MavClad ¼″ Troweled Mortar Systems
When a coating isn't enough, you trowel a floor. MavClad EM is a 100% solids epoxy mortar placed at a full ¼″ over MavPrime EP — a seamless, monolithic overlay engineered for the chemical exposure and mechanical abuse that thin-film systems can't survive. It rebuilds worn slabs and protects new ones, then takes a pigmented topcoat tuned to the service.
System Overview
A Quarter-Inch of Engineered Mortar, Not a Coat of Paint
MavClad EM combines a 100% solids epoxy binder with trowel aggregate — 3 gallons of mixed resin to 200 lbs. of aggregate per batch — placed with a screed box and steel-troweled smooth at a nominal ¼″. It is a true mortar body, not a self-leveling film: it fills coves, keyways, and chases, rebuilds eroded concrete, and shrugs off forklift traffic and dropped tooling.
The mortar is primed with MavPrime EP, grouted tight with a MavCoat OPE coat to fill pinholes, then finished with a pigmented Maverick topcoat for UV, chemical, and traffic resistance. One troweled body — documented end to end in the MavClad EM data sheet — specified to your floor.
Why Facilities Specify MavClad
- Mechanical abuse resistance — 13,250 psi compressive strength and a Shore D hardness of 75–90 stand up to hard wheels, impact, and point loads.
- Rebuilds worn slabs — a ¼″ monolithic overlay restores spalled, pitted, and chemically etched concrete to a flat, sound wearing surface.
- Seamless and chemically resistant — 100% solids, zero VOC, with no grout lines or joints in the wear surface for contamination to live in.
- Fills coves, keyways, and chases — troweled detailing ties the floor into walls, drains, and trenches as one surface.
- Repairable for life — damaged areas are abraded and re-troweled; the floor never has to come out.
System Build-Up
MavClad EM Cross-Section
The standard ¼″ troweled build-up: penetrating primer, epoxy mortar body, a tight grout coat, and a pigmented topcoat selected per service. Thicknesses adjust per the project data sheet.
System Components
Every Component, Documented
The products that make up the system, what each one does, and where to get its technical data. Components are supplied as factory-batched kits and installed by Maverick crews per the project specification.
| Role | Product | Function in the System | Documents |
|---|---|---|---|
| Primer | MavPrime EP | Penetrating 100% solids epoxy primer over CSP 3–5 prepared concrete — the bond coat under the mortar at 175–250 sq.ft./gal. MavCoat MVB substitutes where moisture vapor is present. | TDS (PDF) |
| Troweled mortar body | MavClad EM | ¼″ trowel-applied 100% solids epoxy mortar — the structural wearing body for heavy-duty industrial traffic; fills coves, keyways, and chases. | TDS (PDF) |
| Grout coat | MavCoat OPE | Tight grout coat pulled over the sanded mortar to fill voids and pinholes for a smoother, denser finish before the topcoat. | Request TDS |
| Decorative heavy-duty variant | MavClad EF-HD | Epoxy flake heavy-duty build — the troweled mortar broadcast with decorative flake and locked under a clear sealer where appearance matters as much as durability. | Shop Drawing (PDF) |
| Topcoat | MavSeal / MavCoat Topcoat | Pigmented finish coat selected per service environment for UV stability, chemical resistance, and the specified texture — required over the epoxy mortar for color stability. | Color Charts |
Where It Performs
Built for These Environments
- Warehousing & Distribution
- Manufacturing
- Chemical Processing
- Laboratories
- Healthcare & Hospitals
- Correctional Facilities
- Traffic Aisles & Assembly Lines
- Cafeterias & Commercial Kitchens
Performance
Typical System Properties
| Property | Test Method | Typical Value |
|---|---|---|
| Compressive strength | ASTM C-579 | 13,250 psi |
| Tensile strength | ASTM D-638 | 8,650 psi |
| Flexural strength | ASTM C-580 | 5,000 psi |
| Hardness, Shore D | ASTM D-2240 | 75–90 |
| Bond strength to concrete | ASTM D-4541 | 350 psi (concrete failure) |
| Abrasion resistance, CS-17 wheel | ASTM D-4060 | 75 mg loss |
| Solids by volume / VOC | — | 100% / 0 g/L |
| Return to service, foot traffic | — | 12–24 hours |
| Return to service, full | — | 48–72 hours |
Shop Drawings
Isometric Shop Drawings — MavClad Systems
Formal isometric shop drawings for the troweled mortar build-ups — layer by layer, ready for the project file. Direct download, no gating. The full library lives in the Architect Center.
MavClad EF-HD
Download PDFSpecifying a Troweled Floor?
Send us your slab condition, traffic, and chemical exposure. You'll have a recommended MavClad build-up and budget range within 48 hours.