements to marine structures.

Colour Palette

Packaging

10 kg
TDS

Product Description

FOX EPOFLOW® FC541 is an epoxy-based, three-component (A: Epoxy Resin, B: Epoxy Hardener, C: Specially Graded Quartz), solvent-free structural repair and filling mortar. It is evaluated within the scope of Bayındırlık Poz No: 04.613/8-b and complies with EN 1504-3 standard class R4. The product delivers high mechanical performance with compressive strength of >40 N/mm² at 1 day and >70 N/mm² at 7 days. Adhesion strength to concrete is >2 N/mm² and to steel >2,5 N/mm². With an application thickness range of 4 mm to 50 mm, it can close wide repair sections in a single coat. Applied at substrate temperatures between +5°C and +35°C; withstands service temperatures from -15°C to +70°C. Solvent-free and hardens without shrinkage.

Key Benefits

  • Thanks to EN 1504-3/R4 compliance, it can be confidently specified in structural repair projects.
  • Its solvent-free formulation enables safer application in enclosed and poorly ventilated areas.
  • Provides permanent and reliable adhesion with >2 N/mm² bond strength to concrete and >2,5 N/mm² to steel.
  • With >70 N/mm² compressive strength at 7 days, it delivers long-lasting repairs on high load-bearing structural elements.
  • Direct application without a primer shortens the work process and reduces costs.
  • A single-coat application thickness range of 4–50 mm offers the flexibility to repair damage of varying depths in a single operation.

Advantages

  • Applied without primer.
  • Resistant to chemicals.
  • High compressive, flexural and tensile strength.
  • High abrasion and impact resistance.
  • Long pot life and working time.
  • Solvent-free.
  • Hardens without shrinkage.
PropertyValue
Material Composition – Component AEpoxy Resin
Material Composition – Component BEpoxy Hardener
Material Composition – Component CSpecially Graded Quartz
ColourGrey
Density2,06 kg/lt
Compressive Strength (1 day, TS EN 12190)>40 N/mm²
Compressive Strength (7 days, TS EN 12190)>70 N/mm²
Flexural Strength (1 day, TS EN 12190)>15 N/mm²
Flexural Strength (7 days, TS EN 12190)>25 N/mm²
Adhesion Strength – To Concrete (TS EN 1542)>2 N/mm²
Adhesion Strength – To Steel (TS EN 1542)>2,5 N/mm²
Application ThicknessMin. 4 mm - Max. 50 mm
Substrate Temperature for Application+5°C / +35°C
Service Temperature-15°C / +70°C
Pot Life30 minutes
Recoatability18-24 hours
Foot Traffic24 hours
Full Cure Time7 days
Shelf Life12 months
Public Works Item No.04.613/8-b
Compliant StandardEN 1504-3 / R4

Usage Areas

  • Repair of reinforced concrete structural elements
  • Repair of marine structures
  • Repair of underground civil engineering structures
  • High-strength assembly and repair work on crane beams and supports
  • Filling of gaps between reinforced concrete columns and steel reinforcement

Application Steps

  1. 1

    Surface Preparation

    Surfaces to be repaired must be sound, dry, load-bearing, dust-free and clean. All oil, grease, rust and paraffin residues that could weaken surface adhesion must be thoroughly removed. The edges of the broken surface should be made as vertical as possible, and rust and residues on the reinforcement must be cleaned.

  2. 2

    Mixing

    Components A and B are added to a clean mixing bucket and mixed for 2 minutes using an electric mixer at 400–600 rpm with a suitable mixing paddle. Component C is then added slowly and mixed until a homogeneous, lump-free mixture is obtained.

  3. 3

    Application

    The prepared mixture should be applied to the surface with a trowel. The thickness should be between 4 mm and 50 mm. The maximum application thickness must not exceed 50 mm in a single coat.

  4. 4

    Tool Cleaning

    Tools and equipment used must be cleaned immediately with solvent after application. Once FOX EPOFLOW FC541 has cured, it can only be removed from the surface mechanically.

Critical

FOX EPOFLOW FC541 must not be applied at temperatures below +5°C or above +35°C.

Critical

At +20°C it must be applied within 30 minutes, and at +30°C within 20 minutes; once the working time is exceeded, the material becomes unusable.

Critical

For the material to complete its cure, the substrate and ambient temperature must not fall below the permitted minimum temperature.

Critical

No solvents or similar substances must be added to the prepared mix during application.

Important

Large open surfaces exposed to the atmosphere must be protected from rain and external influences for 24–48 hours after application.

Important

Tools and equipment must be cleaned with solvent immediately after application. Cured product can only be removed by mechanical means.

Important

Opened packages must be resealed and consumed within 1 week.

Important

The product must be stored between +5°C and +30°C, in a cool and dry place away from direct sunlight. Protect from frost.

Critical

Approaching storage and application areas with open flames is dangerous; these areas must be ventilated.

Critical

Work clothing, protective gloves, goggles and a mask must be worn during application. Avoid contact with skin and eyes; in case of contact, wash thoroughly with plenty of water and soap. If swallowed, consult a doctor immediately.

Important

Food and beverages must not be brought into application areas. Store out of reach of children.

Information

Working and reaction times of epoxy-based repair mortars are affected by air temperature, humidity and substrate temperature. High temperatures shorten the working time; low temperatures extend it.

Information

Technical property values are given for +23°C and 50% relative humidity conditions.