NORPHEN MALTA BASE

Epoxy binder
for the realization of quartz mortars

Description

NORPHEN MALTA BASE is a bicomponent liquid epoxy product made up of:

  • component A:   a mix of liquid epoxy prepolymers and special additives;
  • component B:   copolymerization amine.

The product was specifically designed to be additioned  with variable amounts of quartz sands (different particle size) to obtain exceptional resin-quartz mixes. These may be used to produce special mortars offering superior mechanical and chemical properties with respect to cement based ones.

Usage field

NORPHEN MALTA BASE is used as a mortar binder in the following applications:

  • building gradients made up of layers from 1mm thick upwards, prior to resin coating, in particular for the food processing industry;
  • repairing holes and depressions on industrial quartz concrete floors;
  • making joinings and props on bridges and viaducts;
  • making floor-to-wall borders before laying down resin floors.
Packaging

NORPHEN MALTA BASE is available in 3 kg and 12 kg packs.

NORPHEN MALTA BASE

Epoxy binder
for the realization of quartz mortars

Substrates preparation

Carefully examine the surface to make sure it provides a suitable and structurally sound base.

  • Industrial quartz concrete can be coated over after  shot blasting, diamond wheel sanding or acid washing, provided humidity content is max 3% (carbide measurement method).
  • Sand and concrete footings must have been left to set for a suitable period of time (at least 28 days); max residual humidity must be lower than 3% (carbide measurement); they must also have a minimum  250 - 300kg/cm² compression resistance, otherwise you must increase it by deep impregnation with NORPHEN SW SOLID (diluted according to technical card instructions); you will need between 50 and 100 g pure product (at least) for each centimetre thickness of the surface to be consolidated.
  • SC 1 ready footings can be coated over after 8 days (20°C and 50% residual humidity).
  • SC 1-R quick ready footings can be coated over after 48 hours (20°C and 50% RH).
  • Any footing realized with SC 1 BASE-like binders plus various sand types can be coated over 12 - 15 days later (20°C and 50% RH), after checking subfloor residual humidity.
  • Tiled surfaces must be made rough using a diamond cup wheel.
  • Large wood panelled surfaces can be coated over after treating the gaps with NORPHEN PU reinforced with a 160g/m² GLASS MESH strip (about 5 - 7 cm wide), followed by fine dusting with 0.1 - 0.5 mm. quartz sand.
Specific preparation

1) Surface humidity content lower than 3%:

  • before proceeding with NORPHEN MALTA BASE, it is essential always to treat the surface with a layer of  NORPHEN FONDO SL, finely dusted with 0.2-0.7 mm quartz sand (amount needed: approx. 250 g/m² if you are using a roller and 1000 g/m² if you are using a  spatula).


2) Surface humidity content between 3%  and 4.5 %:

  • Apply a coat of NORPHEN SW SOLID, plain or diluted with 20%-30% water (in weight);
  • the day after, go ahead with NORPHEN MALTA BASE.


3) Surface humidity content higher than 4.5 %:

  • Replace NORPHEN MALTA BASE with NORPHEN SW SOLID, adding just enough water to allow for easy handling.

 

4) Industrial quartz concrete:

  • shot blasting is the best way to prepare this type of surface before applying NORPHEN MALTA BASE. On the now rougher surface you can apply a layer of NORPHEN FONDO SL, followed by quartz dusting, before carrying on with any further operation.


5) Section gaps

Pay special attention to section gaps; this the procedure to follow:

a) industrial quartz floors up to 15 cm thick, less than 1 year old, with only one reinforcing mesh:

  • cut and seal  to finish;

b) floors as above, more than 18 cm thick and with two reinforcing meshes, or else floors with only one reinforcing mesh (more than 1 year old):

  • fill the gap and make up a band of NORPHEN PU elastomeric resin reinforced with 160g/m² GLASS MESH strip. 
Product preparation

To prepare quartz epoxy mortars you need a fixed body mixer with internal rotor; that does not apply, however, if you are preparing up to 50 kg mix at a time, in which case a small mixer with a plastic tank and fixed blade unit, easily found on the market, will do.

Product application
  • bring the prepared mix to the working area;
  • pour it over the surface, spreading with a rake, and adjust thickness with a trowel, if the amount of binder is max 10% the amount of quartz sand;
  • pour over the surface, spreading with a steel spatula, if the amount of binder exceeds by 10% the amount of  sand.

The day after, fill up any open pore on the mortar prepared with <10% binder by applying a layer of NORPHEN FONDO SL, possibly additioned with 0.1-0.3 mm sand, and thickened with SILICA (1.0¸1.5% in weight).

You can then proceed with any further planned operation.

NORPHEN MALTA BASE

Epoxy binder
for the realization of quartz mortars

Average Consumption

The amounts needed are approximately:

  • for mortars with less than 10% binder out of the total  (resin+quartz sand) weight: c. 2 kg /m²/mm;
  • for mortars with more than 10% binder out of the total  (resin+quartz sand) weight: from 1.6 to 1.8 kg/m²/mm.

NORPHEN MALTA BASE

Epoxy binder
for the realization of quartz mortars

Features

SUMMER version

Mass per volume (A+B), UNI 8310 

 g/cm³ 

 1.05 ± 0.05 

Pot-life, UNI EN ISO 9514

min

25

Surface drying time, UNI 8904

min

180 ± 15

Minimum setting time

days

> 7

Application temperature

°C

 +15 to +35

 A : B  ratio

 

2 : 1

Note: test data refer to quoted regulations.

 

WINTER version

Mass per volume (A+B), UNI 8310 

 g/cm³

 1.05 ± 0.05 

Pot-life, UNI EN ISO 9514

min

10

Surface drying time,

UNI 8904

min

90 ± 15

Minimum setting time

days

> 7

Application temperature

°C

+5 to +15

A : B  ratio

 

2 : 1

Note: test data refer to quoted regulations.

NORPHEN MALTA BASE

Epoxy binder
for the realization of quartz mortars

Warning and informations
  • Do not use on:

-   parquet;
-   linoleum;
-   rubber and any surface likely to expand considerably at the gaps.

  • Measure the temperature of the room where you are going to operate in order to find out the correct product version to use:

 Temperature interval [°C]

NORPHEN MALTA BASE version

 +0 to +15

WINTER

Over +15

SUMMER

 

  • According to the temperature found in the room, keep the product cool in summer, to prevent any increase of the system reaction speed with temperature, and warm in winter, because cold makes resins more likely to crystallize and become less fluid.
  • Pay special attention to product mixing and application times when you use WINTER NORPHEN MALTA BASE, is it hardens quite quickly at temperatures between +8°C and +15°C.
  • Mechanical compacting with float trowel blades will deliver considerably improved compression resistance properties.
  • Read the safety card.
Preservation

Store indoors at temperatures between +4 and +30°C.

NORPHEN MALTA BASE

Epoxy binder
for the realization of quartz mortars