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, finished with an optional MavSeal UPA grout 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: MavPrime EP primer, epoxy mortar body, an optional 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.
| Application | Product | Function in the System | Documents |
|---|---|---|---|
| Primer | MavPrime EP | Penetrating epoxy primer over CSP 3–5 prepared concrete — the bond coat under the mortar at 175–250 sq.ft./gal per the MavClad EM data sheet. 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. | Data Sheet (PDF) |
| Grout coat | MavSeal UPA (optional) | Optional grout coat pulled tight over the sanded mortar at 175 sq.ft./gal to fill voids and pinholes for a smoother, denser finish — per the MavClad EM data sheet. | TDS (PDF) |
| 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 |
Chemical Resistance
MavClad EM is a mortar body, and its finished chemical resistance is governed by the topcoat specified over it — the MavClad EM data sheet calls for a Maverick pigmented topcoat for UV, chemical, and traffic resistance. For reagent-by-reagent ratings, use the table for the topcoat on your build: MavCoat SLE for epoxy topcoats, or MavSeal UPA for polyaspartic topcoats. Maverick publishes no reagent table for the bare mortar body, so send us the exposure list and we will confirm the build against the data sheets rather than estimate.
FAQ
Common Questions
How thick is a MavClad troweled floor?
MavClad EM is placed with a screed box and steel-troweled smooth at a nominal ¼″ — a true mortar body, not a self-leveling film. That quarter inch rebuilds spalled, pitted, and chemically etched concrete to a flat, sound wearing surface.
How soon can the floor return to service?
Foot traffic in 12–24 hours and full return to service in 48–72 hours, based on laboratory results at 70°F. Request the TDS for project values.
How much mechanical abuse can MavClad take?
13,250 psi compressive strength and a Shore D hardness of 75–90 stand up to hard wheels, impact, point loads, forklift traffic, and dropped tooling. Damaged areas are abraded and re-troweled — the floor never has to come out.
How does surface preparation work?
The concrete is mechanically prepared to a CSP 3–5 profile, then primed with penetrating MavPrime EP at 175–250 sq.ft./gal per the MavClad EM data sheet. MavCoat MVB substitutes where moisture vapor is present.
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.