KERAPOXY

Two-component acid-resistant epoxy grout

(available in 17 colours) for joints of at least 1 mm.
Can also be used as an adhesive

CLASSIFICATION IN COMPLIANCE WITH EN 13888

Kerapoxy is a reaction resin (R) grout (G) classified as RG.

CLASSIFICATION IN COMPLIANCE WITH EN 12004

Kerapoxy is an improved (2) reaction resin adhesive (R) and slip resistant (T) classified as R2T.
Conformity of Kerapoxy is declared in TT certificate n° 25040322/Gi (TUM) issued by the Technische Universität München
laboratory (Germany) and in TT certificates n° 2008-B-2748/7.1, 2008-B-2748/8.1 and 2008-B-2748/9.1 issued by the
Institute MPA Dresden (Germany).

WHERE TO USE
Indoor and outdoor grouting of ceramic tile and natural stone floors and walls. Also suitable for acid-resistant bonding
and rapid setting of ceramic tiles, stone materials, fibre-cement, concrete and any other building material on all types of
substrates normally used in construction.
Kerapoxy allows you to create floors, walls and worktops, etc. in compliance with the HACCP system and the
requirements of EC Regulation No. 852/2004 on the hygiene of foodstuffs.

Some application examples

· Grouting floors and walls in the food industry (dairies, abattoirs, breweries, wine-cellars, conserved-food plants, etc.),
shops and areas where hygiene is required (ice-cream shops, butchers, fish vendors, etc.).
· Grouting industrial floors and walls (electrical industries, tanneries, battery rooms, paper-mills, etc.), where high
mechanical resistance and resistance to acid attack is required.
· Grouting swimming pools; particularly suitable for basins containing salt or thermal water.
· Grouting tanks containing aggressive chemicals (purification plants, etc.).
· Grouting ceramic tiles on laboratory benches, kitchen work surfaces, etc.
· Acid-resistant bonding of tiles (used as an adhesive in compliance with class R2T specification according to EN 12004
standard).
· Bonding marble doorsteps and window-sills.
· Bonding tiles in plastic reinforced by fibre glass swimming pools.
· Bonding special pieces of tiles.
 An example of grouted ornamental An example of a bonded and grouted
An example of a grouted battery room stones kitchen worktop

An example of a grouted wine cellar

An example of a grouted brewery floor floor

TECHNICAL CHARACTERISTICS
Kerapoxy is a two-component, epoxy-resin-based product with silica sand and special components, with excellent
resistance to acids and excellent cleanability.
This is a product with very low emission of volatile organic compounds and is classified Emicode EC1 Plus by GEV when
used for grouting.
The following features are obtained when used correctly:
· excellent mechanical and chemical resistance, therefore excellent durability;
· a smooth final surface with low water absorption, therefore easy to clean; ensures hygiene;
· easy workability and finishing;
· becomes very hard and is highly resistant to heavy traffic;
· no shrinkage, therefore absence of cracks and fissures;
· uniform colours that are resistant to ultra-violet rays and atmospheric agents;
· excellent bonding.

RECOMMENDATIONS
· Thanks to the tiles’ reduced thickness, Kerapoxy can also be used for grouting glass mosaics.
· When grouting ceramic tiled floors and walls subject to oleic acid attack (e.g. ham and sausage industries, oil-mills, etc.)
and aromatic hydrocarbon, Kerapoxy IEG can be used (available in 113 or 130 reference colour of MAPEI range).
· For flexible expansion joints or joints subject to movement use an elastic sealant from the MAPEI line (e.g. Mapesil AC,
Mapesil LM, Mapeflex PU 45 FT or Mapeflex PU21).
· Kerapoxy does not ensure perfect adhesion when used for grouting tiles with wet edges or contaminated with cement,
dust, oil, grease, etc.
· Unglazed klinker tiles should be grouted with the same colour tone Kerapoxy. All other colours should be used only with
glazed tiles.
· Do not use Kerapoxy for grouting terracotta tiles because they are difficult to clean.
· Make preliminary sample tests before grouting porcelain tiles with a contrasting colour of Kerapoxy (e.g. black on white).
· Always carry out preliminary tests before grouting stone or ground porcelain with a porous or rough surface.
· Do not add water or any solvents to Kerapoxy to make it more fluid.
· Use the product in temperatures between +12°C and +30°C.
· The quantities are already in the correct proportions, therefore mistakes should not be made. Do not guess the
quantities when mixing the two components. A wrong catalysis ratio could impair the hardening process.
· When removing already cured Kerapoxy from the joints, use a hot air industrial drier. Remove hardened Kerapoxy from
the tiles with Pulicol 2000.
· When grouting large floor surface areas, it is recommended to use Kerapoxy Easy Design, because it is very easy to apply
and to clean.

APPLICATION PROCEDURE
Preparing the joints
The joints must be dry, clean, free of dust and emptied at least 2/3 of the tile thickness. The excess adhesive or mortar
should be removed while still fresh.
Before grouting, make sure that the installation mortar or the adhesive has set and released most of its moisture.
Kerapoxy is not affected by the moisture on the surface; the joints should not be wet during work.

Preparing the mix

Pour the hardener (component B), into the container of component A and mix well until a smooth paste is obtained. For
perfect mixing and avoiding overheating of the mixture, which could reduce working time, a low-speed electric mixer
should be used. Use the paste within 45 minutes from mixing.

Applying the grout

Spread Kerapoxy with an appropriate rubber float (such as MAPEI float), making sure the joints are completely filled. Use
the same float, but on edge, to remove excess grout.

Finishing
After grouting with Kerapoxy, floors and walls should be cleaned immediately, before the product dries.
Wet the surface thoroughly and emulsify with an abrasive pad for cleaning joints (such as Scotch-Brite® or MAPEI tile-
joint cleaning kit), making sure not to wash-out the joints. When cleaning walls, the cleaning pad should be fully soaked
with water. The excess liquid can be removed with a hard cellulose sponge (e.g. MAPEI sponge), and should be replaced
when too full of resin. Use the same type of sponge for the final tooling of the grout.
It is very important that, once the finishing process has ended, no traces of Kerapoxy are left on the tile surface because it
will be very difficult to remove. It is therefore necessary to frequently rinse the sponge with clean water during the
cleaning process.
When finishing large floor surface areas, use a rotary, disc-type power float with Scotch-Brite® abrasive pads, well
saturated with water. All excess liquid can be removed with a rubber squeegee.
UltraCare Kerapoxy Cleaner (special cleaning solution for epoxy grout) may also be used for the final cleaning cycle.
UltraCare Kerapoxy Cleaner can be used both immediately after grouting and after completing laying work.
If cleaning is carried out a few hours after applying the grout, it may be necessary to leave it standing for longer (at least
15-20 minutes) or you may need to repeat the cycle.
The efficiency of UltraCare Kerapoxy Cleaner depends on the amount of residual resin and how much time has passed
since application.
For residues that have cured on the surface over time or if residues persist then use UltraCare Epoxy Off Gel, special high-
viscosity cleaner to remove epoxy residues.
For the use of products from the UltraCare range, please refer to the relative Techincal Data Sheets.

Grouting of single fired tile wall with a Finishing of single fired tile wall with Finishing of single fired tile wall with
float a Scotch-Brite® pad a sponge
 Finishing a porcelain tiled floor with
single-brushed power float or rubber Grouting a ceramic tile floor with Finishing a ceramic tile floor with
squeegee wood inlays with a trowel wood inlays with a sponge

APPLICATION PROCEDURE AS AN ADHESIVE

After mixing the two components as described above, spread the adhesive with a notched trowel. Apply the tile under
firm pressure to ensure good contact. After setting, bonding becomes extremely strong and resistant to chemical agents.

SET TO LIGHT FOOT TRAFFIC

At +20°C, floors are set to light foot traffic after 24 hours.

READY FOR USE

(with hypothetical curing at +23°C and 50% R.H.)
4 days. After 10 days, the surfaces may also be subjected to chemical attack. Basins and swimming pools can be filled up
10 days after grouting. Times may vary according to the temperature.

CLEANING
Clean tools and containers with plenty of water before Kerapoxy hardens. When Kerapoxy has hardened, removal is only
possible by mechanical means or with Pulicol 2000.

CONSUMPTION
Consumption of Kerapoxy varies depending on the width of the joints, the size and thickness of the tiles. The table shows
consumption in kg/m².
When Kerapoxy is used as an adhesive, consumption is 2-4 kg/m².

PACKAGING
Kerapoxy is supplied, with mixing proportions carefully measured, in drums containing component A and bottles of
component B to be mixed when using the product.
The total weight of the units is: 10, 5 and 2 kg in total.

COLOURS
Kerapoxy is available in 17 colours from the “MAPEI Coloured Grouts” range.

STORAGE
Kerapoxy can be stored 24 months in a dry place in original packaging.
Store component A at a temperature of at least +10°C to avoid crystallisation which, however, can be reversed by
warming.

SAFETY INSTRUCTIONS FOR PREPARATION AND APPLICATION

Instructions for the safe use of our products can be found on the latest version of the Safety Data Sheet, available from
our website www.mapei.com.
PRODUCT FOR PROFESSIONAL USE.

TECHNICAL DATA (typical values)

In compliance with:
– European EN 12004 as R2T
– ISO 13007-1 as R2T
– European EN 13888 as RG
– ISO 13007-3 as RG

PRODUCT IDENTITY

component A component B

Consistency: thick paste dense liquid

Colour: 17 colours available

Density (g/cm³): 1.64 0.97

Dry solids content (%): 100 100

Brookfield viscosity (mPa·s) 3,500,000 900

EMICODE (as a grout): EC1 Plus - very low emission

APPLICATION DATA (at +23°C and 50% R.H.)

Mix ratio: component A : component B = 9 : 1

Consistency of mix: thick paste

Density of mix (kg/m³): 1,550

Pot life: 45 minutes

Application temperature: from +12°C to +30°C

Open time (as an adhesive): 30 minutes

Adjustability time (as an adhesive): 60 minutes

Set to light foot traffic: 24 hours

Ready for use: 4 days (10 days for basins and swimming pools).
Times may vary according to the temperature.

FINAL PERFORMANCE

Shear adhesion strength according to EN 12003 (N/mm²): 25

– initial: 23
– after water immersion: 25
– after thermal shock:

Flexural strength (EN 12808-3) (N/mm²): 31

Compressive strength (EN 12808-3) (N/mm²): 55

Resistance to abrasion (EN 12808-2): 147 (loss in mm³)

Water absorption (EN 12808-5) (g): 0.05

Resistance to moisture: excellent

Resistance to ageing: excellent

Resistance to solvents and oils: very good (see table)

Resistance to acids and alkalis: excellent (see table)

Temperature in use: from -20°C to +100°C

CONSUMPTION RATES ACCORDING TO THE SIZE OF THE TILES AND THE WIDTH OF THE JOINTS (kg/m2)

Width of joint (mm)

Size of tile (mm)
3 5 8 10
75x150x6 0.6 1.0 1.5 1.9
100x100x7 0.7 1.1 1.8 2.2
100x100x9 0.9 1.4 2.3 2.9
150x150x6 0.4 0.6 1.0 1.3
200x200x7 0.3 0.6 0.9 1.1
200x200x9 0.4 0.7 1.2 1.4
300x300x10 0.3 0.5 0.9 1.1
300x300x20 0.6 1.1 1.7 2.1
300x600x10 0.2 0.4 0.6 0.8
400x400x10 0.2 0.4 0.6 0.8
500x500x10 0.2 0.3 0.5 0.6
600x600x10 0.2 0.3 0.4 0.5
750x750x10 0.1 0.2 0.3 0.4
100x600x9 0.5 0.8 1.3 1.7
150x600x9 0.4 0.6 1.0 1.2
150x900x9 0.3 0.6 0.9 1.1
150x1200x10 0.4 0.6 1.0 1.2
225x450x9 0.3 0.5 0.8 1.0
225x900x9 0.2 0.4 0.6 0.8
250x900x9 0.2 0.4 0.6 0.7
250x1200x10 0.2 0.4 0.6 0.8
600x600x5 0.1 0.1 0.2 0.3
600x600x3 0.1 0.1 0.2
1000x500x5 0.1 0.1 0.2 0.2
1000x500x3 0.1 0.1 0.1
1000x1000x5 0.1 0.1 0.2
1000x1000x3 0.1 0.1
3000x1000x5 0.1 0.1 0.1
3000x1000x3 0.1 0.1

FORMULA FOR THE COVERAGE CALCULATION:

A = length of tile (in mm)

B = width of the tile (in mm)
C = thickness of the tile (in mm)
D = width of the joint (in mm)

For sizes not covered by the table, our website www.mapei.com has a calculator available to estimate consumption
rates according to the size of the tiles and the width of the joints.

CHEMICAL RESISTANCE OF CERAMIC TILING GROUTED WITH KERAPOXY*

PRODUCT USE
INDUSTRIAL FLOORING
Group Name Concentration % Laboratory benches Permanently Sporadically
used (+20°C) used (+20°C)
Acids Acetic acid 2.5 + + +
5 + (+) +
10 – – –
Hydrochloric acid 37 + + +
Chromic acid 20 – – –
Citric acid 10 + (+) +
Formic acid 2.5 + + +
10 – – –
Lactic acid 2.5 + + +
5 + (+) +
10 (+) – (+)
Nitric acid 25 + (+) +
50 – – –
Pure oleic acid – – –
Phosphoric acid 50 + + +
75 (+) – (+)
Sulphuric acid 1.5 + + +
50 + (+) +
96 – – –
Tannic acid 10 + + +
Tartaric acid 10 + + +
Oxalic acid 10 + + +
Alkalis Ammonia in solution 25 + + +
Caustic soda 50 + + +
Sodium hypochlorite in
solution: active chlorine 6.4 g/l + (+) +
active chlorine 162 g/l – – –
Potassium 5 + (+) +
permanganate 10 (+) – (+)
Potassium hydroxide 50 + + +
Sodium bisulphite 10 + + +
Saturated Sodium hyposulphite + + +
solutions Calcium chloride + + +
at +20°C Ferric chloride + + +
Sodium chloride + + +
Sodium chromate + + +
Sugar + + +
Aluminium sulphate + + +
Oils and Petrol, fuels + (+) +
fuels Turpentine + + +
Diesel fuel + + +
Tar oil + (+) (+)
 Olive oil (+) (+) +
Light fuel oil + + +
Petrol + + +
Solvents Acetone – – –
Ethylene glycol + + +
Glycerine + + +
Methylene glycol acetate – – –
Perchloroethylene – – –
Carbon tetrachloride (+) – (+)
Ethyl alcohol + (+) +
Trichloroethylene – – –
Chloroform – – –
Methylene chloride – – –
Tetrahydrofurane – – –
Toluene – – –
Carbon sulphide (+) – (+)
White spirit + + +
Benzene – – –
Trichloroethane – – –
Xylene – – –
Mercuric chloride (HgCl2) 5 + + +
Hydrogen peroxide 1 + + +
10 + + +
25 + (+) +
Legend: + excellent resistance (+) good resistance – poor resistance

* Evaluated in compliance with EN 12808-1 standards

Kerapoxy

100 WHITE

111 SILVER GREY

112 MEDIUM GREY

113 CEMENT GREY

114 ANTHRACITE

110 MANHATTAN 2000

172 SPACE BLUE

130 JASMINE

131 VANILLA

132 BEIGE 2000

141 CARAMEL

142 BROWN

144 CHOCOLATE

145 TERRA DI SIENA

 143 TERRACOTTA

120 BLACK

150 YELLOW

N.B.: Due to the printing processes involved, the colours should be taken as merely indicative of the shades of the actual
product

WARNING
Although the technical details and recommendations contained in this product data sheet correspond to the best of our
knowledge and experience, all the above information must, in every case, be taken as merely indicative and subject to
confirmation after long-term practical application; for this reason, anyone who intends to use the product must ensure
beforehand that it is suitable for the envisaged application. In every case, the user alone is fully responsible for any
consequences deriving from the use of the product.
Please refer to the current version of the Technical Data Sheet, available from our website www.mapei.com

LEGAL NOTICE
The contents of this Technical Data Sheet (“TDS”) may be copied into another project-related document, but the
resulting document shall not supplement or replace requirements per the TDS in force at the time of the MAPEI product
installation.
The most up-to-date TDS can be downloaded from our website www.mapei.com.
ANY ALTERATION TO THE WORDING OR REQUIREMENTS CONTAINED OR DERIVED FROM THIS TDS EXCLUDES THE
RESPONSIBILITY OF MAPEI.

141-8-2021-gb

. Any reproduction of texts, photos and illustrations published here is prohibited and subject to .
prosecution