79005718 fosroc catalogue

constructive solutions

Technical data sheet catalogue10th edition

Alphabetical index

Cebex 100Cebex 250Cebex 653Cemtop (S, GP12, GP30, XD)Colpor 200PFConbextra BBConbextra EP (EP10 & EPR)Conbextra GPConbextra HFConbextra TSConbextra UWConcure WB

Dekguard ClearDekguard E2000Dekguard ElasticDekguard SDekguard TexturedDekguard WDemokret Eco D1

ExpandafoamExpoband H45Expocrete UAExpoflex 800

Famguard GS100Flamex Fire Protection -(Flamex One & Two)Flamex SFosroc Acid EtchFosroc FibreboardFosroc XR 45Fosroc XR 90Fosroc XR CobblesetFosroc XR PE20Fosroc XR RSC

C

D

E

F

294296297147174274287277280283285162

117120123126129132359

211264

86183

234203

207164213107109111113115

Galvafroid

Hilastic LMHydrocell XLHydromax

Integra

Lokfix (P25 & S25)

Mulseal DP

Nitobond AR/HARNitobond EPNitobond SBRNitocote CM210Nitocote EP403Nitocote EP405Nitocote EP410Nitocote SN502Nitocote SN511Nitofil LV/THNitoflor FC130/FC140Nitoflor Hardtop SNitoflor LithurinNitokit LV/THNitomortar FCNitomortar HBNiomortar PENitomortar SNitoprime Zincrich PlusNitoseal MS50Nitoseal MS100Nitoseal MS300Nitoseal MS600Nitoseal 12Nitoseal 333Nitoseal 878

145

185215338

237

290

239

151618

241135137139141143102151154157105

8891949822

187189192169166176178

G

H

I

L

M

N


Alphabetical index

Patchroc GPPaverocPlastijointPlastisealPliastic (N2 & 77)Polyurea FLMPolyurea WPEProofex 3000Proofex 3000MRProofex CavitydrainProofex EngageProofex HydromatProofex LMProofex Radon BarrierProofex SheetdrainProofex TotalProofex WG

Renderoc DSRenderoc FCRenderoc GPRenderoc HBRenderoc HB30Renderoc HB45Renderoc HBSRenderoc LARenderoc LA55Renderoc Plug (Plug 1, Plug 20)Renderoc RP252Renderoc SRenderoc SCRenderoc ST 05

P

R

2428

172194180159245248268250252254257270259272262

3236404448525660646870747882

SecofoamSilicone Sealant 33HMSupercast Butyl-NekSupercast PVCSupercast SWSupercast SynkoflexSupercast Twinstop

Thioflex 600

217197220222226228232

200

S

T


Product group index

Concrete Repair &Remediation

Cementitious RepairNitobond AR/HARNitobond EPNitobond SBRNitoprime Zincrich PlusPatchroc GP*Paveroc*Renderoc DS*Renderoc FC*Renderoc GP*Renderoc HB*Renderoc HB30*Renderoc HB45*Renderoc HBS*Renderoc LA*Renderoc LA55*Renderoc Plug (Plug 1, Plug 20)*Renderoc RP252*Renderoc S*Renderoc SC*Renderoc ST 05** EN1504 compliant

Resin repairsExpocrete UANitomortar FCNitomortar HBNitomortar PENitomortar S

Crack injection resinsNitofil LV/THNitokit LV/TH

Road rehabilitationFosroc XR 45Fosroc XR 90Fosroc XR CobblesetFosroc XR PE20Fosroc XR RSC

1 1516182224283236404448525660646870747882

8688919498

102105

107109111113115

Finishes

Anti-carbonation & chloride resist-ant coatingsDekguard ClearDekguard E2000Dekguard ElasticDekguard SDekguard TexturedDekguard WNitoprime DG (see Dekguard)

2

3

4

5 117120123126129132

Chemical resistant coatingsNitocote EP403Nitocote EP405Nitocote EP410

Water resistant coatingsNitocote SN502Nitocote SN511Polyurea WPE

Metal protective coatingGalvafroid

Flooring materialsCemtop (S, GP30, GP12, XD)Nitoflor FC130/FC140Nitoflor Hardtop SNitoflor LithurinPolyurea FLM

Surface treatmentsConcure WBFosroc Acid Etch

135137139

141143245

145

147151154157159

162164

6

7

8

9

10

18

17

16

Product group index

20

21

22

Grouts & Anchors

Cement & ConcreteTechnology

11

Barriers

Water industry sealantsNitoseal 12Nitoseal MS600Plastijoint

Road & pavement sealantsColpor 200PFNitoseal 333Nitoseal 878Pliastic (N2 & 77)

Building sealantsExpoflex 800Hilastic LMNitoseal MS50Nitoseal MS100Nitoseal MS300Nitoseal MS600PlastisealSilicone Sealant 33HMThioflex 600

Fire protection sealantsFlamex Fire Protection(Flamex One & Two)

Flamex S

Joint fillersExpandafoamFosroc FibreboardHydrocell XLSecofoam

166169172

174176178180

183185187189192169194197200

203207

211213215217

12

13

14

15

Joint Sealants

19 Gas membranesProofex 3000MRProofex EngageProofex Radon BarrierProofex Total

Cementitious groutsConbextra BBConbextra GPConbextra HFConbextra TSConbextra UW

Epoxy resin groutsConbextra EP (EP10 & EPR)Lokfix (Lokfix P25 & S25)

Grout admixturesCebex 100Cebex 250Cebex 653

274277280283285

287290

294296297

Waterproofing

WaterstopsSupercast Butyl-NekSupercast PVCSupercast SWSupercast SynkoflexSupercast Twinstop

Waterproofing membranesFamguard GS100IntegraMulseal DPNitocote CM210Polyurea WPEProofex 3000Proofex CavitydrainProofex EngageProofex HydromatProofex LMProofex SheetdrainProofex WG

Joint overbanding systemExpoband H45

234237239241245248250252254257259262

264

Gas membranes

220222226228232

268252270272

Polymer emulsion bonding agents

Uses

Nitobond AR and Nitobond HAR are recommendedprimers for the Renderoc cementitious repair systems.

Nitobond AR is also recommended as a curingmembrane for Renderoc repairs. It may also be used asan economical dust proofer for non-traffickedcementitious surfaces.

Advantages

Single component No site mixingEasy to use Ready to use straight from

the containerHigh bond strength Excellent bond strength

between Renderoc systemsand concrete

Cost effective Economical in useCuring aid Can be used as curing

membrane for Renderocsystems

Description

Nitobond AR and Nitobond HAR are single componentpolymer emulsion systems designed as bonding agentsand curing membranes for Renderoc repair products.They may also be used as concrete surface sealers innon-traffic areas.

Application instructions

Preparation

All surfaces should be clean and free from dust andcontamination.

Application

Nitobond AR and Nitobond HAR are supplied ready foruse when used as bonding primers or curingmembranes. When used as a surface sealer NitobondAR should be diluted 1:1 with water for the first coat andas supplied for the second coat. Application should be by

spray, brush or medium pile roller. Care should be takento ensure complete and thorough wetting of the surface.

Cleaning

Wash all equipment with clean water immediately afteruse.

Estimating

SupplyNitobond AR 1 litre and 5 litre bottles,

25 litre drumsNitobond HAR 1 litre and 5 litrebottles,

25 litre drums

Coverage and yieldAs PrimerNitobond AR & Nitobond HAR 4-6m

2/litre

As Curing MembraneNitobond AR 6-8m

2/litre

As Surface SealerNitobond AR 6-10m

2/litre

Limitations

Do not use Nitobond AR or Nitobond HAR when thetemperature is below 50C and falling.

Storage

Store in dry conditions at 5o-25oC. Shelf life is 12 months ifstored in dry conditions. Protect from frost.

Precautions

Health and safety

For further information refer to appropriate Product SafetyData Sheet.

Fire

Nitobond AR and Nitobond HAR are non-flammable.


Fosroc® Nitobond ARNitobond HAR

1CI/SfB:

June 2008

Fosroc LimitedDrayton Manor Business ParkColeshill Road, Tamworth,Staffordshire B78 3TL. UK

telephone: fax: email:+44 (0) 1827 262222 +44 (0) 1827 262444 [email protected]

Certificate number FM 610

Important noteFosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for theSupply of Goods and Services, copies of which may be obtained on request. Whilst Fosroc endeavours to ensure that any advice,recommendation, specification of information it may give is accurate and correct, it cannot, because it has no direct or continuous controlover where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether ornot in accordance with any advice, specification, recommendation of information given by it.

Nitobond is the trade mark of Fosroc International Limited

15

Epoxy-resin concrete bonding agent

Uses

For bonding new cementitious materials to existingcementitious surfacesFor use on horizontal surfaces and on verticalsurfaces where mortar or concrete can be supportedby formworkIdeal for extensions and repairs to concrete infactories, loading bays, trucking aisles, bridges, roads,bonded or granolithic floor toppings, etc

Advantages

Can be applied to dry or damp surfacesHigh mechanical strengthGood positive adhesionCan be applied where a substrate/repair barrier isrequiredStandard and slow set grades

Description

Nitobond EP is based on solvent-free epoxy resinscontaining pigments and fine fillers. It is supplied as atwo-part material in pre-weighed quantities ready for on-site mixing and use.

Coloured components, white base and green hardener,provide visual evidence that adequate mixing is achieved.

Properties

Standard Slow set

Pot life @ 20°C: 35 to 45 minutes 5 to 6 hoursInitial hardness: 24 hours 48 hoursFull cure: 7 days 7 daysMaximum overlaytime @ 20°C: 90 minutes 24 hoursMinimum applicationtemperature: 5°C 5°C

The following results were obtained at a temperature of20°C for Nitobond EP standard:

Compressive strength(BS 6319, Pt. 2): 50 N/mm² @ 7 daysFlexural strength(BS 6319, Pt. 3): 35 N/mm² @ 7 daysTensile strength(BS 6319, Pt. 7): 20 N/mm² @ 7 daysSlant shear bond(BS 6319, Pt. 4): 25 N/mm² @ 7 daysAdhesive strength In general, the bond will alwaysto concrete: exceed the tensile strength of the

concrete


Preparation

All surfaces to be treated should be mechanicallyprepared (scabble or grit-blast) to expose aggregate andall debris and dust removed.

Oil and grease deposits should be removed by steamcleaning, detergent scrubbing or the use of a proprietarydegreaser. The effectiveness of decontamination shouldthen be assessed by a pull-off test.

Expose fully any corroded steel and remove all loosescale and corrosion deposits. Steel should be cleaned toa bright condition paying particular attention to the back ofexposed steel bars. Grit-blasting is recommended for thisprocess.

Reinforcing steel priming

The cleaned steel should be coated within 3 hours. Applyone full coat of Nitoprime Zincrich and allow to dry beforecontinuing. If any doubt exists about having achieved anunbroken coating, a second application should be madeand, again, allowed to dry before continuing.

Mixing

The contents of the base and hardener cans should bestirred thoroughly to disperse any settlement. The entirecontents of the hardener can should be added to the basecontainer and mixed thoroughly for at least 3 minutes untila uniform colour is obtained, taking particular care toscrape the sides and bottom of the container. It isrecommended that mechanical mixing be employed,using a Jiffy mixer on a heavy duty, slow speed electricdrill.

To facilitate application at temperatures below 10°C theseparate components should be warmed in hot water to amaximum of 25°C before mixing. However, the mixedmaterial will need to be used speedily as the pot life of thestandard grade will be reduced to 20 minutes.

Alternatively the materials should be stored in a heatedbuilding and only removed immediately before use.

Application

The thoroughly mixed material should be applied with asuitable stiff nylon-type brush and must be firmlyscrubbed into the surface, ensuring an even coating. Thenew concrete or screed should be applied to Nitobond EPstandard within 1½ hours at 20°C, or within 1 hour at 30°Cand Nitobond EP slow set within 24 hours at 20°C, orwithin 8 hours at 30°C.

To form a barrier between chloride contaminated concreteand Renderoc repair material, the prepared concreteshould be primed with Nitobond EP standard and allowedto cure for 8 to 24 hours. This coating should beinperforate and any unfilled voids (blow-holes) should befilled with Nitomortar FC before proceeding.

Fosroc® Nitobond EP constructive solutions

1CI/SfB: Yt3June 2008

16

Fosroc® Nitobond EP


www.fosroc.com

telephone: fax: email:+44 0 (1827) 262222 +44 0 (1827) 262444 [email protected]


Apply a second coat of Nitobond EP standard and leavefor 30 minutes before the overlay is applied to the tackysurface.

Alternatively Nitobond EP slow set can be used to allowfor application prior to the fixing of shuttering orreinforcement. The concrete, Renderoc LA55 or screedcan then be placed up to 24 hours after the application ofNitobond EP slow set. However, it should be left for 1 hourbefore the overlay is applied to the tacky surface.

Cleaning

Tools and equipment should be cleaned with FosrocSolvent 102 immediately after use.

Limitations

Nitobond EP is formulated for application to clean, soundconcrete.

Nitobond EP should not be applied over existing coatings.

Application should not be undertaken if the temperature isbelow 5°C, or is 5°C and falling.

Although Nitobond EP may be applied to damp concrete,there must be no standing or running water.

Estimating

Supply and coverage Pack weight Coverage

Nitobond EP standard: 2.5 kg 5.5 m²4.5 kg 10 m²

Nitobond EP slow set: 4.5 kg 10 m²Fosroc Solvent 102: 5 and 25 litre tins

The coverage figures are theoretical — due to wastagefactors and the variety and nature of substrates, practicalcoverage figures may be substantially reduced.

Important: Unless otherwise specified, Nitobond EP issupplied with the standard hardener. Where the slow sethardener is required, care should be taken to ensure thisis specifically requested.

Storage

12 months minimum shelf life if stored between 5-25°C.

Precautions

Health and safety


Fire

Nitobond EP is non-flammable.


Nitobond is the trademark of Fosroc International Limited


17

Polymer bonding aid and mortar additive

UsesFor improving and bonding concrete repair mortars, floortoppings and screeds, waterproof renders andcementitious slurries. Mortars and bonding slurriesproduced with Nitobond SBR may be used for horizontal,vertical and overhead repair work and are suitable forpermanent immersion. Nitobond SBR may be used toform a bonding agent for slip bricks, ceramic tiles, etc.

AdvantagesSingle component liquid can be easily gauged asrequiredImproves cohesion and workabilityImproves mortars to provide waterproof repairs,renders and toppings which are highly resistant tofreeze/thaw cyclingImproved tensile and flexural properties allow thinapplicationsExcellent bond to concrete, masonry, stonework,plaster and blockworkContains no chloride admixturesCan be applied to damp substrates

DescriptionNitobond SBR is a modified styrene butadiene rubberemulsion which is supplied as a ready to use white liquid.It is designed to improve the qualities of site-batchedcementitious mortars and slurries. Being resistant tohydrolysis, it is ideal for internal and external applicationsin conjunction with cement.

Specification clauses

Polymer bonding aid and mortar additive. The polymerbonding aid and site-batched mortar shall be modified bythe use of Nitobond SBR, a single component styrenebutadiene rubber emulsion.

Properties

The results listed below were achieved by assessing themechanical properties of a 3:1 sand:cement mortarcontaining Nitobond SBR in the proportions 10 litres per50 kg cement against a 3:1 sand:cement control mortar.The test methods used were in full accordance withBS 6319 at 28 days — air cured.

Test method Typical result ControlCompressive strength(BS 6319, Pt 2: 1983): 62 N/mm2 46 N/mm2

Tensile strength(ASTM C-190-85): 3.3 N/mm2 2.7 N/mm2

Flexural strength(BS 6319, Pt 3: 1983): 9 N/mm2 7.9 N/mm2

Slant shear bond(BS 6319, Pt 4: 1984): 53 N/mm2 11 N/mm2

Chemical resistance: Cementitious materials havelimited chemical resistance.The addition of Nitobond SBRto cement mortars reducespermeability and thereforehelps reduce the rate of attackby aggressive chemicals, acidgases and water.


Preparation

Saw cut or cut back the extremities of the repair locationsto a depth of at least 10 mm to avoid feather-edging and toprovide a square edge. Break out the complete repairarea to a minimum depth of 6 mm up to the sawn edge.Clean the surface and remove any dust, unsound orcontaminated material, plaster, oil, paint, grease,corrosion deposits or algae. Where breaking out is notrequired, roughen the surface and remove any laitance bylight scabbling or grit-blasting.


Expose fully any corroded steel in the repair area andremove all loose scale and corrosion deposits. Steelshould be cleaned to a bright condition paying particularattention to the back of exposed steel bars. Grit-blasting isrecommended for this process.

Where corrosion has occurred due to the presence ofchlorides, the steel should be high-pressure washed withclean water immediately after grit-blasting to removecorrosion products from pits and imperfections within itssurface.


Apply one full coat of Nitoprime Zincrich Plus to anyexposed steel reinforcement and allow to dry beforecontinuing. If any doubt exists about having achieved anunbroken coating, a second application should be madeand, again, allowed to dry before continuing.

Fosroc®

Nitobond SBR constructive solutions

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18

Fosroc®

Nitobond SBR

Substrate priming

The substrate should be thoroughly soaked with cleanwater and any excess removed prior to commencement. Aslurry primer should be prepared consisting of 1 volumeNitobond SBR to 1 volume clean water to 3 volumes freshcement. To obtain a smooth consistency, the cementshould be blended slowly into the premixed liquids. Theslurry primer should be stirred frequently during use tooffset settlement.

The slurry primer should be scrubbed well into thesurface of the concrete. Avoid applying too thickly andavoid ‘puddling’. The repair mortar, topping or render mustbe applied on to the wet slurry primer. If the slurry primerdries before application of the mortar, it must be removedand the area reprimed before continuing.

In exceptional circumstances, e.g. where a substrate /repair barrier is required Nitobond EP bonding aid shouldbe used. Contact the local Fosroc office for furtherinformation.

Mixing

Care should be taken to ensure that Nitobond SBRmortars are thoroughly mixed. A forced-action mixer isessential. Mixing in a suitably sized drum using anapproved spiral paddle in a slow speed (400/500 rpm)heavy-duty drill is acceptable for occasional use.

A wide range of mix designs is achievable using NitobondSBR. Typical designs are detailed below:

1. Patching and repair mortar:50 kgs Ordinary Portland Cement150 kgs grade C/M sharp sand10 litres Nitobond SBR8 litres (approximately) clean waterRecommended thickness: 6 mm to 40 mm.

2. Heavy-duty floor screed:50 kgs Ordinary Portland Cement75 kgs 3 to 6 mm granite chips75 kgs grade C/M sharp sand10 litres Nitobond SBR6 litres (approximately) clean waterThe screed should be of a semi-dry cohesive consistency.Recommended thickness: 10 mm to 40 mm.

3. Render:50 kgs Ordinary Portland Cement150 kgs grade C/M sharp sand10 litres Nitobond SBR6 litres (approximately) clean waterThe render should be of a semi-dry cohesive consistency.Recommended thickness: 6 mm to 9 mm.

4. Bonding mortar for slip bricks, tiles, etc:50 kgs Ordinary Portland Cement125 kgs grade C/M sharp sand10 litres Nitobond SBR7 litres (approximately) clean water

Water is adjusted to give a firm mortar. For fine joints, usegrade M/F sand. Support where necessary until the mortaris set. Recommended thickness: 6 mm to 40 mm.Note that these mix designs are based on the use of drysand and aggregate. Adjustments must be made to thewater demand relative to the moisture content of the sandand aggregate used. It should also be noted that, due tothe frequent inconsistencies of site-stored materials andvariable conditions, actual results may differ from thosepublished above.

Weigh the cement, sand and, where required, aggregateinto the mixer and dry blend together for one minute. Withthe machine in operation, add the pre-mixed NitobondSBR and clean water. Continue mixing for 3 minutes toensure complete dispersal into the sand and cement.Make any small adjustment to the quantity of clean waterbut do not significantly exceed the literage shown above.Additional water should be kept to a minimum. Continuemixing up to a maximum of 5 minutes until a smooth andfully homogeneous consistency is achieved with therequired workability and application properties. It is criticalthat allowance is made for the moisture content of thesand and aggregate, particularly where they are stored onsite.

Application

For application to all surfaces, Nitobond SBR mortars,toppings and renders must be well-compacted on to theprimed substrate by trowel. It is frequently beneficial towork a thin layer of the mortar into the slurry primer and thenbuild the mortar on to this layer. Exposed steel reinforcementshould be completely encapsulated by the mortar.

Nitobond SBR mortars can be applied at a minimumthickness of 6 mm and up to 40 mm thickness,dependent on the location and configuration of the repairzone. Where thicknesses over 40mm are to be applied inone application, reduce the Nitobond SBR content by40%.


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Fosroc®

Nitobond SBR

The thickness achievable in overhead locations withoutthe use of formwork is largely dependent on the profile ofthe substrate. Refer to the recommended thicknessesshown in the ‘Mix design’ section above. If therecommended thickness is exceeded and saggingoccurs, the affected section must be completely removedand reapplied in accordance with the proceduredescribed above. The use of formwork may facilitateachieving the required build. If formwork is used, it shouldhave properly sealed faces to ensure that no water isabsorbed from the repair material.

Where thicker sections up to a total thickness of 40 mmare to be built up by hand or trowel application, the surfaceof the intermediate layers should be scratch-keyed andcured with Nitobond AR. Application of the slurry primerand a further application of Nitobond SBR mortar mayproceed as soon as this layer has set.

Finishing

Nitobond SBR mortars can be finished with a steel,plastic or wood float, or by a damp sponge technique, toachieve the desired surface texture. The completedsurface should not be overworked.

Low temperature working

In cold conditions down to 5oC, the use of warm water (upto 30oC) is advisable to accelerate strength development.Normal precautions for winter working with cementitiousmaterials should then be adopted.

High temperature working

At ambient temperatures above 35oC, the material shouldbe stored in the shade and cool water used for mixing.

Curing

Nitobond SBR mortars, toppings and renders are cement-based. In common with all cementitious materials, theymust be cured immediately after finishing in accordancewith good concrete practice. The use of Nitobond AR orConcure WB, sprayed on to the surface of the finishedmortar in a continuous film, is recommended. In harshdrying conditions, supplementary curing with polythenesheeting must be used.

Overcoating with protective decorativefinishes

Nitobond SBR mortar repairs are extremely durable andwill provide excellent protection to the embedded steelreinforcement within the repaired locations. Thesurrounding parts of the structure will generally benefit

from the application of a barrier/decorative coating to limitthe advance of chlorides and carbon dioxide, thusbringing them up to the same protective standard as therepair itself. Fosroc recommend the use of the Dekguardrange of protective, anti-carbonation coatings. Theseproducts provide a decorative and uniform appearance aswell as protecting areas of the structure which mightotherwise be at risk from the environment. Dekguardproducts may be applied over the repair area without priorremoval of the Nitobond AR curing membrane. ConcureWB curing membrane must be removed prior to theapplication of Dekguard products. This is best achievedby light grit or sand-blasting.

Cleaning

Nitobond SBR and Nitobond AR should be removed fromtools, equipment and mixers with clean water immediatelyafter use. Cured material can only be removedmechanically.

Equipment used with Nitoprime Zincrich Plus, NitobondEP and Concure WB should be cleaned with FosrocSolvent 102. Cured material can only be removedmechanically.

Estimating

Supply

Nitobond SBR: 5, 25 and 210 litre drumsNitoprime Zincrich Plus: 1.9 litre and 800ml cansNitobond EP: 4.5 kg packsNitobond AR: 5 litre drumsConcure WB: 20 litre drumsFosroc Solvent 102: 5 litre cans

Coverage and yield

Nitobond SBR: Refer to mix designsNitobond SBR(as slurry primer): Approximately 2 to 3 m2/litreNitoprime Zincrich Plus: 8 m2/litreNitobond EP: 10 to 11.5 m2/packNitobond AR: 6 to 8 m2/litreConcure WB: 3.5 to 5 m2/litre

Limitations

Nitobond SBR mortars, toppings and renders should notbe applied when the temperature is below 5oC and falling.Neither should they be exposed to moving water duringapplication. Exposure to heavy rainfall prior to the final set


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August 2007

20

may result in surface scour. If any doubts arise concerningtemperature or substrate conditions, consult the localFosroc office.

Storage

Shelf Life

Store in unopened packaging in cool dry internalconditions. Nitobond SBR and Nitobond AR should beprotected from frost.

The product has a shelf life of 12 months from the date ofmanufacture if kept in a dry storage in the original,unopened packaging between 5oC and 25oC.

Nitoprime Zincrich Plus must be stored in accordancewith the Highly Flammable Liquids and LiquefiedPetroleum Gases Regulations 1972.

1CI/SfB: (4-) Vt3

August 2007Fosroc®

Nitobond SBR

Precautions

Health and safety


Fire

Nitobond SBR, Nitobond AR, Concure WB and Nitobond EPare non-flammable.

Nitoprime Zincrich Plus and Fosroc Solvents 102 areflammable. Keep away from sources of ignition. Nosmoking. In the event of fire, extinguish with CO2 or foam.Do not use a water jet.

Flash points

Nitoprime Zincrich Plus: 41oCFosroc Solvent 102: 33oC

For further information, refer to the Product Safety DataSheet.

Fosroc LimitedDrayton Manor Business Park,Coleshill Road, Tamworth,Staffordshire B78 3TL. UK

www.fosroc.com




Nitobond is the trade mark of Fosroc International Limited

21

Single component epoxy zinc primer

Uses

Nitoprime Zincrich Plus is the recommended anti-corrosion primer for exposed steel reinforcement for usewith Fosroc concrete repair mortars.

It is fully compatible with all Renderoc mortars and fluidmicro-concretes.

Advantages

‘Active’ zinc-rich system combats corrosion by electro-chemical meansFormulated for use with Renderoc repair productsSingle component product — easy to use with norestrictive pot-lifeEconomical — single component ensures almost nowaste

Description

Nitoprime Zincrich Plus is supplied as a singlecomponent grey-coloured liquid based on metallic zincand epoxy resins.

Standards compliance

The product has also been approved by the British Boardof Agrément, Certificate No. 98/3461 as part of theRenderoc System of Concrete Repair.


Steel reinforcement primer

The steel reinforcement primer shall be NitoprimeZincrich Plus, a single-component zinc-rich liquid packedand supplied ready to use. An unbroken 40 microns thickcoating shall be capable of providing ‘active’ galvanicprotection. It shall be a suitable viscosity to enable thecoating to penetrate imperfections and pits within thesurface of corrosion-damaged steel bars.

The formulation of the primer shall be such that dryingoccurs to allow the application of the repair mortar toproceed after 90 minutes at 20°C.

It shall be fully compatible with the Renderoc system ofconcrete repair.

Properties

Test method Typical result

Specific gravity: 2.0Recommended thickness per coat: 40 microns (dry)Application thickness per coat: 100 microns (wet)Drying times — @ 20°CTouch dry: 90 minutesFully dry/recoatable: 3 hours

Note: at temperatures below 20°C, the drying times will beslower.


Preparation



Application

The application of Nitoprime Zincrich Plus must takeplace as soon as possible to a dry steel surface aftercompletion of the preparation work but always within 3hours. Although a single component product, it should bestirred thoroughly before use in order to redisperse anysettlement.

Apply one full and unbroken coat of Nitoprime ZincrichPlus by suitable brush, making sure that the back ofexposed steel reinforcing bars are properly coated. Asmall brush is generally more suitable for this purpose.Allow to dry fully before continuing. If any doubt existsabout having achieved an unbroken coating, a secondapplication should be made as soon as the first coat isfully dry (generally after 90 minutes).

The primed surfaces should not be left exposed to theelements for longer than necessary before overcoating orapplication of the repair material. Nitoprime Zincrich Pluswill, however, protect steel under clean interior exposureconditions for a period of several months. In non-aggressive exterior environments, a maximum interval of14 days will be tolerated but in industrial and/or marineenvironments this interval should be reduced to thepractical minimum.

Fosroc® NitoprimeZincrich Plus constructive solutions

1CI/SfB:

October 2006

22

Fosroc® NitoprimeZincrich Plus

The application of concrete repair materials shouldproceed as soon as the Nitoprime Zincrich Plus is touchdry (generally 90 minutes — see under Properties).


The minimum application temperature is 5°C. Thematerial should not be applied when the substrate and/orair temperature is 5°C and falling. At 5°C statictemperature or at 5°C and rising, the application mayproceed.

Cleaning

Nitoprime Zincrich Plus should be removed from tools,equipment and mixers with Fosroc Solvent 102immediately after use.

Estimating

Supply

Nitoprime Zincrich Plus: 1.9 litre and 800ml cansFosroc Solvent 102 : 5 and 25 litre tins

Coverage

Nitoprime Zincrich Plus: 8 m2 / litre

Note: this coverage figure is theoretical — due to wastagefactors and the variety and nature of possible steelsubstrates, practical coverage figures will be reduced.

Limitations

Nitoprime Zincrich Plus should not be applied when thetemperature is below 5°C or is 5°C and falling. If anydoubts arise concerning temperature or applicationconditions, consult the local Fosroc office.

Storage

Store in dry conditions in the original containers.Nitoprime Zincrich Plus and Fosroc Solvent 102 have ashelf life of 12 months if kept in a dry store in the original,unopened containers.

If stored at high temperatures and/or high humidityconditions the shelf life may be reduced.

Precautions

Health and safety

For further information refer to the appropriate ProductSafety Data Sheet

Fire

Nitoprime Zincrich Plus and Fosroc Solvent 102 areflammable. Keep away from sources of ignition. Nosmoking. In the event of fire, extinguish with CO2 or foam.Do not use a water jet.

Flash points

Nitoprime Zincrich Plus: 41°CFosroc Solvent 102: 33°C

For further information, refer to the Product Material SafetyData Sheet.

Additional information

Nitoprime Zincrich Plus is the approved reinforcing steelprimer for use with the Renderoc, Patchroc and Paverocsystems of concrete repair.

1CI/SfB:

October 2006


www.fosroc.com




Nitomortar is the trade mark of Fosroc International Limited

23

Fast setting emergency patching mortar forconcrete pavements and floors conforming tothe requirements of BS EN 1504-3 Class R4

Uses

For emergency and permanent reinstatement of localisedpatches in concrete pavements, airport aprons, access rampsand floors.

Particuly useful when interuption of traffic must be minimised

The product is alkaline in nature and will protect embedded steelreinforcement. It may be used internally and externally.

For the reinstatement of large areas of concrete pavementsand floors, the use of Paveroc is recommended.

Patchroc GP is suitable for repair methods 3.2, 4.4, 7.1 and7.2, as defined by BS EN 1504-3.

Advantages

Rapid strength gain — will generally accept traffic in 2hours.High strength, abrasion and weather resistanceOne component, pre-bagged to overcome site-batchedvariations requires only the site addition of clean waterExcellent bond to the concrete substrateShrinkage compensatedContains no chloride admixtures

Description

Patchroc GP is supplied as a ready to use blend of dry powderswhich requires only the site addition of clean water to producea highly consistent repair mortar.

It is based on Portland cements, graded aggregates, andchemical additives providing a mortar with good handlingcharacteristics while minimising water demand. The lowwater requirement ensures good strength gain and long-termdurability.

Patchroc GP is designed for horizontal use. It may be appliedup to a maximum thickness of 100 mm. Thicker sections canbe built up in layers. Material should not be applied at less than12 mm thickness. Individual bay sizes should not exceed 4m².Consult the local Fosroc office for further information.

Specification Clause

The repair mortar shall be Patchroc GP, a one componentcementitious mortar conforming to the requirements of BSEN 1504-3 Class R4

The cured mortar shall achieve a compressive strength of 65MPa at 28 days and a drying shrinkage of <300 microstrainat 7 days.


Patchroc GP complies with the classification R4 accordingto EN 1504-3, repair methods 3.3, 4.4, 7.1 and 7.2

Fosroc® Patchroc GP

1CI/SfB: (4-) Pr4October 2009


llihseloC,kraPssenisuBronaMnotyarD,dtLcorsoFLT387B,SFFATS,htrowmaT,daoR

905480-DPC-0730

3-4051NECCratromriaperlarutcurtsrofstcudorpriaperetercnoC

)tnemecciluardyhnodesab(

htgnertsevisserpmoC (4RssalC ≥ )aPM54

tnetnocnoiedirolhC ≤ %50.0

htgnertsdnobevisehdA ≥ aPM0.2

htgnertsdnobevisehdAlamrehtwahtezeerfretfa

gnilcyc≥ aPM0.2

ecnatsisernoitanobraC dk ≤ etercnoclortnoc

noitprosbayrallipaC ≤ m/gk5.0 2- h. 5.0-

nisuludomcitsalEnoisserpmoc ≥ aPG02

ecnatsiserdikS IIIssalC

erifotnoitcaeR 1AssalC

secnatsbussuoregnaD 4.5htiwseilpmoC

24




dohtemtseT dradnatS 4R4051NEtnemeriuqeR tluseR

htgnertSevisserpmoC 9991:09121NE ≥ aPM54

aPM02sruoh2@aPM05syaD1@aPM55syaD7@aPM56syaD82@

:ffollupybhtgnertsdnoB 9991:2451NE ≥ aPM0.2 2.2 aPM

:tnetnocnoiedirolhC 0002:71-5101NE ≤ %50.0 %20.0

:gnilcycwahtezeerF 2002:1-78631NE ≥ aPM0.2 0.2 aPM

dnoitanobracotecnatsiseR k 5002:59231NE ≤ etercnocfer smrofnoC

nisuludoMcitsalEnoisserpmoC 21431NE ≥ aPG02 syad82@aPG92

ecnatsiseRdikS 4-63031NE tew55>IIIssalC IIIssalC

gnitareriF 1-10531NE elbitsubmoC-noN1AssalC

emitgnitteS 0891:41tP1554SB - snim04:teslaitinIsnim06:teslaniF

:efilgnikroW - - C°02@C°01@nim02nim04

-emitciffarT:nairtsedeP:raluciheV

-C°02@C°01@sruoh2sruoh3sruoh2sruoh3

ecnatsiserlacimehC

PGcorhctaPfoytilibaemrepwolehTnikcattalacimehcsdraterylerevesderucehT.stnemnorivneevissergga

,sesagdicaotelbaemrepmisiratrom.negyxodnasnoiedriolhcenrobretaw

scitsiretcarahCdliuB)deilppadnah(

:ssenkcihtmuminiMssenkcihtmumixaM

aerayabxaM

---

---

mm21mm001

m4 2

Properties

The following results were obtained at a water : powder ratio of 0.11 and a temperature of 20°C unless otherwise stated.

Clarification of property values:The typical properties given above are derived from laboratory testing. Results derived fromfield applied samples may vary.


Preparation

Saw cut the edges of the repair to a depth of at least 12 mmto provide a square edge. Break out the complete repair areato a minimum depth of 12 mm up to the sawn edge.

Clean the surface and remove any dust, unsound orcontaminated material, plaster, oil, paint, grease, corrosiondeposits or algae. Where breaking out is not required,roughen the surface and remove any laitance by lightscabbling or abrasive-blasting.


Expose fully any corroded steel in the repair area and removeall loose scale and corrosion deposits. Steel should becleaned to a bright condition paying particular attention to theback of exposed steel bars. Abrasive-blasting isrecommended for this process.

Where corrosion has occurred due to the presence ofchlorides, the steel should be high-pressure washed with

25




clean water immediately after abrasive-blasting to removecorrosion products from pits and imperfections within itssurface.


Apply one full coat of Nitoprime Zincrich Plus and allow to drybefore continuing. If any doubt exists about having achievedan unbroken coating, a second application should be madeand, again, allowed to dry before continuing.

Concrete Priming

Pedestrian trafficThe concrete substrate should be saturated surface dryimmediately before the application of the primer i.e. it shouldbe thoroughly saturated with clean water and any residualsurface water removed prior to applying Renderoc Primer.Under severe drying conditions repeated soaking may benecessary to ensure the substrate is still saturated at the timeof application of the primer.Add 3 parts by volume of Renderoc Primer Part A to 1 part byvolume Renderoc Primer Part B (4 to 1 by weight) in a cleanmixing vessel and mix with a spatula or slow speed drill untila homogeneous smooth paste is produced.Scrub Renderoc Primer slurry into the surface.Patchroc GP can be applied immediately to the primedsurface. If the primer dries apply another coat of primerbefore continuing.Open bags of Renderoc Primer Part A should be sealed andstored in a dry area. Use within 14 days.

Vehicular trafficPrime using Nitobond EP. Thoroughly stir the individualcomponents to disperse any settlement. Add the entirecontents of the hardener to the base container and mixthoroughly for at least 3 minutes until a uniform colour isobtained, taking particular care to scrape the sides andbottom of the container. It is recommended that a Jiffy mixeron a heavy duty, slow speed electric drill is used.

The mixed product should be applied with a suitable stiffnylon-type brush and firmly scrubbed into the surface,ensuring an even coating. The Patchroc GP should beapplied to Nitobond EP standard within 1½ hours at 20°C, orwithin 1 hour at 30°C and Nitobond EP slow set within 24hours at 20°C, or within 8 hours at 30°C. See separateproduct data sheet for further details.

Mixing

Care should be taken to ensure that Patchroc GP isthoroughly mixed. A forced-action mixer is essential. Mixingin a suitably sized drum using an approved Renderoc SpiralPaddle with a slow speed (400/500 rpm) heavy-duty drill isacceptable for the occasional one-bag mix.Free-fall mixers must not be used. Mixing of part bags shouldnever be attempted.

For normal applications, place 2.4 to 2.8 litres of drinkingquality water into the mixer.With the machine in operation, add one full bag of PatchrocGP and mix, for a minimum of 3 minutes and a maximum of5 minutes, until fully homogeneous.The consistency may be adjusted by the addition of smallamounts of water up to the maximum total water content of2.8 litres.Note that the powder must always be added to the water.

Mixing warning

As with other ‘one pack’ repair mortars, Patchroc GP mayexhibit satisfactory handling characteristics even thoughinadequately mixed. This will result in a significantly lowerlevel of performance or possible failure. It is therefore essentialthat mixing instructions are strictly adhered to with particularemphasis on the quantity of water used and the time of themixing operation.

Application

Exposed steel reinforcing bars should be firmly secured toprevent movement during application.

While the Renderoc Primer/Nitobond EP is still tacky, applythe mixed Patchroc GP evenly by trowel and tamp in place witha wood float to ensure complete compaction. Thoroughlycompact the mortar around any exposed steel reinforcement.Patchroc GP can be applied up to 100 mm in a singleapplication.

Patchroc GP should be struck off to the correct level andfinished with a steel trowel to a fully closed surface. A texturedsurface can be achieved with a suitable roller or brush. Thefinshed surface should not be overworked.

Build-up

Additional build-up can be achieved by application of multiplelayers.

The surface of the intermediate layers should be combscratch-keyed. A further application of Patchroc GP mayproceed as soon as this layer has set.

Reprime with Renderoc Primer or Nitobond EP and applyfurther Patchroc GP as described above.


In cold conditions down to 5°C, the use of warm mixing water(up to 30°C) is advisable to accelerate strength development.Normal precautions for winter working with cementitiousmaterials should then be adopted. The material should notbe applied when the substrate and/or air temperature is 5°Cand falling. At 5°C static temperature or at 5°C and rising, theapplication may proceed.


At ambient temperatures above 35°C, the material shouldbe stored in the shade and cool water used for mixing.

26



www.fosroc.com





Curing

Patchroc GP is a cement-based repair mortar. In commonwith all cementitious materials, it must be cured immediatelyafter finishing in accordance with good concrete practice.The use of Concure WB, sprayed on to the surface of thefinished mortar in a continuous film, is recommended. A lowpressure atomising sprayer is essential for applying theConcure WBLarge areas should be cured as trowelling progresses(0.5 m2 at a time) without waiting for completion of the entirearea.In fast drying conditions, supplementary curing with polythenesheeting taped down at the edges must be used. In coldconditions, the finished repair must be protected from freezing.

Overcoating with protective decorative finishes

Patchroc GP is extremely durable and will provide an excellenthard wearing surface to the repaired locations. Surroundingfloor areas may benefit from the application of an abrasionor chemical-resistant protective coating. For internal locations,Fosroc recommend the use of the Nitoflor FC range ofprotective coatings.These products provide a decorative and uniform appearanceas well as protecting areas of the floor which might otherwisebe at risk. Nitoflor FC products may be applied over the repairarea after prior removal of the curing membrane; generallyafter 3 days. The local Fosroc office should be contacted foradvice about external protective overlayments.

Cleaning

Patchroc GP should be removed from tools, equipment andmixers with clean water immediately after use. Cured materialcan only be removed mechanically. Clean tools used withNitoprime Zincrich Plus and Nitobond EP before curing, withFosroc Solvent 102.

Estimating

Supply

Patchroc GP: 25 kg bagsNitoprime Zincrich Plus: 1.9 litre and 800 ml cansNitobond EP 2.5 and 4.5 Kg packsRenderoc Primer 20 Kg Part A + 5 litres part BConcure WB 20 and 200 litre drumsFosroc Solvent 102: 5 and 25 litre tins

Coverage and yield

Patchroc GP: Approximately 12 litres / 25kg bag (approximately 12 m²at 12 mm thickness)

Nitoprime Zincrich Plus: 8 m2/litre

Nitobond EP Approximately 2 m2 / kg

Renderoc Primer Approximately 13 litres- 2m2/ litre

Concure WB 5 m2/ litreNotes: the actual yield per bag of Patchroc GP will dependon the consistency used.

Limitations

Patchroc GP should not be used when the temperature isbelow 5°C and falling. Do not mix part bags.

Patchroc GP should not be exposed to moving water duringapplication. Exposure to heavy rainfall prior to the final setmay result in surface scour.

If any doubts arise concerning temperature or substrateconditions, consult the local Fosroc office.

Storage

The product has a shelf life of 12 months from the date ofmanufacture if kept in dry storage in the original, unopenedbags. If stored at high temperatures and/or high humiditythe shelf life may be reduced to less than 6 months.

Precautions

Health and safety

For further information refer to the appropriate Safety DataSheets available at www.fosroc.com.

Fire

Patchroc GP, Nitobond EP and Renderoc Primer are non-flammable.Nitoprime Zincrich Plus and Fosroc Solvent 102: areflammable. Keep away from sources of ignition. No Smoking.In the event of fire, extinguish with CO2 or foam. Do not usea water jetFlash pointsNitoprime Zincrich Plus: 41°CFosroc Solvent 102: 33°C

27

High performance reinstatement mortar forconcrete pavements and floors conformingto the requirements of BS EN 1504-3 Class R4

Uses

For the reinstatement of large areas of concrete pavementsand floors to avoid the total replacement of bays

The product is alkaline in nature and will protect embeddedsteel reinforcement. It may be used internally and externally.Patchroc GP is recommended.for emergency patching ofsmall areas of concrete pavements and floors.

Paveroc is suitable for repair methods 3.1, 3.3, 4.4, 7.1, 7.2as defined by BS EN 1504-3.

Advantages

Rapid strength gain — will generally accept pedestriantraffic at 12 hours, significantly reducing down-timeHigh strength, abrasion and weather resistanceOne component, pre-bagged to overcome site-batchedvariations requires only the site addition of clean waterExcellent bond to the concrete substrateShrinkage compensatedContains no chloride admixtures

Description

Paveroc is supplied as a ready to use blend of dry powderswhich requires only the site addition of clean water to producea highly consistent repair mortar.

It is based on Portland cements, graded aggregates, andchemical additives providing a mortar with good handlingcharacteristics while minimising water demand. The lowwater requirement ensures good strength gain and long-term durability.

Paveroc is designed for horizontal use. It may be applied upto a maximum thickness of 100 mm. Thicker sections can bebuilt up in layers. Material should not be applied at less than12 mm thickness. Individual bay sizes should not exceed 18m². Consult the local Fosroc office for further information.


The repair mortar shall be Paveroc a one componentcementitious mortar conforming to the requirements of BSEN 1504-3 Class R4

The cured mortar shall achieve a compressive strength of 65MPa at 28 days and a drying shrinkage of < 300 microstrainat 7 days.


Paveroc complies with the classification R4 according to EN1504-3, repair methods 3.1, 4.4, 7.1 and 7.2.

Fosroc® Paveroc

1CI/SfB: q4 (D7)October 2009


905480-DPC-0730

3-4051NECCratromriaperlarutcurtsrofstcudorpriaperetercnoC






gnilcyc≥ aPM0.2


ecnatsiserdikS IIIssalC





28

Fosroc® Paveroc



dohtemtseT dradnatS 4R4051NEtnemeriuqeR

tluseR

htgnertSevisserpmoC9991:09121NE ≥ 54 aPM02yaD1@

aPM54syaD7@aPM56syaD82@





nisuludoMcitsalEnoisserpmoC

21431NE ≥ aPG02 syad82@aPG64

ecnatsiseRdikS 4-63031NE 55>IIIssalC IIIssalC


emitgnitteS 0891:41tP1554SB - sruoh5.3:teslaitinIsruoh0.5:teslaniF

:efilgnikroW - - 01@ o 02@C o 03@C oCnim03nim55nim06

-emitciffarT:nairtsedeP:raluciheV

- - C°03@C°02@C°01@sruoh8sruoh21sruoh81sruoh61sruoh42sruoh63

ecnatsiserlacimehC

corevaPfoytilibaemrepwolehTnikcattalacimehcsdraterylerevesderucehT.stnemnorivneevissergga


scitsiretcarahCdliuB)deilppadnah(

:ssenkcihtmuminiMssenkcihtmumixaM

aerayabxaM

---

---

mm21mm001

m81 2-

Properties


Clarification of property values: The typical properties given above are derived from laboratory testing. Results derived fromfield applied samples may vary.


Preparation

Saw cut the edges of the repair to a depth of at least 12 mmto provide a square edge. Break out the complete repairarea to a minimum depth of 12 mm up to the sawn edge.

Clean the surface and remove any dust, unsound orcontaminated material, plaster, oil, paint, grease, corrosiondeposits or algae. Where breaking out is not required,

roughen the surface and remove any laitance by lightscabbling or abrasive-blasting.


29

Fosroc® Paveroc



Expose fully any corroded steel in the repair area andremove all loose scale and corrosion deposits. Steel shouldbe cleaned to a bright condition paying particular attentionto the back of exposed steel bars. Abrasive-blasting isrecommended for this process.

Where corrosion has occurred due to the presence of chlorides,the steel should be high-pressure washed with clean waterimmediately after abrasive-blasting to remove corrosionproducts from pits and imperfections within its surface.



Concrete Priming

Prime using Nitobond EP. Thoroughly stir the individualcomponents to disperse any settlement. Add the entirecontents of the hardener to the base container and mixthoroughly for at least 3 minutes until a uniform colour isobtained, taking particular care to scrape the sides andbottom of the container. It is recommended that a Jiffy mixeron a heavy duty, slow speed electric drill is used.

The mixed product should be applied with a suitable stiffnylon-type brush and firmly scrubbed into the surface,ensuring an even coating. The Paveroc should be applied toNitobond EP standard within 1½ hours at 20°C, or within 1hour at 30°C and Nitobond EP slow set within 24 hours at20°C, or within 8 hours at 30°C. See separate product datasheet for further details.

Mixing

Care should be taken to ensure that Paveroc is thoroughlymixed. A forced-action mixer is essential. Mixing in a suitablysized drum using an approved Renderoc Spiral Paddle witha slow speed (400/500 rpm) heavy-duty drill is acceptable forthe occasional one-bag mix.Free-fall mixers must not be used. Mixing of part bags shouldnever be attempted.For normal applications, place 1.9 to 2.2 litres of drinkingquality water into the mixer.With the machine in operation, add one full bag of Paverocand mix, for a minimum of 3 minutes and a maximum of 5minutes, until fully homogeneous.The consistency may be adjusted by the addition of smallamounts of water up to the maximum total water content of2.2 litres.Note that the powder must always be added to the water.

Mixing warning

As with other ‘one pack’ repair mortars, Paveroc may exhibitsatisfactory handling characteristics even thoughinadequately mixed. This will result in a significantly lower

level of performance or possible failure. It is thereforeessential that mixing instructions are strictly adhered to withparticular emphasis on the quantity of water used and thetime of the mixing operation.

Application


While the Nitobond EP is still tacky, apply the mixed Paverocevenly by trowel and tamp in place with a wood float to ensurecomplete compaction. Thoroughly compact the mortar aroundany exposed steel reinforcement. Paveroc can be applied upto 100 mm in a single application.

Paveroc should be struck off to the correct level and finishedwith a steel trowel to a fully closed surface. A textured surfacecan be achieved with a suitable roller or brush. The finishedsurface should not be overworked.

Build-up


The surface of the intermediate layers should be combscratch-keyed. A further application of Paveroc may proceedas soon as this layer has set.

Reprime with Nitobond EP and apply further Paveroc asdescribed above.


In cold conditions down to 5°C, the use of warm mixing water(up to 30°C) is advisable to accelerate strength development.Normal precautions for winter working with cementitiousmaterials should then be adopted. The material should notbe applied when the substrate and/or air temperature is 5°Cand falling. At 5°C static temperature or at 5°C and rising,the application may proceed.



Curing

Paveroc is a cement-based repair mortar. In common withall cementitious materials, it must be cured immediately afterfinishing in accordance with good concrete practice. The useof Concure WB, sprayed on to the surface of the finishedmortar in a continuous film, is recommended. A low pressureatomising sprayer is essential for applying the Concure WB

Large areas should be cured as trowelling progresses(0.5 m2 at a time) without waiting for completion of the entirearea.

In fast drying conditions, supplementary curing with polythenesheeting taped down at the edges must be used. In coldconditions, the finished repair must be protected fromfreezing.

30

Fosroc® Paveroc


www.fosroc.com






Paveroc is extremely durable and will provide an excellenthard wearing surface to the repaired locations. Surroundingfloor areas may benefit from the application of an abrasionor chemical-resistant protective coating. For internallocations, Fosroc recommend the use of the Nitoflor FCrange of protective coatings.

These products provide a decorative and uniform appearanceas well as protecting areas of the floor which might otherwisebe at risk. Nitoflor FC products may be applied over the repairarea after prior removal of the curing membrane generallyafter 3 days. The local Fosroc office should be contacted foradvice about external protective overlayments.

Cleaning

Paveroc should be removed from tools, equipment andmixers with clean water immediately after use. Curedmaterial can only be removed mechanically.Clean tools used with Nitoprime Zincrich Plus and NitobondEP before curing, with Fosroc Solvent 102.

Estimating

Supply

Paveroc: 25 kg bags

Nitoprime Zincrich Plus: 1.9 litre and 800 ml cans

Nitobond EP 2.5 and 4.5 Kg packs

Concure WB 20 and 200 litre drums

Fosroc Solvent 102: 5 and 25 litre tins

Coverage and yield

Paveroc: Approximately 11.5 litres / 25kg bag (approximately 0.9 m²at 12 mm thickness)

Nitoprime Zincrich Plus: 8 m2/litreNitobond EP Approximately 2 m2 / kgConcure WB 5 m2/ litreNotes: the actual yield per bag of Paveroc will depend on theconsistency used. The yield will be reduced if the material isapplied by a spray technique.

Limitations

Paveroc should not be used when the temperature is below5°C and falling. Do not mix part bags.

Paveroc should not be exposed to moving water duringapplication. Exposure to heavy rainfall prior to the final setmay result in surface scour.


Storage


Precautions

Health and safety

For further information refer to the appropriate Safety DataSheets available at www.fosroc.com

Fire

Paveroc is non-flammable.

Nitoprime Zincrich Plus and Fosroc Solvent 102: areflammable. Keep away from sources of ignition. No Smoking.In the event of fire, extinguish with CO2 or foam. Do not usea water jet

Flash points


31

Polymer modified dry spray repair mortarconforming to the requirements of BS EN 1504-3Class R4

Uses

Renderoc DS is designed for large area repairs such asbridges, tunnels, retaining walls, dams, etc. The aggregatesare chosen so as to be classified as ‘non-reactive’, and theproduct has an alkali content (expressed as Na2O) of less than3.0 kg/m³.

Renderoc DS is specifically designed to comply with theHighways Agency Specification Series 1700 and BD27/86PE5).

Renderoc DS is suitable for repair method 3.3 and 4.4 asdefined by BS EN 1504.

Advantages

Non-reactive aggregatesControlled alkali levelLow reboundRapid strength gainLow water absorption and chloride ion diffusionHigh resistance to carbon dioxide penetrationExcellent bond to the concrete substrateSingle component — ready to useNo added caustic accelerators

Contains no chloride admixtures

Description

Renderoc DS is supplied as a ready to use blend of drypowders which is formulated for application using the dry sprayprocess.The material is based on Portland cements, graded aggregatessilica fume, chemical additives and polymer modifiers, providinga spray mortar with low rebound and good handling characteristics.The low water requirement ensures good strength gain and longterm durability.

Builds of up to 150 mm vertically and 90 mm overhead can beachieved in a single application.


The repair mortar shall be Renderoc DS a onecomponent polymer modified cementitious dry spray mortarconforming to the requirements of BS EN 1504-3 Class R4.

The cured mortar shall achieve a compressive strength of60 MPa at 28 days and a drying shrinkage of <300 microstrainat 7 days.


Renderoc DS complies with class R4 according to BS EN1504-3 repair principals 3.3 and 4.4

Renderoc DS conforms to the requirements of the UKHighways Agency Design Manual for Roads and Bridges(BD27/86, Clause 5) ‘Materials for the Repair of ConcreteHighway Structures’ and has been formulated to comply withthe requirements of the Specification for Highways WorksClause 1704.5 Control of Alkali-Silica Reaction.

Fosroc® Renderoc DS constructive solutions

1CI/SfB: (4-) Pr4

November 2009

llihseloC,kraPssenisuBronaMnotyarD,dtLcorsoFLT387B,sffatS,htrowmaT,daoR

905480-DPC-0730

3-4051NEratromCCPriaperlarutcurtsrofstcudorpriaperetercnoC

)tnemecciluardyhdeifidomremylopnodesab(





gnilcyc≥ aPM0.2


noitprosbayrallipaC ≤ m/gk5.0 2- h. 5.0-




32

Fosroc® Renderoc DS

Properties



htgnertSevisserpmoC 9991:09121NE ≥ aPM54aPM02yaD1@aPM54syaD7@

06syaD82@ aPM



:gnilcycwahtezeerF 2002:1-78631NE ≥ aPM0.2 aPM9.2

dnoitanobracotecnatsiseR k 5002:59231NE dk ≤ etercnocfer seilpmoC

nisuludoMcitsalEnoisserpmoC 21431NE ≥ aPG02 [email protected]



ytisnedtewhserF - m/gk0022yllanimoN 3

egaknirhS,smsirp582x52x52

72 O HR%55,C- syad7@niartsorcim003<

selcitrapevitcaerilaklA 25B-ITdohteM - ≤ %lov%0.1

noitprosbayrallipaC 75031NE m/gk5.0< 2 h. 5.0- m/gk14.0 2 h. 5.0-

ytivitsiseR - - mcmho00003-82

lamrehtfotneiciffeoCnoisnapxE - - 01x51 6- /oC

ecnatsiserlacimehC -

SDcoredneRfoytilibaemrepwolehTnikcattalacimehcsdraterylerevesderucehT.stnemnorivneevissergga


scitsiretcarahCdliuB

:ssenkcihtmuminiM:lacitreV

:latnoziroH

---

---

mm01mm051otpU

mm09otpU

Clarification of property values: The typical properties given are derived from laboratory testing. Results derivedfrom field applied samples may vary

1CI/SfB: (4-) Pr4

November 2009

33




Preparation

Clean the surface and remove any dust, unsound orcontaminated material, plaster, oil, paint, grease, corrosiondeposits or algae. Where breaking out is not required, i.e.concrete is sound and of good quality, but cover is to beincreased, roughen the surface and remove any laitance bylight scabbling or abrasive-blasting. It will still be necessaryto cut back the perimeter to a depth of 10 mm so that the repairpatch may be ‘toed-in’ and finished flush with the surroundingconcrete.





Extra protection to the reinforcing steel can be achieved byapplication of one full coat of Nitoprime Zincrich Plus andallowing to dry before continuing. If any doubt exists abouthaving achieved an unbroken coating, a second applicationshould be made, and again, allowed to dry before continuing.

Substrate priming

Soak the prepared concrete surface thoroughly, allowingsurplus water to drain off.

Application

Exposed steel reinforcing bars should be firmly secured toavoid movement during the application process as this willaffect mortar compaction, build and bond.

Renderoc DS should be emptied from the bags directly intothe hopper of the dry spray process machine. The amount ofwater added should be controlled by the nozzleman. Too littlewater will increase rebound and dust emission, too wet a mixwill slump.

If sagging occurs during application to vertical or overheadsurfaces, the Renderoc DS should be completely removedand re-applied at a reduced thickness on to the correctlyprepared substrate.

Finishing

Renderoc DS is finished by striking off with a straight edgeand closing with a steel float. Wooden or plastic floats, ordamp sponges may be used to achieve the desired surfacetexture. The completed surface should not be overworked.


Normal precautions for winter working with cementitiousmaterials should then be adopted. The material should notbe applied when the substrate and/or air temperature is 5°Cand falling. At 5°C static temperature or at 5°C and rising, theapplication may proceed.


At ambient temperatures above 35°C, the material should bestored in the shade.

Curing

Renderoc DS is a cement-based mortar. In common with allcementitious materials, Renderoc DS must be curedimmediately after finishing in accordance with good concretepractice, i.e. using wet hessian or polythene. In cold conditions,the finished repair must be protected from freezing.

Cleaning

Renderoc DS should be removed from tools, equipment andmixers with clean water immediately after use. Cured materialcan only be removed mechanically.

Equipment used with Nitoprime Zincrich Plus should becleaned with Fosroc Solvent 102.

Estimating

Supply

Renderoc DS: 25 kg bagsNitoprime Zincrich Plus: 1.9ltr and 800ml cansFosroc Solvent 102: 5 and 25 litre tins

Coverage and yield

Renderoc DS: Approx. 12.5 litres / 25 kg bag(approx. 80 bags/m³)

Nitoprime Zincrich Plus: 8 m2/ litre

Notes: The actual yield per bag of Renderoc DS will dependon the water addition during application. The coverage figuresare theoretical — due to wastage factors and the variety andnature of possible substrates, practical coverage figures willbe reduced.

1CI/SfB: (4-) Pr4

November 2009

34



www.fosroc.com




Limitations

Renderoc DS should not be used when the temperature isbelow 5°C and falling. The product should not be exposed tomoving water during application. Exposure to heavy rainfallprior to the final set may result in surface scour. If any doubtsarise concerning temperature or substrate conditions, consultthe Technical Services Department.

Storage

The product has a shelf life of 12 months from the date ofmanufacture if kept in a dry storage in the original, unopenedbags.

Store in unopened bags in cool dry internal conditions. Ifstored at high temperatures and/or high humidity conditionsthe shelf life may be reduced to less than 6 months.

Precautions

Health and safety


Fire

Renderoc DS is non-flammable.

Nitoprime Zincrich Plus and Fosroc Solvent 102 are flammable.Keep away from sources of ignition. No Smoking. In the eventof fire, extinguish with CO2 or foam. Do not use a water jet.

Flash points


1CI/SfB: (4-) Pr4

November 2009

35

Single component polymer modifiedcementitious fairing coat conforming to therequirements of BS EN 1504-3 Class R2

Uses

Renderoc FC is designed for application in thin layers toproduce a fair-faced appearance to concrete surfaces ormasonry surfaces in readiness to receive a protective/decorative coating. Surface imperfections up to 3 mm indepth can be filled with the scrape-coat application. Voids ofgreater depth should be separately filled as a prior operation,again limiting the material thickness to 3 mm. Alternatively,consideration should be given to the use of Renderoc RP252reprofiling and protection mortar. Where higher compressivestrengths and low permeability characteristics are required,Renderoc RP 252 or Renderoc ST05 should be used.

Renderoc FC can also be used in association with otherRenderoc mortars.

Renderoc FC is suitable for repair methods 3.1, 7.1, 7.2 asdefined by BS EN 1504-3.

Advantages

Compatibility with non-structural concrete of compressivestrength 20 - 35 MPaPolymer-modification provides extremely lowpermeability to water, carbon dioxide and chloridesExcellent bond to concreteCan be applied quickly and efficientlyOne component, pre-bagged to overcome site-batchedvariationsContains no chloride admixtures

Description

Renderoc FC is designed for vertical and overhead use toinfill honeycombing and voids up to 3 mm deep in the surfaceof concrete.

Renderoc FC is supplied as a ready to use blend of drypowders requiring only the site addition of clean water toproduce a highly consistent cementitious fairing mortar. Thematerial is based on a blend of cements, graded aggregates,special fillers and chemical additives to provide a materialwith good handling characteristics, while minimising waterdemand.

The product exhibits excellent thermal compatibility withconcrete and is fully compatible with other Renderoc mortarsand Dekguard coatings.e of exposed reinforcing steel.


Renderoc FC complies with the class R2 according toEN1504-3, repair methods 3.1, 7.1 and 7.2.

Renderoc FC has been approved by the British Board ofAgrement, Certificate No 98/3461.

Fosroc® Renderoc FC constructive solutions

1CI/SfB: (4-) Pr4 w7November 2009

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905480-DPC-0730

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erifotnoitcaeR 0d1s2AssalC


36

Fosroc® Renderoc FC


Preparation

Clean the surface and remove any dust, unsound material,plaster, oil, paint, grease, corrosion deposits or algae.Roughen the surface to remove any laitance and expose thefine aggregate by light scabbling or grit-blasting.


Renderoc repair mortars require no additional preparationprior to the application of Renderoc FC.

No independent priming system is required.

The cleaned areas should be blown clean with oil-freecompressed air before continuing. All prepared areas should

be saturated surface dry immediately before the applicationof Renderoc FC, i.e. they should be thoroughly saturated withclean water and any residual surface water removed. Undersevere drying conditions repeated soaking may be necessaryto ensure the substrate is still saturated at the time ofapplication.

Care should be taken and the work scheduled to ensure thewater does not run onto areas of recently applied RenderocFC less than 12 hours old.

Mixing

Care should be taken to ensure that Renderoc FC is thoroughlymixed. Small quantities (up to 10 kg) can be mixed by handusing a suitable mixing drum or bucket. Greater quantitiesshould be mixed using a forced-action mixer. Mixing in asuitably sized drum using a Renderoc spiral paddle with aslow speed (400/500 rpm) heavy-duty drill is an acceptablealternative.



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PropertiesThe following results were obtained at a water : powder ratio of 0.28 and at a temperature of 20°C unless otherwise stated.


37


Mixing warning

As with other ‘one pack’ repair mortars, Renderoc FC mayexhibit satisfactory handling characteristics even thoughinadequately mixed. This will result in a significantly lowerlevel of performance or possible failure. It is therefore essentialthat mixing Instructions are strictly adhered to with particularemphasis on the quantity of water used and the time of themixing operation.

If mixing small quantities by hand, Renderoc FC should bevolume-batched. Add three volumes of the Renderoc FCpowder (loose-filled to excess and struck off level with the topof the measuring container) to one volume of drinking qualitywater. This should be mixed vigorously for a minimum of 3minutes.

For larger volumes, place 7.0 to 8.0 litres of drinking qualitywater into the mixer and, with the machine in operation, addone full 25 kg bag of Renderoc FC and mix for a minimum of3 minutes (maximum 5 minutes). Dependent on the ambienttemperature and the desired consistency, the amount ofwater required may vary slightly but should not exceed 8.0litres per 25 kg bag of Renderoc FC. Do not subsequently re-temper with extra water.

Note: that in all cases Renderoc FC powder must be addedto water.

Application

Apply the mixed Renderoc FC to the prepared substrate bysteel trowel as a scrape coat of minimal thickness. It shouldbe applied with the minimum of working and be allowed topartly set before finally trowelling to a smooth finish. If a verysmooth finish is required, a small amount of water may beflicked on to the surface of the Renderoc FC with a paint brushprior to final trowelling.

Do not proceed with the application when rainfall is imminentunless in a sheltered or protected situation.

Note: the maximum applied thickness of Renderoc FC is3 mm from the depths of the imperfections to the finishedsurface.




At ambient temperatures above 35°C, the material should bestored in the shade and cool water used for mixing.

Curing

Renderoc FC does not require any form of curing in moderateambient conditions, but under strong drying conditions curingmay be necessary. In this case Renderoc FC should be curedimmediately after finishing in accordance with good concretepractice. The use of Nitobond AR, sprayed on to the surfaceof the finished Renderoc FC in a continuous film, isrecommended. Large areas should be cured as trowellingprogresses (0.5 m2 at a time) without waiting for completionof the entire area. In very fast drying conditions, supplementarycuring with polythene sheeting taped down at the edgesshould be used.

In cold conditions, the finished repair must be protected fromfreezing.


Renderoc FC must be overcoated with the Dekguard rangeof coatings or suitable alternatives. The surrounding parts ofthe structure will benefit from the application of a barrier/decorative coating to limit the advance of chlorides andcarbon dioxide, bringing them to the same protective standardas the repair itself. Fosroc recommend the use of theDekguard range of protective, anti-carbonation coatings.These products provide a decorative and uniform appearanceas well as protecting areas of the structure which mightotherwise be at risk from the environment. Dekguard productsmay be applied over the repair area without prior removal ofthe Nitobond AR curing membrane. Other curing membranesmust be removed prior to the application of Dekguard products.

Cleaning

Renderoc FC should be removed from tools, equipment andmixers with clean water immediately after use. Cured materialcan only be removed mechanically.

Estimating

Supply

Renderoc FC: 25 kg bags

Nitobond AR: 5 and 25 litre drums

Coverage and yield

Renderoc FC: Approximately 15.0 litres /25 kg bag (5 m² at 3 mmthickness)

Nitobond AR: 6 - 8 m2/ litre

Notes: the actual yield per bag of Renderoc FC will dependon the consistency used.



38



www.fosroc.com



Limitations

Renderoc FC should not be used when the temperature isbelow 5°C and falling. Do not mix part bags. Due to thelightweight nature of Renderoc FC, the product should not beused in areas subjected to traffic (in these circumstances,Renderoc S should be considered).

Renderoc FC should not be exposed to moving water duringapplication. Exposure to heavy rainfall prior to the final setmay result in surface scour.


Storage


Nitobond AR should be protected from frost.

Precautions

Health and safety


Fire

Renderoc FC is non-flammable.




Renderoc is the trade mark of Fosroc International Limited

39

High performance lightweight concretereinstatement mortar conforming to therequirements of BS EN 1504-3 Class R2

Uses

For the reinstatement of concrete where low permeabilitycharacteristics are required but where high compressivestrength is not the most important consideration. If highcompressive strengths and low permeability characteristicsare required, Renderoc HB45 should be used.

Renderoc HB has been specifically developed for verticaland overhead repair work where its lightweight nature andhigh build characteristics makes it ideal.

Renderoc HB is suitable for repair methods 3.1, 3.3, 7.1, 7.2as defined by BS EN 1504-3.

Advantages

Compatibility with non-structural concrete of compressivestrength 20 - 35 N/mm²`Lightweight formulation enables extra high-build — fewercold jointsFrequently obviates the need for formworkPolymer-modification provides extremely lowpermeability to water, carbon dioxide and chloridesExceptional system of shrinkage compensation provideslong-term dimensional stabilityCan be applied quickly and efficiently by wet sprayingOne component, pre-bagged to overcome site-batchedvariationsContains no chloride admixtures

Description

Renderoc HB is supplied as a ready to use blend of drypowders requiring only the site addition of clean water toproduce a highly consistent, lightweight repair mortar.

It is based on Portland cements, graded aggregates,lightweight fillers and chemical additives which provide amortar with good handling characteristics while minimisingwater demand. The low water requirement ensures goodstrength gain and long-term durability.

Renderoc HB has been specifically engineered for verticaland overhead repair work. It can be applied in sections up to80 mm thickness in vertical locations and up to 50 mmthickness in overhead locations in a single application andwithout the use of formwork. Thicker sections can be achievedby the use of formwork or can be built up in layers. Deeppockets can sometimes be filled in a single applicationdependent on the configuration of the pocket and the volumeof exposed reinforcing steel.

Renderoc HB can be quickly and efficiently applied by the wetspray technique. Consult the local Fosroc office for furtherinformation.

The material should not be applied at less than 10 mmthickness.


Renderoc HB complies with the class R2 according toEN1504-3, repair methods 3.1, 3.3, 7.1 and 7.2.

Renderoc HB, Nitoprime Zincrich Plus, Nitobond AR andNitobond HAR have been approved by the British Board ofAgrement, Certificate No 98/3461.

Fosroc® Renderoc HB constructive solutions



905480-DPC-0730

3-4051NEriaperlarutcurts-nonrofstcudorpriaperetercnoCciluardyhdeifidomremylopnodesab(ratromCCP

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gnilcyc≥ aPM8.0



44

Fosroc® Renderoc HB


Preparation





Where corrosion has occurred due to the presence ofchlorides, the steel should be high-pressure washed withclean water immediately after abrasive-blasting to removecorrosion products from pits and imperfections within itssurface.







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45


Concrete Priming

The concrete substrate should be saturated surface dryimmediately before the application of the primer i.e. it shouldbe thoroughly saturated with clean water and any residualsurface water removed prior to applying Nitobond HAR.

Under severe drying conditions repeated soaking may benecessary to ensure the substrate is still saturated at the timeof application of the primer.

Scrub Nitobond HAR into the surface.

Renderoc HB can be applied as soon as the primer becomestacky. If the Nitobond HAR is too wet, overhead and verticalbuild up of the Renderoc HB may be difficult.

In exceptional circumstances, e.g. where a substrate/repairbarrier is required or where the substrate is water immersedor likely to remain permanently damp, Nitobond EP bondingaid should be used. Contact the local Fosroc office for furtherinformation.

Mixing

Care should be taken to ensure that Renderoc HB is thoroughlymixed. A forced-action mixer is essential. Mixing in a suitablysized drum using an approved Renderoc Spiral Paddle witha slow speed (400/500 rpm) heavy-duty drill is acceptable forthe occasional one-bag mix.

Free-fall mixers must not be used. Mixing of part bags shouldnever be attempted.

For normal applications, place 3.1 to 3.4 litres of drinkingquality water into the mixer.

With the machine in operation, add one full bag of RenderocHB and mix, for a minimum of 3 minutes and a maximum of5 minutes, until fully homogeneous.

The consistency may be adjusted by the addition of smallamounts of water up to the maximum total water content of3.4 litres.

Note that the powder must always be added to the water.

Mixing warning

As with other ‘one pack’ repair mortars, Renderoc HB mayexhibit satisfactory handling characteristics even thoughinadequately mixed. This will result in a significantly lowerlevel of performance or possible failure. It is therefore essentialthat mixing instructions are strictly adhered to with particularemphasis on the quantity of water used and the time of themixing operation.

Application


Apply the mixed Renderoc HB by gloved hand or trowel,thoroughly compacting onto the primed substrate andaround exposed reinforcement.

If sagging or slumping occurs Renderoc HB should becompletely removed and reapplied at a reduced thickness toa correctly primed substrate.

Build-up


The surface of the intermediate layers should be combscratch-keyed and cured with Nitobond AR. Repriming withNitobond HAR and a further application of Renderoc HB mayproceed as soon as this layer has set.

Spray application

Renderoc HB can be quickly and efficiently applied by the wetspray technique. In circumstances where large areas ofrepair are required, the rapid placement and higher buildattainable by this method offer economic advantages overhand-trowelling. The resultant repair also offers a generallymore dense compound with enhanced mortar/substratebond characteristics.

For further details on wet spray techniques contact the localFosroc office.

Finishing

Renderoc HB is finished by striking off with a straight edgeand closing with a steel float. Wooden or plastic floats, ordamp sponges, may be used to achieve the desired surfacetexture. The completed surface should not be overworked.After spray application, the mortar may need to be ‘cut back’to the required profile using a steel float and then finished withdamp sponges as described above.





Curing

Renderoc HB is a cement-based repair mortar. In commonwith all cementitious materials, it must be cured immediatelyafter finishing in accordance with good concrete practice. Theuse of Nitobond AR, sprayed on to the surface of the finishedmortar in a continuous film, is recommended. A low pressureatomising sprayer is essential for applying the Nitobond AR.Any excessive run-off on verticals or drips on soffits shouldbe removed by brush before they harden.




46



www.fosroc.com



In fast drying conditions, supplementary curing with polythenesheeting taped down at the edges must be used. In coldconditions, the finished repair must be protected from freezing.


Renderoc HB is extremely durable and will provide long-termprotection to the embedded steel reinforcement within therepaired locations. The surrounding parts of the structure willbenefit from the application of a barrier/decorative coating tolimit the advance of chlorides and carbon dioxide, bringingthem to the same protective standard as the repair itself.Fosroc recommend the use of the Dekguard range ofprotective, anti-carbonation coatings. These products providea decorative and uniform appearance as well as protectingareas of the structure which might otherwise be at risk fromthe environment. Dekguard products may be applied over therepair area without prior removal of the Nitobond AR curingmembrane. Other curing membranes must be removedprior to the application of Dekguard products.

Cleaning

Renderoc HB and Nitobond HAR should be removed fromtools, equipment and mixers with clean water immediatelyafter use. Cured material can only be removed mechanically.

Clean tools used with Nitoprime Zincrich Plus and NitobondEP before material cures using Fosroc Solvent 102.

Estimating

Supply

Renderoc HB: 18 kg bags


Nitobond HAR 5 and 25 litre drums



Coverage and yield

Renderoc HB: Approximately 14.5 -15.0 litres /18 kg bag (approximately 1.5 m²at 10 mm thickness)

Nitoprime Zincrich Plus: 8 m2/litreNitobond AR: 6 - 8 m2/ litreNitoprime HAR 3 - 4 m2/ litre

Notes: the actual yield per bag of Renderoc HB will depend onthe consistency used. The yield will be reduced if the material isapplied by a spray technique.

Limitations

Renderoc HB should not be used when the temperature isbelow 5°C and falling. Do not mix part bags. Due to the lightweightnature of Renderoc HB, the product should not be used in areassubjected to traffic (in these circumstances, Renderoc S shouldbe considered).

Renderoc HB should not be exposed to moving water duringapplication. Exposure to heavy rainfall prior to the final set mayresult in surface scour.


Storage

The product has a shelf life of 12 months from the date ofmanufacture if kept in dry storage in the original, unopenedbags. If stored at high temperatures and/or high humidity theshelf life may be reduced to less than 6 months.

Nitobond AR and Nitobond HAR should be protected from frost.

Precautions

Health and safety


Fire

Renderoc HB is non-flammable.

Nitoprime Zincrich Plus and Fosroc Solvent 102: are flammable.Keep away from sources of ignition. No Smoking. In the event offire, extinguish with CO2 or foam. Do not use a water jet

Flash points





47

High performance fibre reinforced lightweightconcrete reinstatement mortar conformingto the requirements of BS EN 1504-3 Class R3

Uses

For the reinstatement of concrete where low permeabilitycharacteristics are required but where high compressivestrength is not the most important consideration. If highcompressive strength is required Renderoc HB45 should beused.

Renderoc HB30 has been specifically developed for verticaland overhead repair work where its lightweight nature andhigh build characteristics makes it ideal.

Renderoc HB30 is suitable for repair methods 3.1, 3.3, 7.1,7.2 as defined by BS EN 1504-3.

Advantages

Maximum compatibility with concrete of compressivestrength 20 - 35 N/mm²Lightweight formulation enables extra high-build — fewercold jointsFrequently obviates the need for formworkPolymer-modification provides extremely lowpermeability to water, carbon dioxide and chloridesExceptional system of shrinkage compensation provideslong-term dimensional stabilityCan be applied quickly and efficiently by wet sprayingOne component, pre-bagged to overcome site-batchedvariationsContains no chloride admixtures

Description

Renderoc HB30 is supplied as a ready to use blend of drypowders requiring only the site addition of clean water toproduce a highly consistent, lightweight repair mortar.


Renderoc HB30 has been specifically engineered for verticaland overhead repair work. It can be applied in sections up to60 mm thickness in vertical locations and up to 40 mmthickness in overhead locations in a single application andwithout the use of formwork. Thicker sections can be achievedby the use of formwork or can be built up in layers. Deeppockets can sometimes be filled in a single applicationdependent on the configuration of the pocket and the volumeof exposed reinforcing steel.

Renderoc HB30 can be quickly and efficiently applied by thewet spray technique. Consult the local Fosroc office forfurther information.



The repair mortar shall be Renderoc HB30, a one component,polymer modified, high build cementitious mortar, conformingto the requirements of BS EN 1504-3 Class R3.

The cured mortar shall achieve a compressive strength of30 MPa at 28 Days and a drying shrinkage of <300microstrain at 7 days.


Renderoc HB30 complies with the class R3 according toEN1504-3, repair methods 3.1, 3.3, 7.1 and 7.2.

Fosroc® Renderoc HB30 constructive solutions



905480-DPC-0730







gnilcyc≥ aPM5.1




48

Fosroc® Renderoc HB30


Preparation




Expose fully any corroded steel in the repair area andremove all loose scale and corrosion deposits. Steel shouldbe cleaned to a bright condition paying particular attention tothe back of exposed steel bars. Abrasive-blasting isrecommended for this process.











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49


Concrete Priming

The concrete substrate should be saturated surface dryimmediately before the application of the primer i.e. it shouldbe thoroughly saturated with clean water and any residualsurface water removed prior to applying Renderoc Primer.Under severe drying conditions repeated soaking may benecessary to ensure the substrate is still saturated at the timeof application of the primer.Add 3 parts by volume of Renderoc Primer Part A to 1 part byvolume Renderoc Primer Part B (4 to 1 by weight) in a cleanmixing vessel and mix with a spatula or slow speed drill andpaddle until a homogeneous slurry is produced.Scrub Renderoc Primer slurry into the surface.Renderoc HB30 can be applied immediately to the primedsurface. If the primer dries apply another coat of primer beforecontinuing.Open bags of Renderoc Primer Part A should be sealed andstored in a dry area. Use within 14 days.In exceptional circumstances, e.g. where a substrate/repairbarrier is required or where the substrate is water immersedor likely to remain permanently damp, Nitobond EP bondingaid should be used. Contact the local Fosroc office for furtherinformation.

Mixing

Care should be taken to ensure that Renderoc HB30 isthoroughly mixed. A forced-action mixer is essential. Mixingin a suitably sized drum using an approved Renderoc SpiralPaddle with a slow speed (400/500 rpm) heavy-duty drill isacceptable for the occasional one-bag mix.Free-fall mixers must not be used. Mixing of part bags shouldnever be attempted.For normal applications, place 3.8 to 4.2 litres of drinkingquality water into the mixer.With the machine in operation, add one full bag of RenderocHB30 and mix for a minimum of 3 minutes and a maximumof 5 minutes, until fully homogeneous.The consistency may be adjusted by the addition of smallamounts of water up to the maximum total water content of4.2 litres.Note that the powder must always be added to the water.

Mixing warning

As with other ‘one pack’ repair mortars, Renderoc HB30 mayexhibit satisfactory handling characteristics even thoughinadequately mixed. This will result in a significantly lowerlevel of performance or possible failure. It is thereforeessential that mixing instructions are strictly adhered to withparticular emphasis on the quantity of water used and thetime of the mixing operation.

Application

Exposed steel reinforcing bars should be firmly secured toprevent movement during application. Apply the mixed

Renderoc HB30 by gloved hand or trowel, thoroughlycompacting onto the primed substrate and around exposedreinforcment.

If sagging or slumping occurs the Renderoc HB30 should becompletly removed and reapplied at a reduced thickness toa correctly primed substrate.

Build-up


The surface of the intermediate layers should be combscratch-keyed and cured with Nitobond AR. Repriming withRenderoc Primer and a further application of Renderoc HB30may proceed as soon as this layer has set.

Spray application

Renderoc HB30 can be quickly and efficiently applied by thewet spray technique. In circumstances where large areas ofrepair are required, the rapid placement and higher buildattainable by this method offer economic advantages overhand-trowelling. The resultant repair also offers a generallymore dense compound with enhanced mortar/substratebond characteristics.For further details on wet spray techniques contact the localFosroc office.

Finishing

Renderoc HB30 is finished by striking off with a straight edgeand closing with a steel float. Wooden or plastic floats, ordamp sponges, may be used to achieve the desired surfacetexture. The completed surface should not be overworked.After spray application, the mortar may need to be ‘cut back’to the required profile using a steel float and then finished withdamp sponges as described above.





Curing

Renderoc HB30 is a cement-based repair mortar. In commonwith all cementitious materials, it must be cured immediatelyafter finishing in accordance with good concrete practice. Theuse of Nitobond AR, sprayed on to the surface of the finishedmortar in a continuous film, is recommended. A low pressureatomising sprayer is essential for applying the Nitobond AR.Any excessive run-off on verticals or drips on soffits shouldbe removed by brush before they harden.



50



www.fosroc.com






Renderoc HB30 is extremely durable and will provide long-term protection to the embedded steel reinforcement withinthe repaired locations. The surrounding parts of the structurewill benefit from the application of a barrier/decorative coatingto limit the advance of chlorides and carbon dioxide, bringingthem to the same protective standard as the repair itself.Fosroc recommend the use of the Dekguard range ofprotective, anti-carbonation coatings. These products providea decorative and uniform appearance as well as protectingareas of the structure which might otherwise be at risk fromthe environment. Dekguard products may be applied over therepair area without prior removal of the Nitobond AR curingmembrane. Other curing membranes must be removedprior to the application of Dekguard products.

Cleaning

Renderoc HB30 and Renderoc Primer should be removedfrom tools, equipment and mixers with clean waterimmediately after use. Cured material can only be removedmechanically.

Clean tools used with Nitoprime Zincrich Plus and NitobondEP before material cures, using Fosroc Solvent 102.

Estimating

Supply

Renderoc HB30: 22 kg bags


Renderoc Primer 20 Kg Part A + 5 litres part B



Coverage and yield

Renderoc HB30: Approximately 15.0 litres / 22kg bag (approximately 1.5 m²at 10 mm thickness)

Nitoprime Zincrich Plus: 8 m2/litreNitobond AR: 6 - 8 m2/ litreRenderoc Primer Approximately 13 litres - 2m2/litre

Notes: the actual yield per bag of Renderoc HB30 will dependon the consistency used. The yield will be reduced if thematerial is applied by a spray technique.

LimitationsRenderoc HB30 should not be used when the temperatureis below 5°C and falling. Do not mix part bags. Due to thelightweight nature of Renderoc HB30, the product should notbe used in areas subjected to traffic (in these circumstances,Renderoc S should be considered).Renderoc HB30 should not be exposed to moving waterduring application. Exposure to heavy rainfall prior to the finalset may result in surface scour.If any doubts arise concerning temperature or substrateconditions, consult the local Fosroc office.

Storage

Renderoc HB30 and Renderoc Primer have a shelf life of12 months from the date of manufacture if kept in dry stor-age in the original, unopened bags. If stored at high tem-peratures and/or high humidity the shelf life may be re-duced to less than 6 months.Nitobond AR and Renderoc Primer Part B should be pro-tected from frost.

Precautions

Health and safety


Fire

Renderoc HB30 is non-flammable.Nitoprime Zincrich Plus and Fosroc Solvent 102: areflammable. Keep away from sources of ignition. No Smoking.In the event of fire, extinguish with CO2 or foam. Do not usea water jet

Flash points





51

High performance fibre reinforced mediumweight concrete reinstatement mortarconforming to the requirements of BS EN1504-3 Class R4

Uses

For the reinstatement of reinforced concrete where lowpermeability characteristics are required and where highercompressive strength is a consideration. Where compatibilitywith lower strength concrete is required, Renderoc HB30should be used.

Renderoc HB45 has been specificaly developed for therepair of columns and beams, but because of its mediumfresh wet density, is also suitable for soffit repairs.

Renderoc HB45 is suitable for repair methods 3.1, 3.3, 4.4,7.1, 7.2 as defined by BS EN 1504-3.

Advantages

Maximum compatibility with concrete of compressivestrength 35 - 60 N/mm²High-build applications possible while maintaining highercompressive strengths — fewer cold jointsFrequently obviates the need for formworkPolymer-modification provides extremely lowpermeability to water, carbon dioxide and chloridesExceptional system of shrinkage compensation provideslong-term dimensional stabilityCan be applied quickly and efficiently by wet sprayingOne component, pre-bagged to overcome site-batchedvariationsContains no chloride admixtures

Description

Renderoc HB45 is supplied as a ready to use blend of drypowders which requires only the site addition of clean waterto produce a highly consistent, medium-weight repair mortar.

It is based on Portland cements, graded aggregates,lightweight fillers and chemical additives providing a mortarwith good handling characteristics while minimising waterdemand. The low water requirement ensures good strengthgain and long-term durability.

Renderoc HB45 has been specifically engineered for verticaland overhead repair work. It can be applied in sections up to40 mm thickness in vertical locations and up to 30 mmthickness in overhead locations in a single application withoutformwork. Thicker sections can be achieved by the use offormwork or can be built up in layers. Deep pockets cansometimes be filled in a single application dependent on theconfiguration of the pocket and the volume of exposedreinforcing steel.

Renderoc HB45 can be quickly and efficiently applied by thewet spray technique. Consult the local Fosroc office forfurther information.



The repair mortar shall be Rendreoc HB45 a one componentpolymer modified high build cementitious mortar conformingto the requirements of BS EN 1504-3 Class R4.

The cured mortar shall achieve a compressive strength of50 MPa at 28 days and a drying shrinkage of <300 microstrainat 7 days.


Renderoc HB45 complies with the classification R4according to EN 1504-3, repair methods 3.1, 3.3, 4.4, 7.1 and7.2.


1CI/SfB:

October 2009


905480-DPC-0730







gnilcyc≥ aPM0.2


noitprosbayrallipaC m/gk5.0 2- h. 5.0-





52



1CI/SfB:

October 2009


tluseR






noitrposbayrallipaC 2002:5031NE ≤ -m/gk5.0 2 h/ 5.0- -m/gk90.0 2 h/ 5.0-

noisserpmoCnisuludoMcitsalE 21431NE ≥ aPG02 syad82@aPG52

gnitareriF 1-10531NE elbitsubmoC-noN0d1s2AssalC

htgnertslaruxelF 0991:3tP9136SB - 5.7 syad82@aPM

htgnertselisneT 5891:3tP9136SB - [email protected]

emitgnitteS 0891:41tP1554SB - sruoh3:teslaitinIsruoh5:teslaniF

ytisnedtewhserF - m/gk0002yllanimoN 3-


72 o HR%55,C- syad7@niartsorcrim003<



coredneRfoytilibaemrepwolehTkcattalacimehcsdraterylerevesSBH

ehT.stnemnorivneevissergganidicaotelbaemrepmisiratromderucdnasnoiedriolhcenrobretaw,sesag

.negyxo



:lacitreV

---

---


PropertiesThe following results were obtained at a water : powder ratio of 0.13 and a temperature of 20°C unless otherwise stated.



Preparation






53



1CI/SfB:

October 2009



Concrete Priming

The concrete substrate should be saturated surface dryimmediately before the application of the primer i.e. it shouldbe thoroughly saturated with clean water and any residualsurface water removed prior to applying Renderoc Primer.Under severe drying conditions repeated soaking may benecessary to ensure the substrate is still saturated at the timeof application of the primer.Add 3 parts by volume of Renderoc Primer Part A to 1 part byvolume Renderoc Primer Part B (4 to 1 by weight) in a cleanmixing vessel and mix with a spatula or slow speed drill untila homogeneous smooth slurry is produced.Scrub Renderoc Primer slurry into the surface.Renderoc HB45 can be applied immediately to the primedsurface. If the primer dries apply another coat of primer beforecontinuing.Open bags of Renderoc Primer Part A should be sealed andstored in a dry area. Use within 14 days.In exceptional circumstances, e.g. where a substrate/repairbarrier is required or where the substrate is wet or likely toremain permanently damp, Nitobond EP bonding aid shouldbe used. Contact the local Fosroc office for further information.

Mixing

Care should be taken to ensure that Renderoc HB45 isthoroughly mixed. A forced-action mixer is essential. Mixingin a suitably sized drum using an approved Renderoc SpiralPaddle in a slow speed (400/500 rpm) heavy-duty drill isacceptable for the occasional one-bag mix.

Free-fall mixers must not be used. Mixing of part bags shouldnever be attempted.For normal applications, place 3.25 to 3.5 litres of drinkingquality water into the mixer.With the machine in operation, add one full bag of RenderocHB45 and mix for a minimum of 3 minutes and a maximumof 5 minutes, until fully homogeneous.The consistency may be adjusted by the addition of smallamounts of water up to the maximum total water content of3.5 litres.Note that the powder must always be added to the water.

Mixing warning

As with other ‘one pack’ repair mortars, Renderoc HB45 mayexhibit satisfactory handling characteristics even thoughinadequately mixed. This will result in a significantly lowerlevel of performance or possible failure. It is thereforeessential that mixing instructions are strictly adhered to withparticular emphasis on the quantity of water used and the

time of the mixing operation.

Application


Apply the mixed Renderoc HB45 by gloved hand or trowel,thoroughly compacting onto the primed substrate and aroundexposed reinforcment.

If sagging or slumping occurs Renderoc HB45 should becompletely removed and reapplied at a reduced thickness toa correctly primed substrate.

Build-up


The surface of the intermediate layers should be combscratch-keyed and cured with Nitobond AR. Repriming withRenderoc Primer and a further application of Renderoc HB45may proceed as soon as this layer has set.

Spray application

Renderoc HB45 can be quickly and efficiently applied by thewet spray technique. In circumstances where large areas ofrepair are required, the rapid placement and higher buildattainable by this method offer economic advantages overhand-trowelling. The resultant repair also offers a generallymore dense compound with enhanced mortar/substratebond characteristics. For further details on wet spraytechniques contact the local Fosroc office.

Finishing

Renderoc HB45 is finished by striking off with a straight edgeand closing with a steel float. Wooden or plastic floats, ordamp sponges, may be used to achieve the desired surfacetexture. The completed surface should not be overworked.After spray application, the mortar may need to be ‘cut back’to the required profile using a steel float and then finished withdamp sponges as described above.





Curing

Renderoc HB45 is a cement-based repair mortar. In commonwith all cementitious materials, it must be cured immediately

54

Important noteFosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply ofGoods and Services, copies of which may be obtained on request. Whilst Fosroc endeavours to ensure that any advice, recommendation,specification of information it may give is accurate and correct, it cannot, because it has no direct or continuous control over where or how itsproducts are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with anyadvice, specification, recommendation of information given by it.


1CI/SfB:

October 2009

after finishing in accordance with good concrete practice. Theuse of Nitobond AR, sprayed on to the surface of the finishedmortar in a continuous film, is recommended. A low pressureatomising sprayer is essential for applying the Nitobond AR.Any excessive run-off on verticals or drips on soffits shouldbe removed by brush before they harden.




Renderoc HB45 is extremely durable and will provide long-term protection to the embedded steel reinforcement withinthe repaired locations. The surrounding parts of the structurewill benefit from the application of a barrier/decorative coatingto limit the advance of chlorides and carbon dioxide, bringingthem to the same protective standard as the repair itself.Fosroc recommend the use of the Dekguard range ofprotective, anti-carbonation coatings. These products providea decorative and uniform appearance as well as protectingareas of the structure which might otherwise be at risk fromthe environment. Dekguard products may be applied over therepair area without prior removal of the Nitobond AR curingmembrane. Other curing membranes must be removedprior to the application of Dekguard products.

Cleaning

Renderoc HB45 and Renderoc Primer should be removedfrom tools, equipment and mixers with clean waterimmediately after use. Cured material can only be removedmechanically.Clean tools used with Nitoprime Zincrich Plus and NitobondEP before material cures using Fosroc Solvent 102.

Estimating

SupplyRenderoc HB45: 25 kg bags





Coverage and yieldRenderoc HB45: Approximately 14 litres / 25

kg bag (approximately 1.4 m²at 10 mm thickness)

Nitoprime Zincrich Plus: 8 m2/litreNitobond AR: 6 - 8 m2/litreRenderoc Primer Approximately 13 litres- 2m2/ litreNotes: the actual yield per bag of Renderoc HB45 willdepend on the consistency used. The yield will be reducedif the material is applied by a spray technique.

Limitations

Renderoc HB45 should not be used when the temperatureis below 5°C and falling. Do not mix part bags.Renderoc HB45 should not be used in areas subjected totraffic (in these circumstances, Renderoc S should beconsidered).Renderoc HB45 should not be exposed to moving waterduring application. Exposure to heavy rainfall prior to the finalset may result in surface scour.If any doubts arise concerning temperature or substrateconditions, consult the local Fosroc office.

Storage

The Renderoc HB45 and Renderoc Primer have a shelf lifeof 12 months from the date of manufacture if kept in drystorage in the original, unopened bags. If stored at hightemperatures and/or high humidity the shelf life may bereduced to less than 6 months.Nitobond AR and Renderoc Primer Part B should be pro-tected from frost.

Precautions

Health and safety

For further information refer to the appropriate Product SafetyData Sheet available at www.fosroc.com

Fire

Renderoc HB45 is non-flammable.Nitoprime Zincrich Plus and Fosroc Solvent 102 are flam-mable. Keep away from sources of ignition. No Smoking. Inthe event of fire, extinguish with CO2 or foam. Do not use awater jet

Flash pointsNitoprime Zincrich Plus: 41°CFosroc Solvent 102: 33°C


www.fosroc.com



High performance fibre reinforced mediumweight concrete reinstatement mortarconforming to the requirements of BS EN1504-3 Class R4

Uses

For the reinstatement of reinforced concrete where lowpermeability characteristics are required and where highercompressive strength is a consideration.

Renderoc HBS has been specificaly developed for the repairof columns and beams but, because of its relatively low freshwet density, is also suitable for soffit repairs.

Where compatibility with lower strength concrete is required,Renderoc HB30 should be used.

Renderoc HBS is suitable for repair methods 3.1, 3.3, 4.4,7.1, 7.2 as defined by BS EN 1504-3.

Advantages

Compatible with concrete of compressive strength 35 -60 N/mm²High-build applications possible while maintaining highercompressive strengths — fewer cold jointsFrequently obviates the need for formworkPolymer-modification provides extremely lowpermeability to water, carbon dioxide and chloridesShrinkage compensated to provides long-termdimensional stabilityCan be applied quickly and efficiently by wet sprayingOne component, pre-bagged to overcome site-batchedvariationsContains no chloride admixtures

Description

Renderoc HBS is supplied as a ready to use blend of drypowders which requires only the site addition of clean waterto produce a highly consistent, medium-weight repair mortar.


Renderoc HBS has been specifically engineered for verticaland overhead repair work. It can be applied in sections up to40 mm thickness in vertical locations and up to 30 mmthickness in overhead locations in a single application withoutthe use of formwork.

Thicker sections can be achieved by the use of formwork orcan be built up in layers. Deep pockets can sometimes befilled in a single application dependent on the configurationof the pocket and the volume of exposed reinforcing steel.

Renderoc HBS can be quickly and efficiently applied by thewet spray technique. Consult the local Fosroc office for furtherinformation.



Renderoc HBS complies with the classification R4 accordingto EN 1504-3, repair methods 3.1, 3.3, 4.4, 7.1 and 7.2.

Fosroc® Renderoc HBS

1CI/SfB:

October 2009


905480-DPC-0730

3-4051NECCPriaperlarutcurtsrofstcudorpriaperetercnoC

)tnemecciluardyhdeifidomremylopnodesab(ratrom





gnilcyc≥ aPM0.2





56



1CI/SfB:

October 2009


htgnertSevisserpmoC 9991:09121NE ≥ aPM54 aPM02yaD1@05syaD82@ aPM






gnitareriF 1-10531NE elbitsubmoC-noN0d1s2AssalC

htgnertslaruxelF 0991:3tP9136SB - 5.6 syad82@aPM

htgnertselisneT 5891:3tP9136SB - 9.2 aPM syad82@


ytisnedtewhserF - m/gk0002yllanimoN 3-


coredneRfoytilibaemrepwolehTkcattalacimehcsdraterylerevesSBHderucehT.stnemnorivneevisserggani,sesagdicaotelbaemrepmisiratrom.negyxodnasnoiedriolhcenrobretaw



:lacitreV

---

---


Properties


Clarification of property values: The typical properties given above are derived from laboratory testing. Results derived fromtesting field applied samples may vary.


Preparation








57



1CI/SfB:

October 2009

Concrete Priming

The concrete substrate should be saturated surface dryimmediately before the application of the primer i.e. it shouldbe thoroughly saturated with clean water and any residualsurface water removed prior to applying Renderoc Primer.Under severe drying conditions repeated soaking may benecessary to ensure the substrate is still saturated at the timeof application of the primer.Add 3 parts by volume of Renderoc Primer Part A to 1 part byvolume Renderoc Primer Part B (4 to 1 by weight) in a cleanmixing vessel and mix with a spatula or slow speed drill untila homogeneous smooth paste is produced.Scrub Renderoc Primer slurry into the surface.Renderoc HBS can be applied immediately to the primedsurface. If the primer dries apply another coat of primer beforecontinuing.Open bags of Renderoc Primer Part A should be sealed andstored in a dry area. Use within 14 days.In exceptional circumstances, e.g. where a substrate/repairbarrier is required or where the substrate is water immersedor likely to remain permanently damp, Nitobond EP bondingaid should be used. Contact the local Fosroc office for furtherinformation.

Mixing

Care should be taken to ensure that Renderoc HBS isthoroughly mixed. A forced-action mixer is essential. Mixingin a suitably sized drum using an approved Renderoc SpiralPaddle in a slow speed (400/500 rpm) heavy-duty drill isacceptable for the occasional one-bag mix.Free-fall mixers must not be used. Mixing of part bags shouldnever be attempted.For normal applications, place 3.25 to 3.5 litres of drinkingquality water into the mixer.With the machine in operation, add one full bag of RenderocHBS and mix, for a minimum of 3 minutes and a maximumof 5 minutes, until fully homogeneous.The consistency may be adjusted by the addition of smallamounts of water up to the maximum total water content of3.5litres.Note that the powder must always be added to the water.

Mixing warning

As with other ‘one pack’ repair mortars, Renderoc HBS mayexhibit satisfactory handling characteristics even thoughinadequately mixed. This will result in a significantly lowerlevel of performance or possible failure. It is therefore essentialthat mixing instructions are strictly adhered to with particularemphasis on the quantity of water used and the time of themixing operation.

Application


Apply the mixed Renderoc HBS by gloved hand or trowel,thoroughly compacting onto the primed substrate and aroundexposed reinforcment.

If sagging or slumping occurs the Renderoc HBS should becompletly removed and reapplied at a reduced thickness toa correctly primed substrate.

Build-up


The surface of the intermediate layers should be combscratch-keyed and cured with Nitobond AR. Repriming withRenderoc Primer and a further application of Renderoc HBSmay proceed as soon as this layer has set.

Spray application

Renderoc HBS can be quickly and efficiently applied by thewet spray technique. In circumstances where large areas ofrepair are required, the rapid placement and higher buildattainable by this method offer economic advantages overhand-trowelling. The resultant repair also offers a generallymore dense compound with enhanced mortar/substratebond characteristics.


Finishing

Renderoc HBS is finished by striking off with a straight edgeand closing with a steel float. Wooden or plastic floats, ordamp sponges, may be used to achieve the desired surfacetexture. The completed surface should not be overworked.After spray application, the mortar may need to be ‘cut back’to the required profile using a steel float and then finished withdamp sponges as described above.





Curing

Renderoc HBS is a cement-based repair mortar. In commonwith all cementitious materials, it must be cured immediatelyafter finishing in accordance with good concrete practice. Theuse of Nitobond AR, sprayed on to the surface of the finishedmortar in a continuous film, is recommended. A low pressureatomising sprayer is essential for applying the Nitobond AR.Any excessive run-off on verticals or drips on soffits shouldbe removed by brush before they harden.

58



www.fosroc.com




1CI/SfB:

October 2009




Renderoc HBS is extremely durable and will provide long-term protection to the embedded steel reinforcement withinthe repaired locations. The surrounding parts of the structurewill benefit from the application of a barrier/decorative coatingto limit the advance of chlorides and carbon dioxide, bringingthem to the same protective standard as the repair itself.Fosroc recommend the use of the Dekguard range ofprotective, anti-carbonation coatings. These products providea decorative and uniform appearance as well as protectingareas of the structure which might otherwise be at risk fromthe environment. Dekguard products may be applied over therepair area without prior removal of the Nitobond AR curingmembrane. Other curing membranes must be removedprior to the application of Dekguard products.

Cleaning

Renderoc HBS and Renderoc Primer should be removedfrom tools, equipment and mixers with clean waterimmediately after use. Cured material can only be removedmechanically.Clean tools used with Nitoprime Zincrich Plus and NitobondEP before material cures, using Fosroc Solvent 102.

Estimating

Supply

Renderoc HBS: 25 kg bags





Coverage and yield

Renderoc HBS: Approximately 15 litres / 25kg bag (approximately 1.5 m²at 10 mm thickness)

Nitoprime Zincrich Plus: 8 m2/litreNitobond AR: 6 - 8 m2/ litreRenderoc Primer Approximately 13 litres- 2m-2/ litreNotes: the actual yield per bag of Renderoc HBS willdepend on the consistency used. The yield will be re-duced if the material is applied by a spray technique.

Limitations

Renderoc HBS should not be used when the temperature isbelow 5°C and falling. Do not mix part bags. Due to thelightweight nature of Renderoc HBS, the product should notbe used in areas subjected to traffic (in these circumstances,Renderoc S should be considered).

Renderoc HBS should not be exposed to moving waterduring application. Exposure to heavy rainfall prior to the finalset may result in surface scour.


Storage


Nitobond AR and Renderoc Primer Part B should be pro-tected from frost.

Precautions

Health and safety


Fire

Renderoc HBS is non-flammable.


Flash points


59

High performance free flowing low alkalimicroconcrete conforming to the requirementsof BS EN 1504-3 Class R4

Uses

For the reinstatement of reinforced concrete where lowpermeability characteristics are required and where highcompressive strength is a consideration.

Renderoc LA has been specificaly developed for the repair oflarge areas of concrete where access is restricted or wherereinforcement is conjested.

It is suitable for use where excellent chloride and carbondioxide resistance is required or for repairs to concrete affectedby alkali-silica reaction (ASR). Renderoc LA is alkaline innature and will protect embedded steel reinforcement.

Renderoc LA is suitable for repair methods 3.2, 4.4, 7.1, 7.2as defined by BS EN 1504-3.

Advantages

Maximum compatibility with concrete of compressivestrength 30 - 60 N/mm²Dual expansion system compensates for shrinkage in theplastic and hardened statesLow alkali content minimises risk of alkali-silica reactionExceptional bond to concrete substrates withoutindependent primerSuitable for placement by pumping or pouring techniquesinto restricted locationsSelf-compacting nature eliminates honeycombing anddisplaces air without vibrationHigh strength and low permeability provide maximumprotection against carbon dioxide and chloridesPre-bagged to overcome site-batched variations — onlythe site addition of clean water is requiredContains no chloride admixtures

Description

Renderoc LA is supplied as a ready to use blend of drypowders requiring only the site addition of clean water toproduce a free-flowing, shrinkage compensated micro-concrete suitable for large volume concrete repairs at nominalthicknesses in excess of 50 mm.

The material is based on Portland cement, graded aggregatesand additives which impart controlled expansion in both theplastic and hardened states while minimising water demand.Its low alkali content minimises the risk of alkali-silica reaction.The hardened product exhibits excellent thermal compatibilitywith concrete.

Renderoc LA is designed for large volume repairs typically inexcess of 50 mm deep. The product can be applied insections generally up to 150 mm thick although greaterthicknesses may be achievable dependent on theconfiguration of the repair location and the volume of exposedreinforcing steel. Consult the local Fosroc office for furtherinformation.


Renderoc LA complies with the classification R4 accordingto EN 1504-3, repair methods 3.2, 4.4, 7.1 and 7.2.

Fosroc® Renderoc LA

1CI/SfB: Eq4

October 2009


905480-DPC-0730

3-4051NEratromCCriaperlarutcurtsrofstcudorpriaperetercnoC






gnilcyc≥ aPM0.2






60



1CI/SfB: Eq4

October 2009



aPM41yaD1@03syaD3@ aPM24syaD7@ aPM06syaD82@ aPM




dnoitanobracotecnatsiseR k 5002:59231NE ≤ etercnocfer seilpmoC

nisuludoMcitsalEnoisserpmoC 21431NE ≥ aPG02 syaD82@aPG13

gnitareriF 1-50531NE 1AssalC

htgnertslaruxelF 0991:3tP9136SB - 9.6 syaD82@aPM

emitgnitteS 0891:41tP1554SB - sruoh2/16:teslaitinIsruoh9:teslaniF

ytisnedtewhserF - m/g0032yllanimoN 3



selcitrapevitcaerilaklA 25B-ITdohteM - ≤ %lov%1

seitreporPwolFycnegAsyawhgiHKU)b(6.4esualC68/72DB

2-59331NE

01nihtiwmm0001sdnoces

7nim03,sdnoces5laitinIsdnoces


foytilibaemrepwolehTsdraterylerevesALcoredneRevissergganikcattalacimehc

ratromderucehT.stnemnorivne,sesagdicaotelbaemrepmisi

dnasnoiedriolhcenrobretaw.negyxo

ssergninoiedirolhC 69331NE -%3nishtnom6retfa%641.0

mmm01-8tanoitulosLCaNhtped

PropertiesThe following results were obtained at a water : powder ratio of 0.13 and a temperature of 20°C unless otherwise stated.


61



1CI/SfB: Eq4

October 2009


The unrestrained surface area of the repair must be kept toa minimum. The formwork should be rigid and tight to pre-vent loss of material and have properly sealed faces to en-sure that no water is absorbed from the repair material. Theformwork should include drainage outlets for pre-soakingand, if beneath a soffit, provision for air-venting. Provisionmust also be made for suitable access points to pour orpump the mixed micro-concrete into place.

Saw cut or cut back the extremities of the repair locations toa depth of at least 10 mm to avoid feather-edging and toprovide a square edge. Break out the complete repair areato a minimum depth of 50 mm up to the sawn edge.






Priming of the steel reinforcement is not normally necessaryunless it is to remain exposed in an environment likely tocause corrosion after preparation. When required apply onefull coat of Nitoprime Zincrich Plus and allow to dry beforecontinuing. If any doubt exists about having achieved anunbroken coating, a second application should be madeand, again, allowed to dry before continuing

Substrate priming

Several hours prior to placing, the prepared concretesubstrates should be saturated by filling the preparedformwork with clean water. Immediately prior to the applicationof Renderoc LA, any excess water should be removed.

In exceptional circumstances, e.g. where a substrate/repairbarrier is required, Nitobond EP bonding aid should be used.Contact the local Fosroc office for further information.

Mixing

Care should be taken to ensure that Renderoc LA is thoroughlymixed. A forced-action mixer is essential. Mixing in a suitablysized drum using an approved Conbextra Spiral Paddle witha slow speed (400/500 rpm) heavy-duty drill is acceptable.Free-fall mixers must not be used. Mixing of part bags shouldnever be attempted.

It is essential that machine mixing capacity and labouravailability is adequate to enable the placing operation to becarried out continuously. Measure 3.3 litres of drinking qualitywater and pour three-quarters into the mixer. With the machinein operation, add one full 25 kg bag of Renderoc LA and mixfor 1 minute before adding the rest of the water. Mix for a further2 to 3 minutes until a smooth even consistency is obtained.Note that powder must always be added to water. Thequantities mixed may be scaled up as required.

When the drill and paddle mixing method is used, thecomplete 3.3 litres of water should be placed in the mixingdrum. With the paddle rotating, add one full 25 kg bag ofRenderoc LA and mix for 2 to 3 minutes until a smooth evenconsistency is obtained.

It is recommended that the mixed product be passed througha suitable coarse metal screen prior to placing or pumpingto highlight any unmixed material.

Mixing warning

As with other ‘one pack’ repair mortars, Renderoc LA mayexhibit satisfactory handling characteristics even thoughinadequately mixed. This will result in a significantly lowerlevel of performance or possible failure. It is therefore essentialthat mixing instructions are strictly adhered to with particularemphasis on the quantity of water used and the time of themixing operation.

Placing

The mixed material should be placed within 30 minutes ofmixing in order to gain the full benefit of fluidity and of theexpansion process. If placing by pump, standard concretepumping practice should be followed. Contact the FosrocOffice for further details.





62



www.fosroc.com




1CI/SfB: Eq4

October 2009


Curing

The formwork should be left in place until the compressivestrength of the Renderoc LA is 10 MPa or as otherwisespecified by the Supervising Officer. Renderoc LA is a cement-based concrete reinstatement material. In common with allcementitious materials, Renderoc LA must be curedimmediately after the formwork is stripped in accordance withgood concrete practice. Immediately after striking the formwork,all exposed faces of the repair should be thoroughly soakedwith clean water and then sprayed with a liquid curingmembrane such as Concure WB. In fast drying conditions,supplementary curing with polythene sheeting taped down atthe edges must be used. In cold conditions, the finished repairmust be protected from freezing.

Overcoating with protective decorative finishesRenderoc LA is extremely durable and will provide long termprotection to the embedded steel reinforcement within therepaired locations. The surrounding parts of the structure willgenerally benefit from the application of a barrier/decorativecoating to limit the advance of chlorides and carbon dioxide,thus bringing them up to the same protective standard as therepair itself. Fosroc recommend the use of the Dekguardrange of protective, anti-carbonation coatings. These productsprovide a decorative and uniform appearance as well asprotecting areas of the structure which might otherwise be atrisk from the environment. All traces of form-release oils andcuring membranes must be removed prior to the applicationof Dekguard products. This is best achieved by light gritblasting.

Cleaning

Renderoc LA and Concure WB should be removed from tools,equipment and mixers with clean water immediately afteruse. Cured material can only be removed mechanically.

Equipment used with Nitoprime Zincrich Plus and NitobondEP should be cleaned with Fosroc Solvent 102.

Limitations

Renderoc LA should not be used when the temperature isbelow 5°C and falling. Do not mix part bags. The productshould not be used to reinstate horizontal areas where thesurface would remain unrestrained during cure. It should notbe exposed to moving water during application. If any doubtsarise concerning temperature, application or substrateconditions, consult the local Fosroc office.

Estimating

Supply

Renderoc LA: 25 kg bagsNitoprime Zincrich Plus: 1.9 litre and 800 ml cansNitobond EP: 4.5 kg packsConcure WB: 20 litre drumsFosroc Solvent 102: 5 and 25 litre tins

Coverage and yield

Renderoc LA: Approx. 12.0 litres / 25 kg bag

Nitoprime Zincrich Plus: 8 m2/litreNitobond EP: 10m2 / 4.5kg packConcure WB: 3.5 to 5 m2/ litre

Notes: the coverage figures for liquid products are theoretical— due to wastage factors and the variety and nature ofpossible substrates, practical coverage figures will bereduced.

Storage

The product has a shelf life of 12 months from the date ofmanufacture if kept in dry storage in the original, unopenedbags. If stored at high temperatures and/or high humiditythe shelf life may be reduced to less than 6 months.Concure WB should be protected from frost.

Precautions

Health and safety

For further information refer to the Safety Data Sheet availableat www.fosroc.com

Fire

Renderoc LA, Nitobond EP and Concure WB are non-flammable.

Nitoprime Zincrich Plus and Fosroc Solvent 102 areflammable. Keep away from sources of ignition. No Smoking.In the event of fire, extinguish with CO2 or foam. Do not use awater jet.

Flash points


63

High performance free flowing low alkalimicroconcrete conforming to the requirementsof BS EN 1504-3 Class R4

Uses

For the reinstatement of reinforced concrete where lowpermeability characteristics are required and where highcompressive strength is a consideration.

Renderoc LA55 has been specifically developed for the repairof large areas of concrete where access is restricted or wherereinforcement is congested.

It is suitable for use where excellent chloride and carbondioxide resistance is required or for repairs to concrete affectedby alkali-silica reaction (ASR). Renderoc LA55 is alkaline innature and will protect embedded steel reinforcement.

Renderoc LA55 is suitable for repair methods 3.2, 4.4, 7.1, 7.2as defined by BS EN 1504-9.

Advantages

Maximum compatibility with concrete of compressivestrength 30 - 60 N/mm²Dual expansion system compensates for shrinkage in theplastic and hardened statesLow alkali content minimises risk of alkali-silica reactionExceptional bond to concrete substrates withoutindependent primerSuitable for placement by pumping or pouring techniquesinto restricted locationsSelf-compacting nature eliminates honeycombing anddisplaces air without vibrationHigh strength and low permeability provide maximumprotection against carbon dioxide and chloridesPre-bagged to overcome site-batched variations — onlythe site addition of clean water is requiredContains no chloride admixtures

Description

Renderoc LA55 is supplied as a ready to use blend of drypowders which requires only the site addition of clean waterto produce a free-flowing, shrinkage compensated micro-concrete suitable for large volume concrete repairs at nominalthicknesses in excess of 50 mm.

The material is based on Portland cement, graded aggregatesand additives which impart controlled expansion in both theplastic and hardened states while minimising water demand.Its low alkali content minimises the risk of alkali-silica reaction.The hardened product exhibits excellent thermal compatibilitywith concrete.

Renderoc LA55 is designed for large volume repairs typicallyin excess of 50 mm deep. The product can be applied insections generally up to 150 mm thick although greaterthicknesses may be achievable dependent on the configuration

of the repair location and the volume of exposed reinforcingsteel. Consult the local Fosroc office for further information.


The repair mortar shall be Renderoc LA55, a one componentmicro-concrete conforming to the requirements of BS EN1504-3 Class R4. The micro-concrete shall exhibit a 3 daycompressive strength not less than 30 MPa and a 28 daycompressive strength of 60 MPa ( at 20oC).


Renderoc LA55 complies with the classification R4 accordingto EN 1504-3, repair methods 3.2, 4.4, 7.1 and 7.2.

Renderoc LA55 conforms to the requirements of the UKHighways Agency Design Manual for Roads and Bridges(BD27/86, Clause 4) ‘Materials for the Repair of ConcreteHighway Structures’ and has been formulated to comply withthe requirements of the Specification for Highway Works,Clause 1704.5 Control of Alkali-Silica Reaction.

Fosroc® Renderoc LA55



905480-DPC-0730







gnilcyc≥ aPM0.2






64





htgnertSevisserpmoC 9991:09121NE

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Properties


Clarification of property values: The typical properties given above are derived from laboratory testing. Results derivedfrom field applied samples may vary.


Preparation

The unrestrained surface area of the repair must be kept toa minimum. The formwork should be rigid and tight to preventloss of material and have properly sealed faces to ensure thatno water is absorbed from the repair material.

The formwork should include drainage outlets for presoakingand, if beneath a soffit, provision for air-venting. Provision

must also be made for suitable access points to pour or pumpthe mixed micro-concrete into place.

Saw cut or cut back the extremities of the repair locations to adepth of at least 10 mm to avoid feather-edging and to providea square edge. Break out the complete repair area to aminimum depth of 50 mm up to the sawn edge.

65




Clean the surface and remove any dust, unsound orcontaminated material, plaster, oil, paint, grease, corrosiondeposits or algae. Where breaking out is not required, roughenthe surface and remove any laitance by light scabbling orabrasive-blasting.

Oil and grease deposits should be removed by steam cleaning,detergent scrubbing or the use of a proprietary degreaser. Theeffectiveness of decontamination should then be assessedby a pull-off test.

Expose fully any corroded steel in the repair area and removeall loose scale and corrosion deposits. Steel should becleaned to a bright condition paying particular attention to theback of exposed steel bars. Abrasive-blasting is recommendedfor this process.



Priming of the steel reinforcement is not normally necessaryunless it is to remain exposed in an environment likely tocause corrosion after preparation. When required apply onefull coat of Nitoprime Zincrich Plus and allow to dry beforecontinuing. If any doubt exists about having achieved anunbroken coating, a second application should be made and,again, allowed to dry before continuing

Substrate priming

Several hours prior to placing, the prepared concrete substratesshould be saturated by filling the prepared formwork withclean water. Immediately prior to the application of RenderocLA55, any excess water should be removed.

In exceptional circumstances, e.g. where a substrate/repairbarrier is required, Nitobond EP bonding aid should be used.Contact the local Fosroc office for further information.

Mixing

Care should be taken to ensure that Renderoc LA55 isthoroughly mixed. A forced-action mixer is essential. Mixing ina suitably sized drum using an approved Conbextra SpiralPaddle with a slow speed (400/500 rpm) heavy-duty drill isacceptable. Free-fall mixers must not be used. Mixing of partbags should never be attempted.

It is essential that machine mixing capacity and labouravailability is adequate to enable the placing operation to becarried out continuously. Measure 3.3 litres of drinking qualitywater and pour three-quarters into the mixer. With the machinein operation, add one full 25 kg bag of Renderoc LA55 and mixfor 1 minute before adding the rest of the water. Mix for a further2 to 3 minutes until a smooth even consistency is obtained.Note that powder must always be added to water. The quantitiesmixed may be scaled up as required.

When the drill and paddle mixing method is used, the complete3.3 litres of water should be placed in the mixing drum. Withthe paddle rotating, add one full 25 kg bag of Renderoc LA55and mix for 2 to 3 minutes until a smooth even consistency isobtained.

It is recommended that the mixed product be passed througha suitable coarse metal screen prior to placing or pumping tohighlight any unmixed material.

Mixing warning

As with other ‘one pack’ repair mortars, Renderoc LA55 mayexhibit satisfactory handling characteristics even thoughinadequately mixed. This will result in a significantly lowerlevel of performance or possible failure. It is therefore essentialthat mixing instructions are strictly adhered to with particularemphasis on the quantity of water used and the time of themixing operation.

Placing

The mixed material should be placed within 30 minutes ofmixing in order to gain the full benefit of fluidity and of theexpansion process. If placing by pump, standard concretepumping practice should be followed. Consult the FosrocOffice for further details.


In cold conditions down to 5°C, the use of warm mixing water(up to 30°C) is advisable to accelerate strength development.Normal precautions for winter working with cementitiousmaterials should then be adopted. The material should not beapplied when the substrate and/or air temperature is 5°C andfalling. At 5°C static temperature or at 5°C and rising, theapplication may proceed.



Curing

The formwork should be left in place until the compressivestrength of the Renderoc LA55 is 10 MPa or as otherwisespecified by the Supervising Officer. Renderoc LA55 is acement-based concrete reinstatement material. In commonwith all cementitious materials, Renderoc LA55 must becured immediately after the formwork is stripped in accordancewith good concrete practice. Immediately after striking theformwork, all exposed faces of the repair should be thoroughlysoaked with clean water and then sprayed with a liquid curingmembrane such as Concure WB. In fast drying conditions,supplementary curing with polythene sheeting taped down atthe edges must be used. In cold conditions, the finished repairmust be protected from freezing.

66



www.fosroc.com







Renderoc LA55 is extremely durable and will provide longterm protection to the embedded steel reinforcement withintherepaired locations. The surrounding parts of the structure willgenerally benefit from the application of a barrier/decorativecoating to limit the advance of chlorides and carbon dioxide,thus bringing them up to the same protective standard as therepair itself. Fosroc recommend the use of the Dekguardrange of protective, anti-carbonation coatings. These productsprovide a decorative and uniform appearance as well asprotecting areas of the structure which might otherwise be atrisk from the environment. All traces of form-release oils andcuring membranes must be removed prior to the applicationof Dekguard products. This is best achieved by light gritblasting.

Cleaning

Renderoc LA55 and Concure WB should be removed fromtools, equipment and mixers with clean water immediatelyafter use. Cured material can only be removed mechanically.

Equipment used with Nitoprime Zincrich Plus and NitobondEP should be cleaned with Fosroc Solvent 102.

Limitations

Renderoc LA55 should not be used when the temperature isbelow 5°C and falling. Do not mix part bags. The productshould not be used to reinstate horizontal areas where thesurface would remain unrestrained during cure. It should notbe exposed to moving water during application. If any doubtsarise concerning temperature, application or substrateconditions, consult the local Fosroc office.

Estimating

Supply

Renderoc LA55: 25 kg bagsNitoprime Zincrich Plus: 1.9 litre and 800 ml cansNitobond EP: 4.5 kg packsConcure WB: 20 litre drumsFosroc Solvent 102: 5 and 25 litre tins

Coverage and yield

Renderoc LA55: Approx. 12.0 litres / 25 kg bag

Nitoprime Zincrich Plus: 8 m2/litreNitobond EP: 10 m2/ 4.5kg packConcure WB: 5 m2/litre

Notes: the coverage figures for liquid products are theoretical— due to wastage factors and the variety and nature ofpossible substrates, practical coverage figures will bereduced.

Storage

The product has a shelf life of 12 months from the date ofmanufacture if kept in dry storage in the original, unopenedbags. If stored at high temperatures and/or high humiditythe shelf life may be reduced to less than 6 months.Concure WB should be protected from frost.

Precautions

Health and safety

For further information refer to the Safety Data Sheetsavailable at www.fosroc.com.

Fire

Renderoc LA55, Nitobond EP and Concure WB are non-flammable.

Nitoprime Zincrich Plus and Fosroc Solvent 102 areflammable. Keep away from sources of ignition. No Smoking.In the event of fire, extinguish with CO2 or foam. Do not usea water jet.

Flash points


67

Rapid setting cement-based, water-stoppingmortars conforming to the requirements ofBS EN 1504 Class R1

Uses

For the rapid patching and plugging of concrete segments,concrete and brick tunnel linings, sewage systems, belowground access chambers, pipes, basements, foundationsand mines.

Advantages

Emergency water-stopping capabilitySingle componentExcellent bond to the substrateLow exotherm minimises thermal crackingPre-bagged to overcome variations in site batchingChloride-freeRenderoc Plug 20: Approved for use in public watersupplies

Renderoc Plug 20 : BS6920 listed product.

Description

Renderoc Plug are rapid setting mortars which are easy toapply to horizontal, vertical or overhead surfaces at a widerange of thicknesses.

There are two grades available: Renderoc Plug 1 with aninitial set time of approximately 1 minute, and Renderoc Plug20 with an initial set time of approximately 20 minutes. (Settimes are based on ambient/substrate temperatures of20°C.)


Renderoc Plug 1 and Renderoc Plug 20 comply with classR1 according to BS EN 1504-3 repair principal 3.1

Renderoc Plug 20: Conforms to:Regulation 31 of the Water Supply (Water Quality)Regulations 2000Regulation 31 of the Water Supply (Water Quality)Regulations 2001 in WalesRegulation 27 of the Water Supply (WaterQuality)(Scotland) Regulations 2001Regulation 30 of the Water Supply (Water Quality)Regulations (Northern Ireland) 2007

Fosroc® Renderoc Plug constructive solutions

1CI/SfB: (4-) Pr4November 2009


905480-DPC-0730

3-4051NECCriaperlarutcurts-nonrofstcudorpriaperetercnoC

)tnemecciluardyhdeifidomnodesab(ratrom

htgnertsevisserpmoC 1RssalC ≥ )aPM01






tlusertseT1gulPcoredneR

tlusertseT02gulPcoredneR

htgnertSevisserpmoC 9991:09121NE ≥ aPM01aPM01ruoH1@aPM91yaD1@aPM32syaD82@

aPM7sruoH6@aPM11yaD1@

aPM54syaD82@

:ffollupybhtgnertsdnoB 9991:2451NE ≥ aPM8.0 [email protected] [email protected]

:tnetnocnoiedirolhC 0002:71-5101NE ≤ %50.0 %10.0 %10.0

gnitareriF 1-10531NE - -noN1AssalCelbitsubmoC

-noN1AssalCelbitsubmoC

02@emitgnitteSlatinI oC - - etunim1yletamixorppA 02yletamixorppAsetunim

PropertiesMaterial tested at a water:powder ratio of 1:3 by volume and temperature at 20oC

Clarification of property values: The typical properties given are derived from laboratory testing. Results derived fromfield applied samples may vary.

68

Fosroc® Renderoc Plug


www.fosroc.com




Preparation

Areas to be patched should be cut back to a depth of15 mm and given a good mechanical key. Feather-edgesmust not be allowed. Surface should be brushed clean toremove loose material, dust and laitance. Grease, slime ormould growth should be removed by steam cleaning orhigh-pressure water jetting. A proprietary degreasing agentshould be used for removal of light oil or greasecontamination.

To seal leaks, crack openings must be chased out toapproximately 20 mm square. The chase should always beundercut to avoid leaving a v-section. All loose material anddebris should be removed.

Mixing

Renderoc Plug should be added to clean water in the followingproportions: One part clean water to three parts RenderocPlug (by volume).

Mix to a stiff consistency in a suitable mixing vessel, using atrowel or gloved hand. Due to the rapid set characteristics ofthe product, only prepare a quantity of mortar which can beplaced within the prescribed set time.

Application

Trowel apply or hand-knead the mixed mortar in place,ensuring maximum contact with the substrate before thematerial sets. No priming system is required but the substratemust be in a saturated surface dry state before application.

If being used to plug running water, Renderoc Plug 1 shouldbe used and held in place until the initial set is reached.

The minimum application thickness of Renderoc Plugproducts is 15 mm.


In cold conditions down to 1°C, the use of warm water (up to20°C) is advisable to accelerate strength development.Normal precautions for winter working with cementitiousmaterials should be adopted. The material should not beapplied when the substrate and/or air temperature is 1°C andfalling. At 1°C static temperature or at 1°C and rising, theapplication may proceed. Set and cure times will be increasedat low temperatures. If in doubt contact the local Fosroc office.


At ambient temperatures above 35°C, the material should bestored in the shade and cooler water (down to 20°C) used formixing. Set and cure times will be reduced at hightemperatures.

Cleaning

Renderoc Plug products should be removed from equipmentwith clean water prior to the initial set. Cured material can onlybe removed mechanically.

Estimating

Renderoc Plug 1 is supplied in 6 kg bags each yielding3 litres.

Renderoc Plug 20 is supplied in 25 kg bags each yielding12.5 litres.

Storage

The product has a shelf life of 12 months from the date ofmanufacture if kept in dry storage in the original, unopenedbags. If stored at high temperatures and/or high humidityconditions the shelf life may be reduced to less than 6months.

Precautions

Health and safety

For further information, refer to the Safety Data Sheets availableat www.fosroc.com.

Fire

Renderoc Plug products are non-flammable.



69

Two component fibre and polymer modifiedcementitious mortar for re-profiling andprotection conforming to the requirementsof BS EN 1504-3 Class R3

Uses

Renderoc RP252 is designed for application from 3 mmto 20 mm to produce a smooth render finish to concrete ormasonry surfaces. It can be used either to produce asurface in readiness for a protective coating or as aprotective mortar layer.

Renderoc RP252 can be used independently to infillsurface imperfections and voids or to render largesections of concrete.

Renderoc RP252 is suitable for repair methods 3.1, 7.1and 7.2 as defined by BS EN1504-3.

Advantages

Easy to useWide range of application thicknessesLow permeability provides protection against carbondioxide and water-borne chloridesExcellent bond to the concrete substratePre-blended to overcome site-batched variationShrinkage compensated

Description

Renderoc RP252 is supplied as a ready to use blend of drypowders and polymer emulsion which when mixed producea highly consistent cementitious re-profiling and protectionmortar. The product exhibits excellent thermal compatibilitywith concrete and is compatible with other Renderoc mortarsand Dekguard coatings.

Renderoc RP252 is designed for vertical or horizontal use.It can be applied as a render from 3 mm to a practicalmaximum depth of 15 to 20 mm on verticals and 10 mm onsoffits. On horizontal surfaces greater thicknesses e.g. 25mm can be applied, however other grades of Renderoc maybe more appropriate.

Prior to the application of Renderoc RP252 any necessaryrepairs to the concrete should be undertaken using theFosroc Systematic Approach. Consult the local Fosroc officefor further information.


Re-profiling mortar

The re-profiling mortar shall be Renderoc RP252, a twocomponent, monofilament fibre reinforced modified cement-based blend of powders and liquid polymer conforming to therequirements of BS EN 1504-3 Class R3.

The cured re-profiling mortar shall achieve a compressivestrength of 42 MPa and a shrinkage of less than 300 microstrainat 7 days.

Protection mortar

The protection mortar shall be Renderoc RP252, a twocomponent monofilament fibre reinforced modified cement-based blend of powders and liquid polymer conforming to therequirements of BS EN 1504-3 Class R3.

The cured mortar shall achieve a compressive strength of 42MPa and a shrinkage of less than 300 microstrain at7 days.

Standards Compliance

Renderoc RP252 has been approved by the British Board ofAgrément, Certificate No 98/3461.

Conforms to the requirements of BS EN 1504-3 Class R3repair methods 3.1, 7.1, and 7.2.

Fosroc® Renderoc RP252 constructive solutions



905480-DPC-0730







/ytilibitapmoclamrehTwahtezeerf

≥ aPM5.1

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70

Fosroc® Renderoc RP252


Preparation

All surfaces should be free from contamination. Wherebreaking out is not required, roughen the surface and removeany laitance by light scabbling or abrasive-blasting.


Substrate conditioning

The cleaned areas should be blown clean with oil-freecompressed air before continuing. All prepared areas shouldbe saturated surface dry immediately before the applicationof one coat of Renderoc RP252 Surface Conditioner, i.e. theyshould be thoroughly saturated with clean water and anyresidual surface water removed. Under severe dryingconditions and on highly absorbent substrates, repeatedsoaking will be necessary. The Renderoc RP252 SurfaceConditioner should be scrubbed well into the surface and




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--

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Properties

The following results were obtained at a temperature of 20oC

Clarification of property values:The typical properties given above are derived from laboratory testing. Results derived fromtesting field applied samples may vary.

71

Fosroc® Renderoc RP252

Renderoc RP252 should be applied before the conditionerdries (film forms).

Care should be taken to ensure that water does not run overfresh areas applied for less than 12 hours.

In circumstances where a barrier is required betweensubstrate and mortar, or where the substrate is likely toremain permanently damp, Nitobond EP bonding aid shouldbe used. Contact the local Fosroc office for further information.

Recently executed Renderoc mortar repairs require noadditional preparation prior to the application ofRenderoc RP252.

Mixing

Care should be taken to ensure that Renderoc RP252 isthoroughly mixed using a forced action mixer or in a suitablysized drum using a Renderoc Mixing Paddle in a slow speed(400/500 rpm) heavy-duty drill.

Place all the Renderoc RP252 liquid polymer into the mixerand with the machine in operation, add one full bag ofRenderoc RP252 powder and mix for a minimum of3 minutes to a maximum of 5 minutes until homogeneous. Donot subsequently re-temper with extra water.

Renderoc RP252 powder must be added to Renderoc RP252liquid. Part-bag mixing is not permitted.

Mixing warning

As with other repair mortars, Renderoc RP252 may exhibitsatisfactory handling characteristics even thoughinadequately mixed. This will result in a significantly lowerlevel of performance or possible failure. It is thereforeessential that mixing instructions are strictly adhered to withparticular emphasis on the time of the mixing operation.

Application

Apply the Renderoc RP252 to the prepared substrate bysteel, wood or plastic float from 3 mm minimum to themaximum practical thickness. The initial application shouldbe worked firmly into the prepared surface as a scrape coatto provide a key to subsequent material. Further build ofmaterial should be applied in wet on wet layers. It should befinished with a minimum of working.

If sagging occurs during application, the Renderoc RP252should be completely removed and reapplied at a reducedthickness.

Build-up

Additional build-up can be achieved by application of multiplelayers. The final thickness is dependent on the materialconsistency and substrate profile. The surface of theintermediate layers should be comb scratch-keyed andcured with Nitobond AR. A further application of

Renderoc RP252 may proceed, without the necessity ofRP252 Surface Conditioner as soon as this layer has set.

Finishing

Renderoc RP252 can be finished using several differenttechniques. Screed rails and guide wires can be used toadvantage on large areas. Steel, wood and plastic floats canall be used to achieve the desired surface texture. The useof a damp sponge to remove trowelling marks isrecommended. The completed surface should not be overworked.


In cold conditions down to 5°C normal precautions for winterworking with cementitious materials should be adopted. At5°C static temperature or at 5°C and rising, the applicationmay proceed.


At ambient temperatures above 35°C the materials shouldbe stored in the shade.

Curing

Renderoc RP252 must be cured immediately after finishingin accordance with good concrete practice. The use ofNitobond AR sprayed onto the surface of the finishedRenderoc in a continuous film is recommended.

A low pressure atomising sprayer is essential for applyingthe Nitobond AR. Any excessive run-off on verticals or dripson soffits should be removed by brush before they harden.

Large areas should be cured as trowelling progresses(0.5 m² at a time) without waiting for completion of the entirearea.

In fast drying conditions, supplementary curing with polythenesheeting taped down at the edges should be used. In coldconditions, the finished repair must be protected from freezing.


Renderoc RP252 may be overcoated with Fosroc’s Dekguardrange of protective primers/decorative coatings. TheRenderoc RP252 should be primed/cured as trowellingprogresses with Nitobond AR, applied as above and allowedto cure for 48 hours prior to the application of the topcoat.

Cleaning

Renderoc RP252, Nitobond AR, Renderoc RP252 SurfaceConditioner should be removed from tools, equipment andmixers with clean water immediately after use. Cured materialcan only be removed mechanically.



72

Renderoc RP252


www.fosroc.com



Estimating

Supply

Renderoc RP252: 20 kg bags, 3.4 litre bottlesRenderoc RP252Surface Conditioner: 5 and 25 litre drumsNitobond AR: 5 and 25 litre drums

Coverage and yield

Renderoc RP252: 12 litres per pack (approximately2.4 m² at 5 mm thickness)

Renderoc RP252Surface Conditioner: 7 to 9 m²/litreNitobond AR: 6 to 8 m²/litre

Notes: The coverage figures for liquid products are theoretical.Due to wastage factors and the variety and nature of possiblesubstrates, practical coverage figures will be reduced.

Limitations

Renderoc RP252 should not be used when the temperatureis below 5°C and falling.

Due to the nature of Renderoc RP252, the product should notbe used in areas subjected to traffic.

Renderoc RP252 should not be exposed to moving waterduring application. Exposure to heavy rainfall before the finalset may result in surface scour.

Storage

The product has a shelf life of 12 months from the date ofmanufacture if kept in dry storage in the original, unopenedpacks.

Store in unopened bags in cool dry internal conditions. Ifstored at high temperatures and / or high humidityconditions the shelf life may be reduced to less than 6months. Renderoc RP252 liquid, Renderoc RP252 SurfaceConditioner and Nitobond AR should be protected from frost.

Precautions

Health and safety

For further information refer to the appropriate Safety DataSheet available at www. fosroc.com.

Fire

Renderoc RP252, Nitobond AR and Renderoc RP252 SurfaceConditioner are non-flammable.



73

High performance concrete reinstatementmortar conforming to the requirements of BSEN 1504-3 Class R4

Uses

For the reinstatement of reinforced concrete where lowpermeability characteristics are required and where highcompressive strength and abrasion resistance is aconsideration. Where compatibility with lower strengthconcrete is required, Renderoc HB30 should be used.

Renderoc S has been specificaly developed for the repair oflarge areas of concrete and also localised patch repairs.

Where high build vertically and overhead is required RenderocHB30 or Renderoc HB45 should be used.

Renderoc S issuitable for repair methods 3.1,3.3, 4.4, 7.1,7.2 as defined by BS EN 1504-9.

Advantages

Maximum compatibility with concrete of compressivestrength 30 - 60 MPaHigh abrasion resistancePolymer-modification provides extremely lowpermeability to water, carbon dioxide and chloridesExceptional system of shrinkage compensation provideslong-term dimensional stabilityCan be applied quickly and efficiently by wet sprayingOne component, pre-bagged to overcome site-batchedvariationsContains no chloride admixtures

Description

Renderoc S is supplied as a ready to use blend of drypowders which requires only the site addition of clean waterto produce a highly consistent, repair mortar.

It is based on Portland cements, graded aggregates andchemical additives providing a mortar with good handlingcharacteristics while minimising water demand. The lowwater requirement ensures good strength gain and long-term durability.

Renderoc S has been specifically engineered for vertical orhorizontal use. It can be applied up to 10 mm thickness invertical locations and up to 100 mm thickness in horizontallocations in a single application. Thicker sections can be builtup in layers. Thicknesses vertically greater than 10 mm canbe achieved by spray application.

For horizontal trafficed locations individual bays should notexceed 4 m-2 in area.

Renderoc S can be quickly and efficiently applied by the wetspray technique. Consult the local Fosroc office for furtherinformation.



Therepair mortar shall be Rendreoc S a one componentpolymer modified high build cementitious mortar conformingto the requirements of BS EN 1504-3 ClassR4

The cured mortar shall acieve a compressive strength of 55MPa at 28 days and a drying shrinkage of < 300 microstrainat 7 days.


Renderoc S complies with the classification R4 according toEN1504-3, repair methods 3.1, 3.3, 4.4, 7.1 and 7.2.

Renderoc S, Nitoprime Zincrich Plus and Nitobond AR havebeen approved by the British Board of Agrement, Certificatenumber 98/3461

Fosroc® Renderoc S

1CI/SfB:(4-) Pr4October 2009


905480-DPC-0730

3-4051NECCPriaperlarutcurtsrofstcudorpriaperetercnoC

)tnemecciluardyhdeifidomremylopnodesab(ratrom





gnilcyyc≥ aPM0.2






74

Fosroc® Renderoc S




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nisuludoMcitsalEnoisserpmoC 21431NE ≥ aPG02 aPG73

gnitareriF 1-50531NE elbatsubmoC-noN0d1s2AssalC

htgnertslaruxelF 0991:3tP9136SB - [email protected]


ytisnedtewhserF - m/gK0512ylanimoN 3





ScoredneRfoytilibaemrepwolehTnikcattalacimehcsdraterylerevesderucehT.stnemnorivneevissergga

dicaotelbaemrepmisiratromdnasnoiedirolhcenrobretaw,sesag

.negyxo



:latnoziroH

---

---


Properties


Clarification of property values: The typical properties given above are derived from laboratory testing. Results derived fromtesting field applied samples may vary.


Preparation

Saw cut the edges of the repair to a depth of at least 5 mm toprovide a square edge. Break out the complete repair areato a minimum depth of 5 mm up to the sawn edge.


Oil and grease deposits should be removed by steamcleaning, detergent scrubbing or the use of a proprietarydegreaser. The effectiveness of decontamination should

then be assessed by a pull-off test.

Expose fully any corroded steel in the repair area and removeall loose scale and corrosion deposits. Steel should becleaned to a bright condition paying particular attention to theback of exposed steel bars. Abrasive-blasting is recommendedfor this process.



Apply one full coat of Nitoprime Zincrich Plus and allow to drybefore continuing. If any doubt exists about having achieved anunbroken coating, a second application should be made and,again, allowed to dry before continuing.

75

Fosroc® Renderoc S



Concrete Priming

The concrete substrate should be saturated surface dryimmediately before the application of the primer i.e. it shouldbe thoroughly saturated with clean water and any residualsurface water removed prior to applying Nitobond AR.

Under severe drying conditions repeated soaking may benecessary to ensure the substrate is still saturated at the timeof application of the primer.

Scrub Nitobond AR into the surface.

Renderoc S can be applied as soon as the primer becomestacky. If the Nitobond AR is too wet, vertical build up of theRenderoc S mortar may be difficult.

In all areas subject to trafficking, where a substrate/repairbarrier is required or where the substrate is wet or likely toremain permanently damp, Nitobond EP bonding aid shouldbe used. Contact the local Fosroc office for further information.

Mixing

Care should be taken to ensure that Renderoc S is thoroughlymixed. A forced-action mixer is essential. Mixing in a suitablysized drum using an approved Renderoc Spiral Paddle witha slow speed (400/500 rpm) heavy-duty drill is acceptable forthe occasional one-bag mix.

Free-fall mixers must not be used. Mixing of part bags shouldnever be attempted.

For normal applications, place 2.5 to 3.0 litres of drinkingquality water into the mixer.

With the machine in operation, add one full bag of RenderocS and mix, for a minimum of 3 minutes and a maximum of 5minutes, until fully homogeneous.

The consistancy may be adjusted by the addition of smallamounts of water up to the maximum total water content of3.0 litres.

Note that the powder must always be added to the water.

Mixing warning

As with other ‘one pack’ repair mortars, Renderoc S mayexhibit satisfactory handling characteristics even thoughinadequately mixed. This will result in a significantly lowerlevel of performance or possible failure. It is therefore essentialthat mixing instructions are strictly adhered to with particularemphasis on the quantity of water used and the time of themixing operation.

Application


Apply the mixed Renderoc S by gloved hand or trowel,thoroughly compacting onto the primed substrate and aroundexposed reinforcment.

If sagging or slumping occurs the Renderoc HB should becompletly removed and reapplied at a reduced thickness toa correctly reprimed substrate.

Build-up

Additional build-up can be achieved by application of multiplelayers. The final thickness is dependent on the materialconsistency and substrate profile.

The surface of the intermediate layers should be combscratch-keyed and cured with Nitobond AR. Reprime withNitobond AR and a further application of Renderoc S mayproceed as soon as this layer has set.

Spray application

Renderoc S can be quickly and efficiently applied by the wetspray technique. In circumstances where large areas ofrepair are required, the rapid placement and higher buildattainable by this method offer economic advantages overhand-trowelling. The resultant repair also offers a generallymore dense compound with enhanced mortar/substratebond characteristics.


Finishing

Renderoc S is finished by striking off with a straight edge andclosing with a steel float. Wooden or plastic floats, or dampsponges, may be used to achieve the desired surface texture.The completed surface should not be overworked. After sprayapplication, the mortar may need to be ‘cut back’ to therequired profile using a steel float and then finished withdamp sponges as described above.





Curing

Renderoc S is a cement-based repair mortar. In commonwith all cementitious materials, it must be cured immediatelyafter finishing in accordance with good concrete practice. Theuse of Nitobond AR, sprayed on to the surface of the finishedmortar in a continuous film, is recommended. A low pressureatomising sprayer is essential for applying the Nitobond AR.Any excessive run-off on verticals or drips on soffits shouldbe removed by brush before they harden.

76

Fosroc® Renderoc S


www.fosroc.com






Large areas should be cured as trowelling progresses(0.5 m2 at a time) without waiting for completion of the entirearea.In fast drying conditions, supplementary curing with polythenesheeting taped down at the edges must be used. In coldconditions, the finished repair must be protected from freezing.


Renderoc S is extremely durable and will provide long-termprotection to the embedded steel reinforcement within therepaired locations. The surrounding parts of the structure willbenefit from the application of a barrier/decorative coating tolimit the advance of chlorides and carbon dioxide, bringingthem to the same protective standard as the repair itself.Fosroc recommend the use of the Dekguard range ofprotective, anti-carbonation coatings. These products providea decorative and uniform appearance as well as protectingareas of the structure which might otherwise be at risk fromthe environment. Dekguard products may be applied over therepair area without prior removal of the Nitobond AR curingmembrane. Other curing membranes must be removedprior to the application of Dekguard products.

Cleaning

Renderoc S and Nitobond AR should be removed from tools,equipment and mixers with clean water immediately afteruse. Cured material can only be removed mechanically.Clean tools used with Nitoprime Zincrich Plus and NitobondEP before material cures, using Fosroc Solvent 102.

Estimating

Supply

Renderoc S: 25 kg bags




Coverage and yield

Renderoc S: Approximately 12 litres / 25kg bag (approximately 1.2 m²at 10 mm thickness)

Nitoprime Zincrich Plus: 8 m2/ litreNitobond AR: 6 - 8 m2/ litre

Notes: the actual yield per bag of Renderoc S will dependon the consistency used. The yield will be reduced if thematerial is applied by a spray technique.

Limitations

Renderoc S should not be used when the temperature isbelow 5°C and falling. Do not mix part bags. Renderoc HB isnot suitable for use in areas subjected to traffic (in thesecircumstances, Renderoc S should be considered).

Renderoc S should not be exposed to moving water duringapplication. Exposure to heavy rainfall prior to the final setmay result in surface scour.


Storage


Nitobond AR should be protected from frost.

Precautions

Health and safety


Fire

Renderoc S is non-flammable.


Flash points


77

Polymer modified dry spray repair mortarconforming to the requirements of BS EN 1504-3Class R4

Uses

Renderoc SC is designed for large area repairs such asbridges, tunnels, retaining walls, dams, etc.

Renderoc SC is suitable for repair method 3.3, 7.1, 7.2 asdefined by BS EN 1504-3.

AdvantagesLow reboundRapid strength gainLow water absorption and chloride ion diffusionHigh resistance to carbon dioxide penetrationExcellent bond to the concrete substrateSingle component — ready to useNo added caustic acceleratorsContains no chloride admixtures

Description

Renderoc SC is supplied as a ready to use blend of drypowders which is formulated for application using the dry sprayprocess.

The material is based on Portland cements graded aggregatessilica fume, and chemical additives which provides a spray mortarwith low rebound and handling characteristics. The low waterrequirement ensures good strength gain and long term durability.

Builds of up to 150 mm vertically and 75 mm overhead can beachieved in a single application.


Renderoc SC complies with class R4 according to BS EN1504-3 repair principal 3.3.

Fosroc® Renderoc SC constructive solutions


905480-DPC-0730

3-4051NEratromCCriaperlarutcurtsrofstcudorpriaperetercnoC






gnilcyc≥ aPM0.2





78

Fosroc® Renderoc SC

PropertiesThe following results were obtained at a temperature of 20°C.



htgnertSevisserpmoC 9991:09121NE ≥ aPM54aPM02yaD1@aPM54syaD7@aPM06syaD82@



:gnilcycwahtezeerF 2002:1-78631NE ≥ aPM0.2 aPM5.2



htgnertslaruxelF 0991:3tP9136SB - syad82@aPM01


ytisnedtewhserF - m/gK0022ylanimoN 3




ytivitsiseR - - mcmho00003-82

lamrehtfotneiciffeoCnoisnapxE - - 01x51 6- /oC


coredneRfoytilibaemrepwolehTlacimehcsdraterylerevesCS

evissergganikcattasiratromderucehT.stnemnorivne

,sesagdicaotelbaemrepmidnasnoiedirolhcenrobretaw

.negyxo

scitsiretcarahCdliuB


:latnoziroH

---

---

mm01mm051otpU

mm57otpU

Clarification of property values: The typical propertiesgiven are derived from laboratory testing. results derivedfrom testing field applied samples may vary


79




Preparation

Clean the surface and remove any dust, unsound orcontaminated material, plaster, oil, paint, grease, corrosiondeposits or algae. Where breaking out is not required, i.e.concrete is sound and of good quality, but cover is to beincreased, roughen the surface and remove any laitance bylight scabbling or abrasive-blasting. It will still be necessaryto cut back the perimeter to a depth of 10 mm so that the repairpatch may be ‘toed-in’ and finished flush with the surroundingconcrete.





Extra protection to the reinforcing steel can be achieved byapplication of one full coat of Nitoprime Zincrich Plus andallowing to dry before continuing. If any doubt exists abouthaving achieved an unbroken coating, a second applicatinshould be made and, again, allowed to dry before continuing.

Substrate priming

Soak the prepared concrete surface thoroughly, allowingsurplus water to drain off.

Application

Exposed steel reinforcing bars should be firmly secured toavoid movement during the application process as this willaffect mortar compaction, build and bond.

Renderoc SC should be emptied from the bags directly intothe hopper of the dry spray process machine. The amount ofwater added should be controlled by the nozzleman. Too littlewater will increase rebound and dust emission, too wet a mixwill slump.

If sagging occurs during application to vertical or overheadsurfaces, the Renderoc SC should be completely removedand re-applied.

Finishing

Renderoc SC is finished by striking off with a straight edgeand closing with a steel float. Wooden or plastic floats, ordamp sponges may be used to achieve the desired surface

texture. The completed surface should not be overworked.




At ambient temperatures above 35°C, the material should bestored in the shade.

Curing

Renderoc SC is a cement-based mortar. In common with allcementitious materials, Renderoc SC must be curedimmediately after finishing in accordance with good concretepractice, i.e. using a curing membrane, Concure WB or wethessian or polythene. Concure WB should not be used whena subsequent coating is to be applied or cathodic protectionsystems are to be used. In cold conditions, the finished repairmust be protected from freezing.

Cleaning

Renderoc SC should be removed from tools, equipment andmixers with clean water immediately after use. Cured materialcan only be removed mechanically.

Equipment used with Nitoprime Zincrich Plus should becleaned with Fosroc Solvent 102.

Estimating

Supply

Renderoc SC: 25 kg bagsNitoprime Zincrich Plus: 1.9ltr and 800ml cansFosroc Solvent 102: 5 and 25 litre tins

Concure WB: 20 and 200 litre drums

Coverage and yield

Renderoc SC: Approx. 12.5 litres / 25 kg bag(approx. 80 bags/m³)

Nitoprime Zincrich Plus: 8 m2/litre

Concure WB: 3.5 - 5.0 m2/litre

Notes: The actual yield per bag of Renderoc SC will dependon the water addition during application. The coverage figuresare theoretical — due to wastage factors and the variety andnature of possible substrates, practical coverage figures willbe reduced.

Limitations

Renderoc SC should not be used when the temperature isbelow 5°C and falling. The product should not be exposed to


80



www.fosroc.com




moving water during application. Exposure to heavy rainfallprior to the final set may result in surface scour. If any doubtsarise concerning temperature or substrate conditions, consultthe Customer Services Department.

Storage

The product has a shelf life of 12 months from the date ofmanufacture if kept in a dry storage in the original, unopenedbags.

Store in unopened bags in cool dry internal conditions. Ifstored at high temperatures and/or high humidity conditions theshelf life may be reduced to less than 6 months.

Precautions

Health and safety

For further information, refer to th eappropriate Safety DataSheet available at www.fosroc.com.

Fire

Renderoc SC is non-flammable.

Concure WB is non-flammable..

Nitoprime Zincrich Plus and Fosroc Solvent 102 are flammable.Keep away from sources of ignition. No Smoking. In the eventof fire, extinguish with CO2 or foam. Do not use a water jet.

Flash points



81

Protective cementitious coating and levellingmortar for applications from feather edge to 5mmconforming to the requirements of BS EN 1504-3Class R4

Uses

For application in thin layers, the filling of blow-holes orimperfections in concrete to produce a smooth surface.

Providing a chloride and carbonation barrier. It can be leftas a fair-face finish or overcoated.

It can be used as a scrape-coat, brush or trowel applied,placed in thicknesses from 0-5 mm.

Renderoc ST 05 is suitable for repair methods:1.3, 2.2, 5.1, 6.1 and 8.2 as defined by BS EN 1504-2:3.1, 7.1 and 7.2 as defined by BS EN 1504-3

Advantages

Easy to mix and applyVertical and horizontal applicationsExcellent bond to concrete without primingFormulated blow hole fillerCarbonation barrierChloride barrierHigh frost resistanceHigh compressive strength

Description

Renderoc ST 05 consists of powder and polymercomponents The powder is added to the liquid, the mixingratio depends on the required consistency and use.

The powder consists of a blend of cements, gradedaggregates and chemical additives, with a maximum grainsizes of 0.5 mm

The liquid component, based on modified acrylic polymers,gives Renderoc ST 05 a creamy consistency with extremelygood application and barrier characteristics.

The product exhibits excellent thermal compatibility withconcrete and is fully compatible with other Renderocmortars and Dekguard coatings.

Exposure to rainfall prior to the final set may result inwater uptake and severe reduction in the performance of

the hardened product. Exposure to mist or high humidityprior to sufficient hardening may result in discolourationof the surfaces. These white discolourations willdecrease with time.

Standards Compliance

Renderoc ST 05 complies with repair principles 1.3, 2.2,5.1, 6.1 and 8.2 as defined by BS EN 1504-2

Renderoc ST 05 complies with Class R4 according to BSEN 1504-3, repair principles 3.1, 7.1, 7.2.

Fosroc®

Renderoc ST 05 constructive solutions

1CI/SfB: (4-)D7q4November 2009


905480-DPC-0730

3-2-4051NEsmetsysnoitcetorpecafruS

CCPriaperlarutcurtsrofstcudorpriaperetercnoC)tnemecciluardyhdeifidomremylopnodesab(ratrom

htgnertsevisserpmoC (4RssalC > )aPM54

tnetnocnoiedirolhC < %50.0

htgnertsdnobevisehdA > aPM0.2


gnilcyyc> aPM0.2

ecnatsisernoitanobraC dk etercnoclortnoc<



ecnatsisernoisarbA gm0003<ssolthgiew

ecnatsisertcapmI IIIssalC

OCotytilibaemreP 2 m05>ds

retawotytilibaemrePruopav IssalC

noissimsnartretawdiuqiLetar m/gK1.0<w 2h 5.0

82

Fosroc®

Renderoc ST 05



dohtemtseT dradnatS 4051NEtnemeriuqeR

tluseR


aPM31yaD1@syaD3@ 62 aPMsyaD7@ 73 aPM

05syaD82@ aPM





gnitareriF 1-50531NE -non(0d1S2AssalC)elbitsubmoc

htgnertslaruxelF 0991:3tP9136SB - syaD82@aPM11

emitgnitteS - -

setunim06yletamixorpA,reyalfossenkcihtnotnadneped

foytisoropdnaerutarepmet.etartsbus

ytisnedtewhserF - m/gK0591yllanimoN 3

selcitrapevitcaerilaklA 25B-ITdohteM - 1≤ %lov%

lacimehcerevesotecnatsiseRkcatta

92531NE

noitcuderssendraH%05<

htiwsyad82-IIIssalCerusserp

a41,21,11,01,3spuorgniIIIssalC

noitprosbayrallipaC 75031NE ≤ m/gk5.0 2h 5.0- m/gk2.0 2h 5.0-

ratromriaperfonoitacilppAdaehrevo 4-59331NE ≥ aPM2 aPM8.2

ruopavretawotytilibaemreP 2-3877OSINE - )IssalC(m84.0dS

retawdiuqilfonoitanimreteDnoissimsnart 3-2601NE ≤ m/gk1.0 2h 5.0- m/gk80.0 2h 5.0-

OCotytilibaemreP 2 6-2601NE m05>dS m75=dS

ecnatsiseRnoisarbA 1-0745OSINE gm0003<ssolthgieW gm5872

ecnatsisertcapmI 1-2726OSINE IIIssalC ≥ mN02 mN5.42

ssergninoiedirolhC 69331NE - %3nishtnom6retfa%171.0htpedmm6-4tanloslCaN

Clarification of property values:The typical properties given above are derived from laboratory testing. Results derived from

testing field applied samples may vary.

Properties

Material tested at liquid : powder ratio of 0.22 and temperature at 20°C

83

Preparation

Surfaces must be clean and sound, with no traces of loosematerial, cement paste, laitance, dust, plaster, oil, grease,corrosion deposits or algae.

Prepare the surfaces by abrasive grit blasting or lightscabbling. Remove oil and grease with suitable detergent.Finally the cleaned surfaces should be blown clean with oilfree compressed air before continuing.

On floors, large pockets greater than 4 mm depth should befilled with Fosroc XR90, finished with a scratched surface.Allow one hour to cure before application of RenderocST 05.

Pre-soaking

All prepared areas should be thoroughly soaked with cleanwater prior to application of Renderoc ST 05, to achieve asaturated surface dry condition. Any residual surface watershould be removed prior to application.

Priming

Under normal circumstances priming is not required.However, porous substrates may require sealing withNitobond AR. This is scrubbed onto the pre-wettedsubstrate and allowed to become tacky before applyingRenderoc ST 05.

Mixing

Renderoc ST 05 should be mixed in a forced action mixer ofadequate capacity. Mixing in a suitable sized drum using aConbextra paddle with a slow speed (500 rpm) heavy-dutydrill is acceptable.

Place the required amount of Renderoc ST 05 liquidcomponent - see table - in the mixer and add the full bag ofRenderoc ST 05 powder . Mix for 5 minutes until fullyhomogeneous. Let the mix rest for 5-10 minutes and adjustthe consistency, if necessary by addition of additional liquid

component. Mix for another minute until the requiredconsistency is obtained.Polymer level can be varied to application method.Mixing ratios:Brush coating - 5.0 ltrs liquid : 20 kg powderFairing coat - 4.0 ltrs liquid : 20 kg powder

The above mixing ratios can be used as guidelines. Partpacks can be mixed provided mix ratios are maintained.

Application

Renderoc ST 05 can be applied by brush, roller or trowelldepending on consistency and application. See table.

The surface finish of the final coat can be obtained in thefollowing ways:I) Smooth surface: Finish with a sponge.II) Rough, granulated surface: Finish with a roller.III) Skid resistant surface: Sprinkle dry quartz sand in the

wet surface or brush finish.

Multiple layers

When applying multiple layers, allow the first application todry for between 2-4 hours (at 20oC). Lightly scratch anddampen surface between layers. Patches at 300 mm2 orless can be applied up to 5mm in one application whencured.


Normal precautions for winter working with cementitiousmaterials should be adopted. In cold conditions down to+5°C, both components should be kept at +15°C to +25°C.Protect applied product from freezing for the first 24 hours.Note: working time and time taken to gain strength will beincreased at lower temperatures.


At ambient temperatures above 35oC both componentsshould be stored in the shade. Note working times will bereduced at elevated temperatures.

Fosroc®

Renderoc ST 05


:scitsiretcarahcdliuB ssenkcihT diuqiLfoemuloVredwopgabrep

kcaprepegarevoC)etartsbusoteudyravnacegarevoC(

snoitacilppalacitreVrellor/hsurB

leworTrellifelohwolbleworT

mm1mm2

deilppamikS

sertil0.5-5.4sertil5.4-0.4

sertil5

m21-5.11 2 [email protected] 2 mm2@

m21acriC 2 ecafrusnotnedneped

snoitacilppalatnoziroHdeercs/leworT

rellor/hsurBmm4mm4

sertil5-5.4sertil5

m9.2 2 [email protected] 2 mm4@


84


www.fosroc.com




Fosroc®

Renderoc ST 05


Curing

Renderoc ST 05 is a cement-based repair mortar. In commonwith all cementitious materials, it must be cured immediatelyafter finishing in accordance with good concrete practice. Theuse of Nitobond AR, sprayed on to the surface of the finishedmortar in a continuous film, is recommended. A low pressureatomising sprayer is essential for applying the Nitobond AR.Any excessive run-off on verticals or drips on soffits should beremoved by brush before they harden.



Renderoc ST 05 is extremely durable and will provide long-term protection to the embedded steel reinforcement withinthe repaired locations. The surrounding parts of the structurewill benefit from the application of a barrier/decorative coatingto limit the advance of chlorides and carbon dioxide, bringingthem to the same protective standard as the repair itself.Fosroc recommend the use of the Dekguard range ofprotective, anti-carbonation coatings. These products providea decorative and uniform appearance as well as protectingareas of the structure which might otherwise be at risk fromthe environment. Dekguard products may be applied over therepair area without prior removal of the Nitobond AR curingmembrane. Other curing membranes must be removed priorto the application of Dekguard products.

Cleaning

Renderoc ST 05 should be removed from tools, equipmentand mixers with clean water immediately after use. Curedmaterial can only be removed mechanically.

Estimating

SupplyRenderoc ST 05 is supplied in 20kg bags of powder and5.0 litres of liquid.

Coverage and yieldApproximatly 12 litres per pack depending on mix ratio -see table.

Limitations

Renderoc ST 05 should not be applied when the substrateand/or air temperature is below +5°C and falling.

Not suitable for heavily trafficked floors.

Storage

Renderoc ST 05 Powder has a shelf life of 12 months ifkept in a dry store in the original, unopened packaging.If stored at high temperatures and/or high humidityconditions the shelf life may be reduced.

Renderoc ST 05 Liquid should be protected against frost.If the product has been exposed to frost and the liquidcomponent becomes grainy, it should not be used.

Precautions

Health and safety

For further information refer to the Safety Data Sheetsavailable at www.fosroc.com.

Fire

Rendreroc ST 05 is non-flammable.

85

Two-part epoxy resin mortars

Uses

For use in exceptionally wet conditions and for underwaterapplications.

Advantages

Possesses outstanding strength and adhesivepowersResistant to physical damageExcellent chemical resistance

Can be used underwater

Description

Expocrete UA is recommended for fixing slip bricks andfor reinstating structures exposed to heavy battering fromthe sea, such as sea walls and concrete jetties and forrepairing submerged steelwork and concrete. Mixedmortar may be transported underwater in polythene bags.

Properties

Form: Two-part compounds —Base: firm puttyHardener: soft putty

Solids content: 100%Fresh wet density: 2000 kg/m³Colour: Base: off-white

Hardener: blackMixed colour: dark grey

Pot life: 30 to 45 minutes at 20°CWater immersion: Expocrete UA may be applied

and cured underwater.Cure time: Initial cure: 24 hours at 20°C

Final cure: 7 days at 20°CAfter 48 hours at 20°CExpocrete UA will haveachieved between 60% to 70%of its final compressivestrength

Compressive strength After 1 week at 20°C —(BS 6319, Pt 2): 65 N/mm²Flexural strength After 1 week at 20°C —(BS 6319, Pt 3): 35 N/mm²Tensile strength After 1 week at 20°C —(BS 6319, Pt 7): 12 N/mm²Thermal expansion: Coefficient of linear expansion:

–25°C to +25°C —3.0 x 10–5 per°C


Mixing Expocrete

The 1.5 litre packs of Expocrete are suitable for handmixing (wearing protective gloves) on a flat, clean surface.The mixing surface should be wetted and the whole of thebase material spread out approximately 10 to 20 mmthick. All of the hardener should be emptied out onto themiddle of the base and the base folded over the hardenerand kneaded until the resultant mortar is of an evenconsistency and uniform colour.

Underwater application

Surfaces must be mechanically cleaned, free of weak orloose material, marine growth, rust, scale, etc. MixedExpocrete UA should be carried in plastic bags to workarea and small quantities, approximately 5 mm thick,pressed into position ensuring that all water is expelledfrom between the repair surface and the Expocrete UA.Mixed mortar should be applied within 30 minutes ofmixing. Contact between the mixed mortar and watershould be avoided until the point of application. Uncuredmaterial should be protected from scouring anddisplacement by moving water until cured.

Fixing of slip bricks, tiles, etc

The concrete surface should be scabbled, wire brushedand washed with clean water. Scrub bond face of brick ortile with clean water and shake to remove excess water.Rub Expocrete UA into the wetted bond surfaces. Apply 25mm thick sausage of Expocrete UA to the tile. Firmly presstiles onto concrete with twisting action to ensure completematerial bed of required thickness (usually 6 to 12 mm).Very thick beds should be made up by previousapplication of Expocrete UA to the prepared concretesurface. The tiles should be supported for 12 to 48 hoursuntil the Expocrete UA has cured sufficiently to preventslipping. The use of Expocrete UA is recommended as itallows the surfaces of the bricks and concrete to bethoroughly washed down immediately prior to fixing.

Cleaning

Expocrete should be removed whilst uncured using wateror detergent solution. Cured mortar can only be removedby mechanical means.

EstimatingExpocrete compounds are supplied in 9 x 1.5 litre packscontaining base and hardener in separate plasticbuckets. Coverage rate is 1 litre/m² per mm thickness.

Fosroc®

Expocrete UA constructive solutions

2CI/SfB: Yr4June 2006

86

LimitationsExpocrete should not be used when the temperature isbelow 5°C and falling. Never mix part packs.

StorageAll products have a shelf life of 12 months at between 5°Cand 20°C and kept in a dry store in the original, unopenedpacks. Storage at higher temperature may reduce shelflife.

PrecautionsHealth and safety


Fosroc®

Expocrete UA

2CI/SfB: Yr4June 2006


www.fosroc.com




Expocrete is the trade mark of Fosroc International Limited

87

Epoxy resin fairing coat

Uses

For filling blow-holes, and eliminating minor irregularitiesprior to the application of Nitocote and Nitoflor epoxycoatings.

Advantages

Non-slump, can be applied to vertical surfaces andtrowelled into blow-holesSuperior bond strength to virtually all substratesSmooth paste consistency is easy to apply and finishReduced usage of subsequent coatingPre-weighed components ensure consistency

Description

Nitomortar FC is a two-component thixotropic materialbased on high quality solvent-free epoxy resin systems.The colour coded material is supplied in pre-weighedquantities ready for on-site mixing and use.

Nitomortar FC can be applied to damp surfaces andquickly cures to form a completely impermeable surfaceready for overcoating.

Nitomortar FC can be applied up to 5 mm thickness onvertical and overhead locations in a single applicationwithout the use of formwork. Greater thicknesses thanthose specified can be achieved by application ofsubsequent layers. Consult Fosroc Customer ServicesDepartment for further information.

For higher build characteristics to vertical or overheadlocations, Nitomortar HB is recommended.


Epoxy resin based fairing coat mortar

The epoxy resin based fairing coat mortar shall beNitomortar FC a two-component solvent-free epoxy resinmortar with a density not greater than 1700 kg/m³. Thecured mortar shall achieve a compressive strength of70 N/mm². The material shall be colour coded to facilitatemixing.

Properties

The following properties were obtained at a temperatureof 20°C unless otherwise specified.

Test method Typical results

Compressive strength(BS 6319, Pt 2): 70 N/mm² @ 7 daysPot life: 4 hours @ 20°C

1½ hours @ 35°C

Initial cure: 10 hours @ 20°C4 hours @ 35°C

Overcoating time: 10 to 24 hours @ 20°C4 to 18 hours @ 35°C

Full cure: 7 days @ 20°C4 days @ 35°C

Fresh wet density: Approximately 1700 kg/m³ (fullycompacted)

Chemical resistance: The low permeability ofNitomortar FC retards chemicalattack in aggressiveenvironments

Performance of Nitomortar FC continually immersed at20°C:

Citric acid 10% ExcellentTartaric acid 10% ExcellentDiesel fuel / Petrol 100% ExcellentSugar solution Saturated Very goodLactic acid 10% Very goodHydrocarbons 100% Very goodPhosphoric acid 50% Very good


Preparation

Clean the surface and remove any dust, unsound orcontaminated material, plaster, oil, paint, grease,corrosion deposits or algae.

The surface should preferably be prepared using high-pressure water jetting or light abrasive blasting, followedby thorough washing to remove dust and remainingparticles.


All steel surfaces should be abrasive blasted to meet therequirements of BS 7079, SA2.5 immediately beforeapplication.

No independent priming system is required.

Mixing

Care should be taken to ensure that Nitomortar FC isthoroughly mixed to produce a fully homogeneoustrowellable mortar.

Nitomortar FC can be mixed by hand or with a slow speeddrill fitted with a suitable paddle.

The ‘base’ and ‘hardener’ components should be stirredthoroughly in order to disperse any settlement beforemixing them together. The entire contents of the

Fosroc®

Nitomortar FC constructive solutions

2CI/SfB:(4-)Pr4 W7November 2005

88

Fosroc®

Nitomortar FC

‘hardener’ tub should be emptied into the ‘base’ containerand the components mixed thoroughly until a uniformcolour consistency is obtained, taking particular care toscrape the sides and bottom of the container. Under nocircumstances should part packs be used.

Application

Apply the mixed Nitomortar FC to the prepared substrateby spatula, filling knife, squeegee or steel float, tighttrowelling onto the substrate to ensure positive adhesionand that all blow-holes and defects are completely filled toproduce a smooth even finish.

Application thickness will vary with profile and alignmentof substrate. Where necessary, mortar should be built-upin layers.

Build-up

Additional build-up can be achieved by application ofmultiple layers. Where thicker sections are required, thesurface of the intermediate applications should be lightlyabraded and the resulting dust removed to provide asuitable surface for subsequent layers. The application ofadditional layers should follow between 10 and 24 hours(at 20°C) after the first application. This time should beincreased at lower temperatures. Application ofNitomortar FC may then proceed.

If sagging occurs during application, the Nitomortar FCshould be completely removed and re-applied at areduced thickness on to the substrate.

Finishing

Any ridges left by the trowel can be brushed out while thematerial is still wet or ground down with a carborundumstone before overcoating.

Important note: Do not use solvent to thin components asthis will prevent proper cure.


At ambient temperatures above 35°C, Nitomortar FC willhave shorter pot life and working life. The materialsshould be stored in the shade or in air-conditionedenvironments and should not be applied in direct sunlight.

Curing

Curing protection is not necessary for Nitomortar FC.

Overcoat with protective/decorative finishes.

The Nitomortar FC should be overcoated within 24 hoursat 20°C.

For surrounding areas not subjected to chemical orphysical wear, Fosroc recommend the use of theDekguard range of anti-carbonation, anti-chloride

coatings, thus bringing them up to the same protectivestandard as the repair itself. These products provide adecorative and uniform appearance as well as protectingareas of the structure which might otherwise be at riskfrom the environment.

Nitocote epoxy resin coatings should be applied within24 hours. Dekguard products should not be applied overthe repair area until the Nitomortar FC is at least 3 daysold. For further advice, consult Fosroc Customer ServicesDepartment.

Cleaning

Nitomortar FC should be removed from tools, equipmentand mixers with Fosroc Solvent 102 immediately afteruse. Hardened material can only be removedmechanically.

Estimating

Supply

Nitomortar FC: 1 kg packsFosroc Solvent 102: 5 and 25 litre tins

Coverage and yield

Nitomortar FC: 1 kg pack = 0.6 ltrCoverage 0.6 m2 @ 1mmthickness

The coverage figure is theoretical — due to wastagefactors and the variety and nature of possible substrates,practical coverage figures may be substantially reduced.

Limitations

Do not mix part packs under any circumstances.Nitomortar FC should not be exposed to moving waterduring application. Exposure to heavy rainfall prior to finalset may result in surface scour. If any doubt arisesconcerning temperature or substrate condition, consultFosroc Customer Services Department.

Application should not be undertaken if the temperature isbelow 5°C or is 5°C and falling, nor when the prevailinghumidity exceeds 90%.

Storage

Store in dry conditions in the original, unopenedcontainers. All products have a shelf life of 12 months at20°C if kept in a dry store in the original, unopenedcontainers.



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Precautions

Health and safety


Fire

Nitomortar FC is non-flammable.

Fosroc Solvent 102 is flammable. Keep away fromsources of ignition. No Smoking. In the event of fire,extinguish with CO2 or foam. Do not use a water jet.

Flash point

Fosroc Solvent 102: 33°C




www.fosroc.com Certificate number FM 610



90

High build epoxy reinstatement mortar

Uses

For the fast and permanent reinstatement of concrete,particularly where resistance to chemicals is required.Nitomortar HB can be used for small, localised patchrepairs and, because of its lightweight nature, is ideallysuited for use in vertical and overhead locations, and foremergency repairs where fast strength gain is important.When properly compacted, the mortar is highlyimpermeable.

For fast repairs to floors and other locations subjected towear and abrasion, the use of Nitomortar S is recommended.

Advantages

Lightweight formulation enabling extra high build andthereby saving time and expenseObviates the need for formworkEarly development of strength minimises disruptionHighly resistant — unaffected by a wide range ofchemicalsExtremely low permeabilityEqual to the strength of high quality concrete within3 daysPre-weighed components ensure consistency

Description

Nitomortar HB is based on a high performance solvent-free epoxy resin system. The special lightweight filler isspecifically designed to give excellent ‘hanging’ propertiesfor vertical and overhead work. Nitomortar HB is a three-component material supplied in pre-weighed quantitiesready for on-site mixing and use.

Properties

The following results were obtained at a temperature of20°C unless otherwise specified.


Compressive strength(BS 6319, Pt 2): 40 N/mm² @ 7 daysFlexural strength (BS 6319, Pt 3): 15 N/mm² @ 7 daysTensile strength (BS 6319, Pt 7): 7 N/mm² @ 7 daysCompressive modulus(ASTM C 469-65): 4.5 kN/mm² @ 7 daysPot life: 45 minutes @ 20°C

20 minutes @ 35°CInitial hardness: 24 hoursFull cure: 7 daysFresh wet density: Approximately

1160 kg/m³ (fullycompacted)

Chemical resistance: The low permeability ofNitomortar HB retardschemical attack inaggressiveenvironments

Performance of Nitomortar HB blocks continuallyimmersed at 20°C:Citric acid 10% ExcellentTartaric acid 10% ExcellentHydrochloric acid 25% ExcellentSodium hydroxide 50% ExcellentDiesel fuel/petrol 100% ExcellentSulphuric acid 10% Very goodSugar solutions Saturated Very goodLactic acid 10% Very goodHydrocarbons 100% Very goodPhosphoric acid 10% Very goodNitric acid 10% GoodAcetic acid 5% Limited


Preparation

Clean the surface and remove any dust, unsoundmaterial, plaster, oil, paint, grease, corrosion deposits oralgae. Roughen the surface and remove any laitance bylight scabbling or grit-blasting. Saw cut or cut back theextremities of the repair locations to a depth of at least10 mm to avoid feather-edging and to provide a squareedge. Break out the complete repair area to a minimumdepth of 10 mm up to the sawn edge.




The cleaned steel should be coated within 3 hours. Applyone full coat of Nitoprime Zincrich Plus and allow to drybefore continuing. If any doubt exists about havingachieved an unbroken coating, a second applicationshould be made and, again, allowed to dry beforecontinuing.

Substrate priming

The dry substrate should be primed using Nitoprime 28.The primer should be mixed in the proportions supplied,adding the entire contents of the ‘hardener’ tin to the

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‘base’ tin. The two components should be thoroughlymixed together for 3 minutes.

The mixed primer should be scrubbed well into theprepared substrate, taking care that all imperfections inthe surface are properly coated and avoiding ‘puddling’ indepressions. If the Nitoprime 28 is absorbed within30 minutes, a second coat should be applied beforecontinuing.

Nitomortar HB can be applied as soon as the primer hasstarted to gel but still has surface ‘tack’. This is normallybetween 30 minutes and 4 hours dependent on theambient and substrate temperatures. If Nitoprime 28cures hard, a second application must be made beforeapplication of Nitomortar HB.

The usable life of the mixed primer is approximately 60minutes at 20°C or 30 minutes at 35°C.

Mixing

Care should be taken to ensure that Nitomortar HB isthoroughly mixed to produce a fully homogeneous,trowellable mortar.

‘Standard’ packs may be mixed by hand. The ‘hardener’and ‘base’ components should be stirred thoroughly inorder to disperse any settlement before mixing themtogether. The entire contents of the ‘hardener’ and ‘base’containers should then be emptied into the plastic bucketand thoroughly mixed for 3 minutes. While mixingcontinuously, the entire bag of aggregate should then beadded slowly and the three components blended togetherfor a further 2 to 3 minutes, ensuring that the aggregate isthoroughly wetted out with the mixed resins. Under nocircumstances should part packs be used.

‘Industrial’ packs must be mixed mechanically. Again, the‘hardener’ and ‘base’ components should be stirredthoroughly in order to disperse any settlement beforemixing them together. The entire contents of the‘hardener’ container should then be emptied into the‘base’ container and thoroughly mixed for 3 minutes, thenemptied into a forced action mixer of adequate capacity(e.g. Cretangle or Pennine). Add the aggregate slowly withthe mixer running and continue for 2 to 3 minutes until allthe components are thoroughly blended. Under nocircumstances should part packs be used.

Application

Apply the mixed Nitomortar HB to the prepared substrateby wood float, pressing firmly into place to ensure positiveadhesion and full compaction. Thoroughly compact themortar around any exposed reinforcement. In restrictedlocations, or where exposed reinforcing steel is present,application by gloved hands is an acceptable alternativebut, in all cases, the product must be finished to a tightsurface with a steel trowel. Nitomortar HB can be applied

in sections up to 50 mm thickness in vertical locations oroverhead locations in a single application and without theuse of formwork. Thicker sections should be built up inlayers but are sometimes possible for smaller repairs,generally up to 75 mm, in a single application dependenton the actual configuration of the repair area and thevolume of exposed reinforcing steel.

When larger areas are being rendered (generally over2 m²) a chequerboard application technique isrecommended.

Note: the minimum applied thickness of Nitomortar HB is10 mm.

Build-up

Additional build-up can be achieved by application ofmultiple layers. Exposed steel reinforcing bars should befirmly secured to avoid movement during the applicationprocess as this will affect mortar compaction, build andbond.

Where thicker sections are required, the surface of theintermediate applications should be scratch-keyed toprovide a suitable surface for subsequent layers. Theapplication of additional layers should follow between8 and 24 hours (@ 20°C) after the first application. Thistime should be reduced at higher temperatures.Repriming with Nitoprime 28 and a further application ofNitomortar HB may then proceed.

If sagging occurs during application, the Nitomortar HBshould be completely removed and reapplied at areduced thickness on to the correctly reprimed substrate.

Finishing

Nitomortar HB is finished by the use of a wood float andclosed with a steel trowel wiped with a cloth dampenedwith Fosroc Solvent 102. The completed surface shouldnot be overworked.


Nitoprime 28 and Nitomortar HB can be applied in coldconditions down to 5°C. The materials should not beapplied when the substrate and/or air temperature is 5°Cand falling. At 5°C static temperature or at 5°C and rising,the application may proceed.


At ambient temperatures above 35°C, Nitoprime 28 andNitomortar HB will have shorter pot lives and workinglives. The materials should be stored in the shade or inan air-conditioned environment and should not be appliedin direct sunlight.

Curing

Unlike cementitious materials Nitomortar HB does not



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require curing immediately after finishing, but doesrequire protection from rain and wet conditions during theinitial 24 hours after placement.

Overcoating with protective/decorative finishes

Nitomortar HB is extremely durable and resistant to awide range of acids, alkalis and industrial chemicals andwill provide excellent protection to the concrete andembedded steel reinforcement within the repairedlocations. The surrounding parts of the structure maybenefit from the application of a protective coating, thusbringing them up to the same protective standard as therepair itself. Fosroc recommend the use of the Nitocoterange of epoxy resin, chemical-resistant, protectivecoatings.

For surrounding areas not subjected to chemical attack orphysical wear, Fosroc recommend the use of the Dekguardrange of anti-carbonation, anti-chloride protective coatings.These products provide a decorative and uniformappearance as well as protecting areas of the structurewhich might otherwise be at risk from the environment.

Nitocote epoxy resin protective coatings should be appliedwithin 24 hours. Dekguard products should not be applieduntil the Nitomortar HB is at least 3 days old. For furtheradvice, consult the local Fosroc office.

Cleaning

Nitoprime Zincrich Plus, Nitoprime 28 and Nitomortar HBshould be removed from tools, equipment and mixerswith Fosroc Solvent 102 immediately after use.

Estimating

Supply

Nitomortar HB: 2.9 kg ‘Standard’ packs9.3 kg ‘Industrial’ packs

Nitoprime Zincrich Plus: 1.9litre and 800ml cansNitoprime 28: 0.45 kg ‘Handy’ packs

4.2 kg ‘Industrial’ packsFosroc Solvent 102: 5 and 25 litre tins

Coverage and yield

Nitomortar HB: 2.5 litres / 2.9 kg ‘Standard’ pack8.0 litres / 9.3 kg ‘Industrial’ pack

Nitoprime Zincrich Plus: 8 m²/litre

Nitoprime 28: 2.4 m² / 0.45 kg ‘Handy’ pack20 m² / 4.2 kg ‘Industrial’ pack

Notes: the coverage figures for Nitoprime Zincrich Plusand Nitoprime 28 are theoretical — due to wastagefactors and the variety and nature of possible substrates,practical coverage figures will be reduced.

Limitations

Nitomortar HB should not be used when the temperatureis below 5°C and falling. Do not mix part packs under anycircumstances. Due to the lightweight nature ofNitomortar HB, the product should not be used in areassubjected to traffic, point loading or abrasion. Neithershould it be exposed to moving water during application.Exposure to heavy rainfall prior to the final set will result insurface softening and scour. Nitoprime 28 is not a damptolerant primer. If any doubts arise concerningtemperature or substrate conditions, consult the localFosroc office.

Storage

Store in dry conditions in the original, unopened packaging.All products have a shelf life of 12 months at 20°C if keptthese conditions. If stored at high temperatures, the shelflife may be reduced to 4 to 6 months.

Precautions

Health and safety

For further information see appropriate Product SafetyData Sheet.

Fire

Nitomortar HB is non-flammable.

Nitoprime Zincrich Plus, Nitoprime 28 and Fosroc Solvent102 are flammable. Keep away from sources of ignition.No smoking. In the event of fire, extinguish with CO2 orfoam. Do not use a water jet.

Flash pointsNitoprime Zincrich Plus: 41°CFosroc Solvent 102: 33°C

Nitoprime 28 27°C



www.fosroc.com




93

High strength jointing and multi-purposerepair compounds

Uses

For fast and emergency reinstatement of concrete,bedding, jointing and reprofiling of concrete, masonry andbrickwork. Nitomortar PE is ideally suited for the repairand reprofiling of precast concrete units, damaged arrisesand treads. It can be used to infill hollows and holes inconcrete floors, bedding and fixing kerbstones, manholesets, frames, brick slips, ceramic tiles, slabs and copingstones. Nitomortar PE Concrete should be used to repairlarger voids. The products are especially useful wherefast strength gain is important. When properly compacted,they are highly impermeable.

Advantages

Fast development of strength minimises disruption —stronger than concrete within 2 hoursNo primer requiredHigh chemical and oil resistanceExtremely versatile — can be poured, trowelled ormodified with aggregate without significantly affectingsetting times or strengthsExtremely low wastage due to ability to mix part packsto consistencies requiredWill cure down to 0°CPre-weighed components ensure consistency

Description

Nitomortar PE products are based on a polyester resinsystem. There are two grades.

Nitomortar PE: The standard material for general purposeuse.

Nitomortar PE Concrete: A special grade allowing usersto add suitable aggregate, thereby substantially reducingthe cost of infilling larger voids.

Winter versions of Nitomortar PE is available which arefaster setting at low ambient temperatures. Both grades ofNitomortar PE are supplied as two-component productswith pre-weighed quantities of liquid resin and powderedhardener, ready for on-site mixing and use. The hardenersystem enables the mix to be varied from a pourableconsistency to a trowellable mortar without significantlyaffecting the setting times or strengths achieved.

Properties

General

Bond strength: Nitomortar PE forms a strong bond tomost structural materials provided the surfaces are dryand suitably prepared. The resulting bond betweenNitomortar PE and concrete will be stronger than thetensile strength of the concrete itself.

Shrinkage: The polyester resin used in Nitomortar PE isformulated to reduce shrinkage to a minimum. Linearshrinkage will be approximately 0.8%. No furthershrinkage will occur after the material has cured.

Durability: Cured Nitomortar PE performs undertemperatures as high as 60°C and down to sub-zeroconditions.

Chemical resistance: Fully cured Nitomortar PE isunaffected by water, petrol, oil and many corrosivechemicals. It is not recommended for use in contact withketones, phenols, strong alkalis and oxidising agents.Because chemical resistance can be affected by externalvariable factors (e.g. temperature), the local Fosroc officeshould be consulted for specific applications.

Underwater use: Nitomortar PE will cure under water. Thelocal Fosroc office should be consulted when consideringthis type of application.

Working time

Temperature Nitomortar PE Nitomortar PEConcrete

5°C: 160 minutes 250 minutesWinter grade: 60 minutes15°C: 35 minutes 90 minutesWinter grade: 20 minutes25°C: 15 minutes 50 minutes35°C: 5 minutes 25 minutes

Compressive strength gain: All grades of Nitomortar PEwill develop strengths equivalent to mature concretewithin a 2 to 6 hour period at temperatures above 15°C.Typical compressive strength development is shownbelow.

Nitomortar PE

Note: The performance of Nitomortar PE winter grade at5°C is similar to that of the standard grade at 20°C.

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Nitomortar PE Concrete

Property at 20°C Nitomortar PE Nitomortar PEflowable Concrete*consistency

Compressivestrength at 7 days(BS 6319, Pt 2): 100 N/mm² 100 N/mm²Flexural strength(BS 6319, Pt 3): 28 N/mm² 25 N/mm²Tensile strength(BS 6319, Pt 7): 14 N/mm² 12 N/mm²Young’s Modulusof Elasticity: 16 kN/mm² 23 kN/mm²Thermal conductivity: 1.0 Watt/m/°C —Coefficient ofthermal expansion: 30 x 10–6 per °C —

* Note that the strengths quoted for Nitomortar PEConcrete may vary dependent on the type of aggregateselected.

Mix design — Nitomortar PEMix design — Nitomortar PEMix design — Nitomortar PEMix design — Nitomortar PEMix design — Nitomortar PE

Hardener : resin ratio Density Yield(volume) (weight) kg/m³ litres/kg

Trowellable: 3.2 :1 4.2 :1 1,920 0.52Flowable: 2.5 :1 3.5 :1 1,840 0.54

Fluid: 1.6 :1 2.0 :1 1,680 0.60

Mix design — Nitomortar PE Concrete

For each full pack of Nitomortar PE Concrete containing5 litres (5.5 kg) resin and 3.75 litres (5.5 kg) powderedhardener, use one of the alternative aggregate typesdescribed in the table.

Dried aggregate Quantity Yield

Grade C sand: 17 litres (30 kg) 20 litresGrade M sand: 14 litres (25 kg) 17.5 litresGrade F sand: 11.5 litres (21 kg) 15 litresGrade M sand: 6.5 litres (12 kg)10 mm aggregate: 12 litres (21 kg)

22.5 litres

Grade M sand: 5.5 litres (10 kg)10 mm aggregate: 5.5 litres (9.5 kg) 27.5 litres20 mm aggregate: 11 litres (19 kg)


Preparation

Saw cut or cut back the extremities of the repair locationsto a depth of at least 5 mm to avoid feather-edging and toprovide a square edge. Break out the complete repairarea to a minimum depth of 5 mm up to the sawn edge.

The surface should be free from any contamination.Where breaking out is not required, roughen the surfaceand remove any laitance by light scabbling or grit-blasting.


Fully expose any corroded steel in the repair area andremove all loose scale and corrosion deposits. Steelshould be cleaned to a bright condition paying particularattention to the back of exposed steel bars. Grit-blasting isrecommended for this process.



Exposed steel reinforcement should be treated with onefull coat of Nitoprime Zincrich Plus. This should beallowed to dry before continuing.

If any doubt exists about having achieved an unbrokencoating, a second application should be made and, again,allowed to dry before continuing.



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Substrate priming

No priming is necessary when using Nitomortar PEproducts.

Mixing

Pour the required quantity of liquid resin into a cleanplastic mixing bucket and add the powdered hardenerslowly, stirring continuously. Continue mixing for 3minutes until a uniform consistency is achieved.

For Nitomortar PE Concrete, measure out the correctvolume of surface dry aggregate (coarse/fine) appropriateto the proposed application. Add this to the previouslymixed resin (see above) until a uniform consistency isachieved. Mechanical mixing is recommended forNitomortar PE Concrete and a forced-action mixer (e.g.Mixal or Cretangle type) should be used.

Do not mix more material than can be used within thepot-life of the product.

Application

Apply the mixed Nitomortar PE to the prepared substrateby steel trowel, pressing firmly into place to ensurepositive adhesion and full compaction. In the case ofrepairs to very dense or non-absorbent substrates, thefirst layer of Nitomortar PE should be made slightly ‘resin-rich’ to ensure that the surface to be bonded is properly‘wetted-out’.

Thoroughly compact the mortar around any exposedreinforcement. Refer to the ‘Design criteria’ chart formaximum thicknesses in a single application. Thickersections should be built up in layers. If sagging occursduring application, the Nitomortar PE should becompletely removed and reapplied at a reducedthickness.

When larger areas are being rendered (generally over0.25 m² for Nitomortar PE and 0.50 m² for Nitomortar PEConcrete) a chequerboard application technique isrecommended.

For certain applications, particularly where access isrestricted, the mixed Nitomortar PE can be poured intoplace. The local Fosroc office should be consulted beforeproceeding.

When used for bedding purposes or for fixing brick slips,ceramic tiles, slabs, coping stones, etc, provision mightbe necessary for temporary support.

Note: The minimum applied thickness of Nitomortar PEand Nitomortar PE Concrete is 5 mm.

Build-up

The following guidelines should be used.

Nitomortar NitomortarPE PE Concrete

Maximum thickness: 12 mm 40 mmMinimum thickness: 5 mm 5 mm*Maximum plan area: 0.25 m² 0.50 m²Maximum linear run: 1 metre 1 metre

Greater thicknesses should be built up in layers andlarger areas should be applied in a ‘chequerboard’fashion. Consult the local Fosroc office for furtherinformation.

* Note: When using aggregate larger than a sand grading,the minimum thickness will be increased. Consult thelocal Fosroc office for further information.

Additional build-up can be achieved by application ofmultiple layers. Exposed steel reinforcing bars should befirmly secured to avoid movement during the applicationprocess as this will affect mortar compaction, build andbond.

Where thicker sections are required, the surface of theintermediate applications should be scratch-keyed toprovide a suitable surface for subsequent layers. Theapplication of additional layers should follow between8 and 24 hours after the first application.

Finishing

Nitomortar PE is finished by the use of a steel trowelwhich may be wiped from time to time with a clothmoistened with Fosroc Solvent 105. The completedsurface should not be overworked.


Nitomortar PE can be applied in cold conditions down to0°C. The material should not be applied when thesubstrate and/or air temperature is below freezing orwhere the substrate is contaminated with frost or ice. Incold conditions, the winter grade may be moreappropriate. Consult the local Fosroc office for furtherinformation.


At ambient temperatures above 25°C, Nitomortar PE willhave shorter pot lives and working lives. The materialshould not be used at ambient or surface temperaturesabove 35°C. At elevated temperatures, the product shouldbe stored in the shade or in an air-conditionedenvironment for 24 hours prior to use and should not beapplied in direct sunlight.



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Curing

Curing protection is not necessary for Nitomortar PEproducts.

Cleaning

Nitomortar PE should be removed from tools, equipmentand mixers with Fosroc Solvent 105 immediately afteruse.

Estimating

Supply

Nitomortar PE: 14 kg packsNitomortar PEwinter grade: 14 kg packsNitomortar PE Concrete: 11 kg packsNitoprime Zincrich Plus 1.9 litre and 800ml cans

Coverage and yield

Nitomortar PE: 7.5 litres / 14 kg packNitomortar PEwinter grade: 7.5 litres / 14 kg packNitomortar PE Concrete: 15 to 27.5 litres / 11 kg pack

(dependent on aggregateaddition)

Nitoprime Zincrich Plus 8.0 m2 per litre

Note: The coverage figures given are theoretical — due towastage factors and the variety and nature of possiblesubstrates, practical coverage figures will be reduced.

Limitations

The products should not be applied to damp or wetsurfaces where there is total reliance on bond nor shouldthey be exposed to moving water during application.Exposure to heavy rainfall prior to the final set may resultin surface scour. If any doubts arise concerning

temperature or substrate conditions, consult the localFosroc office.

Storage

Store in dry conditions in the original, unopened bags orpacks. All products have a shelf life of 12 months at 20°Cif kept in a dry store in the original, unopened packaging.

If stored at high temperatures and/or high humidityconditions the shelf life may be significantly reduced.

Precautions

Health and safety


Fire

Nitomortar PE products are flammable. Keep away fromsources of ignition. No Smoking. In the event of fire,extinguish with CO2 or foam. Do not use a water jet.

Flash point

Nitomortar PE resin: 29°C

Nitoprime Zincrich Plus 41oC



www.fosroc.com





97

High strength, abrasion-resistant epoxyreinstatement mortar

Uses

For the fast and permanent reinstatement of concrete,particularly where high strength, abrasion-resistance andresistance to chemicals is required. The product isdesigned for horizontal use but can be applied vertically,although generally in thinner sections. It is ideally suitedfor acid tanks, sea walls, industrial floors and for use as abedding mortar. Nitomortar S can be used for emergencyrepairs where fast strength gain is important.When properly compacted, the mortar is highlyimpermeable.

In certain instances, Nitomortar S can be used on metalsubstrates. Contact the local Fosroc office for advice inthis respect.

For fast repairs in vertical and overhead locations where ahigher-build, lightweight formulation is required, the useof Nitomortar HB is recommended.

Advantages

High ultimate strength — suitable for structural useEarly development of strength minimises disruptionAbrasion-resistance — suitable for heavily traffickedareasHighly resistant to a wide range of chemicalsCured product is highly impermeable to water when‘tight trowel’ finishedTypically twice as strong as good quality concretePre-weighed components ensure consistency

Description

Nitomortar S is based on a high quality solvent-free epoxyresin system. The special silica aggregates provide highstrength and excellent abrasion resistance. Nitomortar Sis a three-component material supplied in pre-weighedquantities ready for on-site mixing and use.

Properties

The following results were obtained at a temperature of20°C unless otherwise specified.


Compressive strength(BS 6319, Pt 2): 70 N/mm² @ 7 daysFlexural strength (BS 6319, Pt 3): 20 N/mm² @ 7 daysTensile strength (ASTM C 307): 10 N/mm² @ 7 daysCompressive modulus(ASTM C 469): 16.2 kN/mm² @ 28 daysWater absorption: 0.2% (concrete - 5.0%)

Pot life: 45 minutes @ 20°C20 minutes @ 35°C

Initial hardness: 24 hoursFull cure: 7 daysFresh wet density: Approximately

2015 kg/m³ (fullycompacted)

Chemical resistance: The low permeabilityof Nitomortar S retardschemical attack inaggressiveenvironments

Performance of Nitomortar S blocks continually immersedat 20°C:Citric acid 10% ExcellentTartaric acid 10% ExcellentHydrochloric acid 25% ExcellentSodium hydroxide 50% ExcellentDiesel fuel / petrol 100% ExcellentSulphuric acid 10% Very goodSugar solutions Saturated Very goodLactic acid 10% Very goodHydrocarbons 100% Very goodPhosphoric acid 50% Very goodNitric acid 10% GoodAcetic acid 5% Limited


Preparation

Clean the surface and remove any dust, unsoundmaterial, plaster, oil, paint, grease, corrosion deposits oralgae. Roughen the surface and remove any laitance bylight scabbling or grit-blasting. Saw cut or cut back theextremities of the repair locations to a depth of at least5 mm to avoid feather-edging and to provide a squareedge. Break out the complete repair area to a minimumdepth of 5 mm up to the sawn edge.



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The cleaned steel should be coated within 3 hours. Applyone full coat of Nitoprime Zincrich Plus and allow to drybefore continuing. If any doubt exists about havingachieved an unbroken coating, a second applicationshould be made and, again, allowed to dry beforecontinuing.

Substrate priming

Horizontal or damp substrates should be primed usingNitoprime 25. Predominantly vertical and metal substratesshould be primed using Nitoprime 28. In both cases, theprimer should be mixed in the proportions supplied,adding the entire contents of the ‘hardener’ tin to the‘base’ tin. The two components should be thoroughlymixed together for 3 minutes.

The mixed primer should be scrubbed well into theprepared substrate, taking care that all imperfections inthe surface are properly coated and avoiding ‘puddling’ indepressions. If the primer is absorbed within 30 minutes,a second coat should be applied before continuing.Nitomortar S can be applied as soon as the primer hasstarted to gel but still has surface ‘tack’. This is normallybetween 30 minutes and 4 hours dependent on the ambientand substrate temperatures. If the primer cures hard, asecond application must be made before application ofNitomortar S. The usable life of the mixed primer isapproximately 60 minutes at 20°C or 30 minutes at 35°C.

Mixing

Care should be taken to ensure that Nitomortar S isthoroughly mixed to produce a fully homogeneous,trowellable mortar.

‘Standard’ packs may be mixed by hand. The ‘hardener’and ‘base’ components should be stirred thoroughly inorder to disperse any settlement before mixing themtogether. The entire contents of the ‘hardener’ and ‘base’containers should then be emptied into the plastic bucketand thoroughly mixed for 3 minutes. While mixingcontinuously, the entire bag of aggregate should then beadded slowly and the three components blended togetherfor a further 2 to 3 minutes, ensuring that the aggregate isthoroughly wetted out with the mixed resins. Under nocircumstances should part packs be used.

‘Industrial’ packs must be mixed mechanically. Again, the‘hardener’ and ‘base’ components should be stirredthoroughly in order to disperse any settlement beforemixing them together. The entire contents of the‘hardener’ container should then be emptied into the‘base’ container and thoroughly mixed for 3 minutes, thenemptied into a forced action mixer of adequate capacity(e.g. Daines, Cretangle or Pennine). Add the aggregateslowly with the mixer running and continue for 2 to 3minutes until all the components are thoroughly blended.

Under no circumstances should part packs be used.

Application

Apply the mixed Nitomortar S to the prepared substrate bywood float, pressing firmly into place to ensure positiveadhesion and full compaction. Thoroughly compact themortar around any exposed reinforcement. In restrictedlocations, or where exposed reinforcing steel is present,application by gloved hands is an acceptable alternativebut, in all cases, the product must be finished to a tightsurface with a steel trowel. Nitomortar S can be applied insections up to 50 mm thickness in horizontal locations orup to 6 mm thickness in vertical locations in a singleapplication and without the use of formwork. Thickervertical sections may sometimes be possible dependenton the profile of the substrate and the volume of exposedreinforcing steel but should generally be built up in layers.

When larger areas are being rendered, a chequerboardapplication technique is recommended.

Note: the minimum applied thickness of Nitomortar S is5 mm.

Build-up

Additional build-up can be achieved by application ofmultiple layers. Exposed steel reinforcing bars should befirmly secured to avoid movement during the applicationprocess as this will affect mortar compaction, build and bond.

Where thicker sections are required, the surface of theintermediate applications should be scratch-keyed toprovide a suitable surface for subsequent layers. Theapplication of additional layers should follow between8 and 24 hours (@ 20°C) after the first application. Thistime should be reduced at higher temperatures.Repriming and a further application of Nitomortar S maythen proceed.

If sagging occurs during application, the Nitomortar Sshould be completely removed and reapplied at areduced thickness on to the correctly reprimed substrate.

Finishing

Nitomortar S is finished by the use of a wood float andclosed with a steel trowel. The completed surface shouldnot be overworked.


Nitoprime 25, Nitoprime 28 and Nitomortar S can beapplied in cold conditions down to 5°C. The materialsshould not be applied when the substrate and/or airtemperature is 5°C and falling. At 5°C static temperatureor at 5°C and rising, the application may proceed.


At ambient temperatures above 35°C, Nitoprime 25,Nitoprime 28 and Nitomortar S will have shorter pot livesand working lives. The materials should be stored in the



99

shade or in an air-conditioned environment and shouldnot be applied in direct sunlight.

Curing

Unlike cementitious materials Nitomortar S does notrequire curing immediately after finishing, but doesrequire protection from rain and wet conditions during theinitial 24 hours after placement.

Overcoating with protective/decorative finishes

Nitomortar S is extremely durable and resistant to a widerange of acids, alkalis and industrial chemicals and willprovide excellent protection to the concrete andembedded steel reinforcement within the repairedlocations. The surrounding parts of the structure maybenefit from the application of a protective coating, thusbringing them up to the same protective standard as therepair itself. Fosroc recommend the use of the Nitocoterange of epoxy resin, chemical-resistant, protectivecoatings.

For surrounding areas not subjected to chemical attack orphysical wear, Fosroc recommend the use of theDekguard range of anti-carbonation, anti-chlorideprotective coatings. These products provide a decorativeand uniform appearance as well as protecting areas ofthe structure which might otherwise be at risk from theenvironment.

Nitocote epoxy resin protective coatings should be appliedwithin 24 hours. Dekguard products should not be applieduntil the Nitomortar S is at least 3 days old. For furtheradvice, consult the local Fosroc office.

Cleaning

Nitoprime Zincrich Plus, Nitoprime 25, Nitoprime 28 andNitomortar S should be removed from tools, equipmentand mixers with Fosroc Solvent 102 immediately afteruse.

Estimating

Supply

Nitomortar S: 5 kg ‘Standard’ packs16 kg ‘Industrial’ packs

Nitoprime Zincrich Plus: 1.9 litre and 800ml cansNitoprime 25: 0.95 kg ‘Handy’ packs

5 kg ‘Industrial’ packsNitoprime 28: 0.45 kg ‘Handy’ packs

4.2 kg ‘Industrial’ packsFosroc Solvent 102: 5 and 25 litre tins

Coverage and yield

Nitomortar S: 2.5 litres / 5 kg ‘Standard’ pack8.0 litres / 16 kg ‘Industrial’

packNitoprime Zincrich Plus: 8 m²/litreNitoprime 25: 5 m² / 0.95 kg ‘Handy’ pack

26 m² / 5 kg ‘Industrial’ packNitoprime 28: 2.4 m² / 0.45 kg ‘Handy’ pack

20 m² / 4.2 kg ‘Industrial’ pack

Notes: the coverage figures for Nitoprime Zincrich Plusand Nitoprime 28 are theoretical — due to wastagefactors and the variety and nature of possible substrates,practical coverage figures will be reduced.

Limitations

Nitomortar S should not be used when the temperature isbelow 5°C and falling. Do not mix part packs under anycircumstances. Nitomortar S should not be used inoverhead locations — use Nitomortar HB for this purpose.Nitomortar S should not be exposed to moving waterduring application. Exposure to heavy rainfall prior to thefinal set will result in surface softening and scour.Nitoprime 28 is not a damp tolerant primer. If any doubtsarise concerning temperature or substrate conditions,consult the local Fosroc office.

Storage

Store in dry conditions in the original, unopened bags orpacks. All products have a shelf life of 12 months at 20°Cif kept in a dry store in the original, unopened bags orpacks.

If stored at high temperatures, the shelf life may bereduced to 4 to 6 months.

Precautions

Health and safety

For further information refer to the appropriate ProductSafety Data Sheet.

Fire

Nitomortar S is non-flammable.

Nitoprime Zincrich Plus, Nitoprime 28 and Fosroc Solvent102 are flammable. Keep away from sources of ignition.No smoking. In the event of fire, extinguish with CO2 orfoam. Do not use a water jet.




100


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Flash points


Nitoprime 28 27°C

For further information, refer to the Product Safety DataSheets.

101

Low viscosity or thixotropic epoxy resininjection grout

Uses

Nitofil LV

Is a low viscosity system for the injection of cracksbetween 0.25 mm and 9 mm wide in concrete andmasonry, where both sides of the crack can be sealed toprevent resin drainage.

Nitofil TH

Has been developed for the injection of cracks 0.5 to 9mm wide in concrete and masonry, and has beenspecially formulated to minimise the drainage of resinfrom cracks which are incompletely sealed.

Advantages

Nitofil LV

Low viscosity: Permits maximum resin penetration

Nitofil TH

Thixotropic: Permits injection of open-ended cracks

Nitofil LV and Nitofil TH

Adhesion: Achieves high strength bond to dry or wetconcreteMinimum creep: Material designed for low creepNon-shrink: No loss of bond or surface contactHigh strength: High compressive, tensile and flexuralstrengthsChemical resistance: Withstands most chemicals,acids and alkalis, also water and frost

Description

Nitofil LV

Is a two pack low viscosity epoxy resin product for therepair of cracked concrete and masonry by the injectionprocess.

Nitofil TH

Is a two pack thixotropic epoxy resin product for the repairof cracked concrete and masonry by the injection process.

Nitokit Surface Sealant

This is a polyester resin compound which combines thedual function of sealing the surface of the crack andbonding on the injection points.

It is supplied as a liquid resin together with a powderhardener, which are mixed together to give a stiff paste.

Nitokit Surface Sealant has the added advantage that itcan be rubbed down with suitable hand or power tools togive a smooth finish which readily blends withsurrounding concrete, minimising the visual impact of the

repaired crack.

The usable life of the product is 20 to 25 minutes at 20°C.

Properties

The following properties were obtained for Nitofil LV andNitofil TH at a temperature of 20°C:

Compressive strength(BS 6319, Pt. 2): 70 N/mm² @ 7 daysTensile strength (BS 6319, Pt. 7): 27 N/mm² @ 7 daysFlexural strength (BS 6319, Pt. 3): 50 N/mm² @ 7 daysSlant shear bond (BS 6319, Pt. 4) —To dry concrete: 50 N/mm² @ 7 daysTo wet concrete: 40 N/mm² @ 7 days

Pot life

The time for which bulk mixed material remains fluid willvary with temperature. Typical values in minutes are:

10°C 20°C 30°CNitofil LV: 40 minutes 20 minutes 10 minutesNitofil TH: 40 minutes 20 minutes 10 minutes

Chemical resistance

Nitofil LV and Nitofil TH are resistant to oil, grease, fats,most chemicals, mild acids and alkalis, fresh and seawater. Where constant contact with specific concentratedchemicals or solvent is anticipated the Fosroc CustomerServices Department should be consulted for advice.

Temperature limitations

During application: Injection can be carried out withoutspecial precautions at ambient temperatures from 5°C to25°C. For application at higher or lower temperatures theFosroc Customer Services Department can advise onrecommended procedures.

In service: The cured grout is completely resistant to frostand extreme sub-zero temperatures, and is suitable forcontinuous use up to 35°C.


Preparation

Ensure all contact surfaces are free from oil or greasecontamination.

Where feasible, insert drinking straws or wires into thecrack at sites (150 to 400 mm apart) selected for injectionports. Bond injection ports over the crack at these pointswith Nitokit Surface Sealant, removing the straws or wiresafter the Nitokit Surface Sealant has hardened. (If crack isobstructed at the surface, access may first be gained byvacuum flush drilling.) The crack should then be sealedbetween ports with Nitokit Surface Sealant.

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Mixing Nitokit Surface Sealant

Mix only the quantity of sealant that can be applied withinthe usable life. Pour a small quantity of the resin into asuitable bucket and slowly add the powder. Stir until asmooth thick cream consistency is obtained. Mix furtherquantities as required.

Mixing Nitofil

Pour all the contents of Hardener pack into Basecontainer. Mix for 2 minutes or more until homogeneous.At extreme temperatures refer to gel time information toenable required handling procedures to be adopted.

NB: Mechanical mixing is preferable (i.e. Jiffy mixer in slowspeed drill) ensuring that the sides and bottom of thecontainer are repeatedly scraped.

Injection

The product may be pumped into place using a standard‘grease gun’ technique. The size of the injection pumpshould be related to the job in hand. For small-scale jobsa Fosroc ‘G’ Gun may be used. Where greater rates ofinjection are required a Tecelmit hand pump may beused, or bulk supplies of Nitofil LV and Nitofil TH may beused with twin metering/mixing machines.

Connect the pump to the injection port using nylonreinforced PVC hose and Unex clips. Injection shouldcommence at the widest part of the crack, or at the lowerend if crack is uniform, closing that port and transferringinjection to the next when the resin is seen to havereached it.

12 to 18 hours after injection, the injection tubes shouldbe broken off and any damage made good using NitokitSurface Sealant.

Cleaning

Tools and application equipment should be cleanedusing Fosroc Solvent 102 for Nitofil LV and Nitofil TH andFosroc Solvent 105 for Nitokit Surface Sealantimmediately after use. Cured material can only beremoved mechanically. Spillages should be absorbedwith sand or sawdust and disposed of in accordance withlocal regulations.

Estimating

Packaging

Nitofil LV: 3 litre packNitofil TH: 1 litre packNitokit Surface Sealant: 5.5 litre packFosroc Solvent 102: 5 and 25 litre tinsFosroc Solvent 105: 5 litre tin

Storage

Nitofil LV, Nitofil TH and Nitokit Surface Sealant have ashelf life of 12 months if stored in dry conditions at 20°C.

Nitokit Surface Sealant should be stored in accordancewith the Highly Flammable Liquids and LiquefiedPetroleum Gases Regulations 1972.

Precautions

Health and safety

For further information refer to appropriate Product SaferyData Sheet.

Disposal

To eliminate risk of exotherm, this product should only bemixed when ready for use and then applied without delay.Any unused residue should be poured on to a disposableimpervious surface to allow cure before disposal.

Fire

Nitofil LV and Nitofil TH are non-flammable.

Fosroc Solvent 102, Fosroc Solvent 105 and NitokitSurface Sealant are flammable. Do Not use near nakedflames. No Smoking during use.

In the event of fire, extinguish with CO2 or foam.

Flash points

Nitokit Surface Sealant: 29°CFosroc Solvent 102: 33°CFosroc Solvent 105: 43°C

Fosroc® NitofilLV and TH

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Nitocote is the trademark of Fosroc International Limited

103

Pre-packaged low viscosity or thixotropicepoxy crack injection systems

Uses

Nitokit LV and Nitokit TH are designed for injecting cracksin concrete and masonry where there is a need toconsolidate a structure or exclude water and air fromcontact with reinforcement.

Nitokit LV is a low viscosity system and is suitable forcracks down to 0.2 mm at the surface and internal crackstapering down to 0.01 mm.

Nitokit TH is a thixotropic system and can be injected intoopen ended cracks where depth and quantity of resinneed to be controlled.

The Nitokit systems are ideal for small scale repairs onsite and are also suitable for in-situ or precast concreteelements.

Advantages

Self contained packs include everything necessary tocomplete the crack injectionConvenient to use disposable cartridge contains bothresin and hardenerSafe and clean to use, non-return valves avoid leakageand spillsHigh strength, excellent bond to concrete, brickworkand masonryLow viscosity and thixotropic options allow costeffective and efficient repair

Description

Nitokit LV or Nitokit TH basic pack incorporates a two-partepoxy crack injection resin contained in a patented singlecartridge, complete with injection nipples and hoses. Aselection of either Nitokit LV, a low viscosity system orNitokit TH, a thixotropic system, ensures the most costeffective and efficient solution.

The Nitokit accessory pack contains additional itemswhich are complementary to the basic pack — a two-partsurface sealer and adhesive for fixing nipples and sealingcracks, an injection gun and the basic safety wear, glovesand goggles.


Low viscosity crack injection

The crack injection system shall be Nitokit LV. It shall beapplied strictly in accordance with ‘Applicationinstructions’ given in the product data sheet.

Thixotropic crack injection

The crack injection system shall be Nitokit TH. It shall beapplied strictly in accordance with ‘Applicationinstructions’ given in the product data sheet.

Properties

Nitokit LV and Nitokit TH resin

Usable life at 10°C: 100 minutes20°C: 50 minutes30°C: 25 minutes40°C: 15 minutes

Viscosity at 10°C: 400 to 800 mPas(Nitokit LV only) 20°C: 250 to 500 mPas

30°C: 100 to 250 mPasSet time at 10°C: 12 hours

20°C: 7 hours30°C: 5 hours40°C: 3 hours

When cured for 7 days at 20°CCompressive strength: > 70 N/mm² (BS 6319)Flexural strength: > 45 N/mm² (ISO R178)Tensile strength: > 55 N/mm² (ISO 527)Modulus of elasticity: 2800 N/mm²Elongation at break: 2.5%Tensile bond strength: When tested to BS 3900,

Pt E10 in both dry and wetstates is greater than averageconcrete

Nitokit Surface Sealant

Usable life at 20°C: 15 to 35 minutes dependenton mix ratio and quantities

Set time at 20°C: 1 to 2 hours dependent on mixratio


Personal protection

Refer to ‘Health and safety’ section of this data sheetbefore commencing work.

Surface preparation

Nitokit Surface Sealant has to retain the injection systemunder pressure. Care must be taken to provide a bondsurface which is dry and free from any contamination.

Mixing the surface sealant

Only mix enough sealant that can be applied within theusable pot-life. Pour a small quantity of the resin into themixing bucket provided and slowly add the powder. Stiruntil a smooth thick cream consistency is obtained.

Application of the surface sealant

Immediately after mixing, apply a small amount of sealantto the back of each nipple ensuring that the valve will notbe blocked, then place the nipple to ensure the valve(centre) is firmly over the crack. Nipples should be placed

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Fosroc® NitokitLV and TH

between 200 and 500 mm apart dependent on crack size.Additional sealant should be applied to the flange of thenipple to ensure a resin-tight seal to the substrate. NitokitSurface Sealant should be knifed into the crack betweennipples to ensure a resin-tight seal.

Where cracks can be sealed on one side only, nipplesshould be placed at centres which are 80% of the depth towhich the resin is required to penetrate.

Application of the injection resin may commence as soonas the Nitokit Surface Sealant has fully hardened (at least1 hour at 20°C or 2 hours at 10°C).

Injection of the Nitokit LV epoxy resin

Lightly tap the side of the resin capsule near the base witha hammer two or three times on different sides to breakinternal glass container of hardener. (The glass can beheard moving when broken.)

To mix the resin, invert the cartridge twenty to thirty timesslowly. Do not shake vigorously otherwise air will beincorporated.

Pierce the foil sealed threaded end of the cartridge.

Screw the Nitokit LV hose on to the cartridge. Ensure the‘O’ ring is in place on the cartridge. Do not over tighten thefitting as this may distort the ‘O’ ring.

Use the mixed material within the useable life.

Place the cartridge into the gun supplied with theaccessory pack.

Push the free end of the Nitokit hose on to the lowestnipple and tighten the locking cap. Do not over tighten.

Insert an air release pin into the next nipple adjacent tothe injection point. Note: do not start pumping until the airrelease pin is inserted to release the non-return valve andenable it to release trapped air.

Commence pumping slowly. Do not use excessivepressure. The rate of acceptance into fine cracks may bevery slow. (Figure 4).

When resin appears at the nipple adjacent to the injectionpoint:(a) Stop pumping.(b) Release the pressure on the injection gun.(c) Remove the air release pin.(d) Unscrew the cap and, with a twisting movement, pull

off the Nitokit hose.

Attach the Nitokit hose to the next nipple, insert air releasepin in the nipple beyond and recommence pumping.

Repeat the process until the entire length of crack hasbeen injected.

On completion of pumping, the last cartridge can be leftconnected and pressurised slightly to allow for possibleseepage into deep-seated cracks.

Injection of the Nitokit TH epoxy resin

Cut the top off the conical nozzle and insert T-shaped rodand turn clockwise to engage mixing head in cartridge.(Figure 1).

Push rod down the full length of the cartridge to break themembrane separating the resin and hardener.

Pump up and down thirty to forty times to mix resin andhardener. (Figure 2).

Turn the T-shaped rod anti-clockwise to disengage andthen remove. Do not shake.

Unscrew the conical nozzle and discard.

Screw the Nitokit hose onto the cartridge. Ensure therubber ‘O’ ring is in place on the cartridge. Do not overtighten the fitting as this may distort the ‘O’ ring. (Figure 3).

Use the mixed material within the usable life.

Place the cartridge into the gun supplied with theaccessory pack.

Push the free end of the Nitokit hose on to the nipplepositioned over the widest point of the crack and tightenthe locking cap. Do not over tighten.

Insert an air release pin into the next nipple adjacent tothe injection point. Note: do not start pumping until the airrelease pin is inserted to release the non-return valve andenable it to release trapped air. Commence pumpingslowly. Do not use excessive pressure. The rate ofacceptance into fine cracks may be very slow. (Figure 4).

When resin appears at the nipple adjacent to the injectionpoint:(a) Stop pumping.(b) Release the pressure on the injection gun.(c) Remove the air release pin.(d) Unscrew the cap and, with a twisting movement, pull

off the Nitokit hose.

Attach the Nitokit hose to the next nipple, insert air releasepin in the nipple beyond and recommence pumping.

Repeat the process until the entire length of crack hasbeen injected.

On completion of pumping, the last cartridge can be leftconnected and pressurised slightly to allow for possibleseepage into deep-seated cracks.


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Making good

After the Nitokit injection resin has set, remove the nipples.These can be knocked off with a hammer. Make good anyholes or voids with Nitokit Surface Sealant. The existingsurface sealant can then be removed by either grinding orheating with a hot air gun and scraping the concrete surfaceuntil the original substrate profile is restored.

Cleaning

Tools and application equipment should be cleanedusing Fosroc Solvent 102 for Nitokit TH and Nitokit LV andFosroc Solvent 105 for Nitokit Surface Sealant.

Estimating

Nitokit LV &Nitokit TH 12 cartridges - (0.25 litre of mixed resin(basic pack): per cartridge)

30 injection nipples6 hoses4 air release pins(Nitokit TH also includes 6 mixing rods)

Nitokit(accessory pack): 1 injection gun

1 plastic bucket2 pairs goggles1 x 5.5 litre pack Nitokit Surface Sealant

Also available separately

Nitokit injection nipples: EachNitokit TH hoses: EachNitokit air release pins: EachNitokit Surface Sealant: 5.5 litre pack

Limitations

Nitokit LV and Nitokit TH should not be used for crackswhere movement is expected to continue. Othermeasures should be taken to accommodate suchmovement, ie cutting and forming a movement joint.

Storage

Nitokit LV, Nitokit TH and Nitokit Surface Sealant have ashelf life of 12 months and should be stored in internal dryconditions at temperatures between 8°C and 25°C.

Precautions

Health and safety


Fire

Nitokit LV and Nitokit TH are non-flammable.

Nitokit Surface Sealant and Fosroc Solvent 105 areflammable. Do not use near naked flames. No Smokingduring use. In the event of fire extinguish with dry powderor CO2. Do not use water jet.

Flash point

Nitokit Surface Sealant: 29°C

Fosroc Solvent 105 43°C

3CI/SfB: Yr4

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Fig 1 Fig 2 Fig 3

Fig 4


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Nitokit is the trademark of Fosroc International Limited

106

Rapid Setting Cementitious Bedding andRepair Mortar

Uses

Fosroc® XR 45 is used for the installation and levelling ofstreet ironwork. It is particularly useful where interruptionto traffic flow must be minimised. It allows the beddingand installation of manhole frames and gulleys and theirreturn to use in less than 45 minutes.

Fosroc® XR 45 can also be used for the emergencyrepair of industrial floors, roads, runways, bridge decksand car park decks.

Advantages

Rapid bedding and levelling of manhole frames

Rapid fixing of signposts and street furnitureRapid deck repairsTrafficable within 1 hourPart bag mixingPre-mixed, only requires addition of clean waterManufactured under an approved BS EN ISO 9001Quality System.


Conforms to Department of Transport Specification,HD27/04.

Design Manual for Roads and Bridges, Vol. 7:Sec 2: 3.11.requirements for rapid repair.

Description

Fosroc® XR 45 is supplied as a ready to use blend ofcements, graded aggregates and additives. It onlyrequires addition of clean water to form a rapid settingmortar. Fosroc® XR45 can be applied in thicknesses from10mm to 75mm in one application.

FOSROC® XR 45 has been specifically formulated forbedding highways ironwork with rapid return to serviceand is particularly useful when temperatures are ex-pected to be at, or just above freezing.

Properties

Property Typical resultCompressive Strength @ 20oC 45 mins:21N/mm2

7 days: >50N/mm2

28 days: >60N/mm2

Compressive Strengthcured @ 5oC 60 mins: 20N/mm2

Tensile strength 3N/mm2

Working life 5 –10 minutes*Setting time 5 –15 minutes*Return to service 45 minutes*Fresh wet density 2200 kg/m³*dependant on temperature

Instructions for use

Preparation


Clean the surface and remove any dust, unsound orcontaminated material, plaster, oil, paint, grease,corrosion deposits or algae. Where breaking out is notrequired, roughen the surface and remove any laitance bylight scabbling or abrasive-blasting.


Where repairs are required due to steel corrosion, thenstandard concrete repair practices should be followed.For more information contact Fosroc.

Substrate priming

Pre-wet the area with clean water and remove anyexcess to leave a damp surface.

Mixing

Mixing should be carried out using gloved hands.Fosroc® XR45 should be added to clean water. Useenough water to initially produce a fluid grout and thenmix in sufficient powder to produce a mortar of therequired consistency. Ensure that all the powder isthoroughly wetted and mixed. 25 kg of dry powderrequires 3.5 litres of clean water. Due to its rapid setcharacteristics do not mix more than can be placed andfinished in 5 minutes. This is typically 3 – 5 kilos. Whensufficient labour is available it can be mixed with a slow

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speed drill and paddle. Due to its rapid setting character-istics the paddle should be cleaned immediately aftereach mixing operation.

When ambient temperature is between 1ºC and 10ºC theuse of warm water up to a maximum of 25ºC is recom-mended.

Application

Apply the mixed Fosroc® XR 45 mortar over the pre-wetted substrate. Apply within 5 minutes of mixing,ensuring maximum contact before the material sets.Level the manhole/gulley frame before the mortar sets.

Cleaning

Fosroc® XR 45 should be removed from tools, equipmentand mixers with clean water immediately after use. Curedmaterial can only be removed mechanically.

LimitationsFosroc® XR 45 should not be used when the temperatureis below 1°C and falling. For cold weather working below5°C, preheat mixing equipment and gauging water to atemperature of 25-30°C,

Large/deep repairs may be subject to cracking. This maybe minimised by limiting repair volumes and reducinglayer thicknesses.

Exposure to heavy rainfall prior to the final set may resultin surface scour. The product should not be exposed tomoving water during application or totally immersed inwater for the first 24 hours after application. If any doubtsarise concerning temperature or substrate conditions,consult the local Fosroc office.

Storage

Store in dry conditions in the original, unopened bags ortubs at between 5°C and 35°C.The product has a shelf life of 6 months if stored asabove. If stored at high temperatures and/or highhumidity conditions the shelf life may be reduced to lessthan 3 months.

Estimating

Supply

25 kg bags

Coverage and yield

Approximately 12.0 litres / 25 kg bag (1.0 m² at 12 mmthickness).Notes: The actual yield per bag of Fosroc® XR 45 willdepend on the consistency used. The coverage figures forliquid products are theoretical — due to wastage factorsand the variety and nature of possible substrates,practical coverage figures will be reduced.

Health & safety

For further information refer to appropriate Product SafetyData Sheet

Fire

Fosroc® XR 45 is non-flammable.


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108

General purpose fast-setting cementitious bedding andrepair mortar.

Uses

FOSROC® XR 90 is used for bedding levelling andinstallation of street ironwork and applications whichrequire high early strength to help reduce road closuretimes.

FOSROC® XR 90 can be used for emergency andgeneral concrete repairs.

Advantages

Rapid strength gain – will accept traffic in 120minutesPre-mixed and bagged material which only requiresthe addition of clean waterLess expensive than epoxy and polyester resinmortarsShrinkage compensated formulationPart bags may be mixedHand or mechanical mixingManufactured under an approved BS EN ISO 9001Quality SystemEasy to use




Description

FOSROC® XR 90 is supplied as a pre-mixed blend ofcements, silica sands and additives, which only requiresmixing with clean water to produce a consistent mortar. Ithas excellent bond strength without the use of a primer

and can be applied in thicknesses of 10mm to 75mm inone application.

FOSROC® XR 90 has been specifically formulated forbedding highway ironwork, with return to service within120 minutes of placing and is particularly useful wheredelays to construction need to be avoided.

FOSROC® XR 90 can be applied in thicknesses of 10mmto 75mm in one application.

Properties

Property Typical resultCompressive Strength@ 20oC 120mins: 20N/mm2

1 day: >30N/mm2

28 days: >50N/mm2

Total chloride ion content 0Tensile strength @ 28 days 3.5N/mm2

Working life 5 -10 minutes*Setting time 10 -15 minutes*Return to service 120 minutes*Fresh wet density 2200 Kg/m3

*dependant on temperature


Preparation



Oil and grease deposits should be removed by steamcleaning, detergent scrubbing or the use of a proprietarydegreaser. The effectiveness of decontamination shouldthen be assessed by a pull-off test..

Substrate priming

Pre-wet the area with clean water and remove anyexcess to leave a damp surface

When used as a repair mortar, an excellent bondstrength can be achieved by mixing FOSROC® XR 90 intoa slurry and using it as a primer immediately prior toapplying FOSROC® XR 90 mortar.

Mixing

Mixing should be carried out using gloved hands. Fosroc®

XR90 should be added to clean water. Use enough water

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to initially produce a fluid grout and then mix in sufficientpowder to produce a mortar of the required consistency.Ensure that all the powder is thoroughly wetted andmixed. 25 kg of dry powder requires 3.5 litres of cleanwater. Due to its rapid set characteristics do not mixmore than can be placed and finished in 5 minutes. Thisis typically 3 – 5 kilos. When sufficient labour is availableit can be mixed with a slow speed drill and paddle. Dueto its rapid setting characteristics the paddle should becleaned immediately after each mixing operation


Application

Apply the mixed FOSROC® XR 90 mortar over the pre-wetted substrate. Apply within 5 minutes of mixing,ensuring maximum contact before the material sets.Level the manhole/gulley frame before the mortar sets

Cleaning

FOSROC® XR 90 should be removed from tools,equipment and mixers with clean water immediately after

Limitations

FOSROC® XR 90 should not be used when thetemperature is below 1°C and falling. Exposure to heavyrainfall prior to the final set may result in surface scour.The product should not be exposed to moving waterduring application or totally immersed in water for the first24 hours after application. If any doubts arise concerningtemperature or substrate conditions, consult the localFosroc office.

Storage

Store in dry conditions in the original, unopened bags ortubs at between 5°C and 35°C.

6 months if stored as above. If stored at hightemperatures and/or high humidity conditions the shelflife may be reduced to less than 3 months.

Estimating

Supply

25 kg bags

Coverage and yield

Approximately 12.0 litres / 25 kg bag (1.0 m² at 12 mmthickness).

Notes: The actual yield per bag of FOSROC® XR 90 willdepend on the consistency used. The coverage figures forliquid products are theoretical — due to wastage factorsand the variety and nature of possible substrates,practical coverage figures will be reduced.

Health & safety


Fire

FOSROC® XR 90 is non-flammable.


FOS/v04-May06/00

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High flow, shrinkage compensated rapid settinggrout

Uses

FOSROC® XR Cobbleset is used for the rapid pointing ofgranite setts, pre-cast concrete stone paviours andslabs. FOSROC® XR Cobbleset is especially beneficialin heavily pedestrianised areas, where a rapid reopeningto the public is required.

Recommended applications include:

Pointing of granite settsFixings bollards and street furnitureGrouting beneath signpost base plates

Advantages

Rapid strength gain – will accept foot traffic in 30minutesPre-mixed and bagged material which only requiresthe addition of clean waterShrinkage compensated formulationExcellent bond strengthEasy to mixManufactured under an approved BS EN ISO 9001Quality System

Description

FOSROC® XR Cobbleset is supplied as a pre-mixedblend of cements, silica sands and additives, which onlyrequire mixing with clean water to produce a consistentmortar. It has excellent bond strength without the use ofa primer and can be applied in thicknesses of 5mm to100mm in one application.

FOSROC® XR Cobbleset has been specificallyformulated for grouting between granite setts with rapid

return to service and is particularly useful when a fastreopening to pedestrians is required.

Technical Service

Fosroc offers a comprehensive range of high quality, highperformance construction products. In addition Fosrocoffers worldwide technical support to specifiers andusers of its products.

Properties

Property Typical resultCompressive Strength @ 20oC 120 mins: 25N/mm2

(BS 1881, Part 116:1983) 7 days: >35N/mm2

28 days: >40N/mm2

Working life 5 –15 minutes*Return to service 30 minutes*Fresh wet density 2.22 Kg/m³*dependant on temperature


Preparation

The granite sett surfaces should be free fromcontamination, oil and any loose material. All loosematerial must be removed from joints to be filled.Blow clean the prepared area with oil-free compressedair. The base must be sound and pre-wetted prior toFOSROC® XR Cobbleset being applied.

Remove all free standing water prior to application.

Mixing

For quantities up to 50 kg a suitable drill and paddle issuitable. Larger quantities will require a mechanicallypowered grout mixer.

The selected water content (between 3.7-3.9 litresdepending on whether grouting is carried out on a levelsurface or slopping area) should be measured into asuitable bucket. Slowly add the total contents of theFOSROC® XR Cobbleset bag, mix continuously for 3minutes ensuring a smooth, even consistency isobtained.

Application

FOSROC® XR Cobbleset can be applied inthicknesses up to 100mm in one pourFOSROC® XR Cobbleset can be applied over smallareas using a watering can or spouted container.For larger areas FOSROC® XR Cobbleset is pouredover the entire area and worked into the joints usinga squeegeeAfter application any excess must be removed fromthe area by a suitable method

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Cleaning

Clean any mixing equipment with water immediatelyafter mixing and prior to the initial setCured material can only be removed mechanicallyWash all tools frequently

Limitations

Temperature

Should not be applied when the substrate and/or airtemperature is 1°C and falling. At 1°C statictemperature or at 1°C and rising, the application mayproceed. If in doubt contact the local Fosroc office.

Never remix or add water.

Storage

Storage conditions


Shelf life

6 months if stored as above. If stored at hightemperatures and/or high humidity conditions the shelflife may be reduced to less than 3 months.

Estimating

Supply 25 kg bagsYield 13 litres approx

Health & safety

Irritating to respiratory system and skinRisk of serious damage to eyesMay cause sensitisation by skin contactDo not breathe dustAvoid contact with eyesWear suitable gloves and eye/face protectionIn case of contact with eyes, rinse immediately withplenty of water. If discomfort continues seek medicaladvice

Fire

FOSROC® XR Cobbleset is non-flammable.


FOS/v03-Mar05/00

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Polyester Resin Mortar for bedding roadironwork where heavily trafficked

Uses

For the rapid installation of manhole frames in Type 1 & 2carriageways. For bedding and fixing kerbstones.Repairing and re-rpofiling precast units

Advantages

Fast development of strength minimises disruptionVersatile mix part packs to consistency requiredNo primer requiredHigh chemical and oil resistanceWill cure down to 0oCManufactured under an approved BS EN ISO 9001Quality SystemMixed by hand or mechanical mixingHigh flexural and tensile strengths




Description

FOSROC® XR PE20 is a two-component material basedon a liquid polyester resin and a powder activator/filler.The consistency of FOSROC® XR PE20 can be variedfrom pourable to trowellable mortar by adjusting the resinto powder ratio, without significant affects on setting timeor strength.

Properties

Bond strength: FOSROC® XR PE20 forms a bond tomost structural materials provided the surfaces aredry and suitably preparedDurability: FOSROC® XR PE20 performs attemperatures as high as 60oC and at sub zerotemperaturesChemical resistance: Fully cured FOSROC® XRPE20 is unaffected by water, petrol, oil and manycorrosive chemicals

Property Typical resultCompressive Strength @ 20oC 1 hour: 50N/mm2

2 hours: >60N/mm2

28 days: >70N/mm2

Tensile strength @ 20oC 28 days: 9N/mm2

Flexural strength @ 20oC 7 days: 20Nmm2

Working life 5-10 minutes*Setting tim 15 minutes*Return to service 60 minutes*Fresh wet density 2140 K/m3

* dependant on temperature


Preparation

For bedding applications:

The surface should be free from contamination, oiland any loose materialThe substrate should be roughened by mechanicalmeans such as grit blasting or scabblingBlow clean the prepared area with oil-freecompressed air

For concrete repair applications:

Saw-cut square the extremities of repair to a depth ofat least 5mm. Break out to a minimum of 5mm up tosawn edge. Clean surface and remove dust and anyother contaminantsExpose any reinforcing steel and remove loosecorrosion, cleaning to a bright condition including thebacks of the bars. Abrasive blasting and highpressure washing of the steel are recommendedBlow clean the prepared area with oil-freecompressed airPrime reinforcing steel with Nitoprime Zincrich Plus.No priming of concrete is required with FOSROC® XRPE20.

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Mixing

Pour the required quantity of liquid resin into the mixingbucket and add the powdered hardener slowly, stirringcontinuously for 3 minutes until a uniform consistency isachieved.

Application

For bedding applications:

Apply the mixed material immediately after mixingDo not try to remix after initial hardening is evidentDo not apply onto wet substrates

For concrete repairs:

Apply by steel trowel, pressing firmly into place forgood adhesion and compaction, compacting wellaround any exposed reinforcing bars. Finish to atight surface with a steel trowelFOSROC® XR PE20 can be applied in sections up to75mm in one layer. Maximum bay size is 0.25m2 anda maximum lineal run of 1 metreDo not apply when the concrete and/or airtemperature is below freezing, or where the surfaceis contaminated with frost or ice

Cleaning

Remove all product from tools with Fosroc Solvent 105immediately after use.

Limitations

FOSROC® XR PE20 should not be applied to damp orwet surfaces where a bond is required, nor should it beexposed to moving water during application. Exposure toheavy rainfall prior to the final set may result in surfacescour.

Apply the mixed FOSROC® XR PE20 immediately aftermixing. Do not re-mix once initial hardening has started.

Do not add water to the mix.

Estimating

Supply 15 kg poly tubsYield 7 litres approx

Storage

Store in dry conditions in original, unopened packs.

Shelf life is 12 months if kept in a dry store in original,unopened packs.

General information

Do not apply to damp or wet surfaces in applicationswhere the bond is critical.

Do not expose to rainfall or moving water prior to the finalset.

Minimum application thickness 5mm.

Health & safety

For further information refer to appropriate ProductSafety Data Sheet.

Flashpoint : 29oC.


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Rapid setting concrete.

Uses

For rapid reinstatement/backfill around manhole framesin roadways and installation of street furniture. FOSROC®

XR RSC is particularly useful where minimum trafficinterruption is required. For the emergency repair andreinstatement of concrete in roads, airfields and factories.

Advantages

Rapid strength gain – will accept traffic in 60 minutesPre-mixed, only requires the addition of clean waterHigh strength, abrasion and weather resistantHand or mechanical mixingSelf compacting, does not require vibratingManufactured under an approved BS EN ISO 9001Quality System

Description

FOSROC® XR RSC is supplied as a ready to use blend ofcements, graded aggregates and additives. It onlyrequires the addition of clean water to form a rapidsetting concrete. FOSROC® XR RSC can be applied inthicknesses from 12mm to 100mm.

Properties

Property Typical resultCompressive strength: 1 hour: 20N/mm2

(BS1881, Pt 116:1983) 7 days: >50N/mm2

@20OC 28 days: >60N/mm2

Working life: 5-10 minutes*

Setting time: 10-15 minutes*

Traffic time: 60 minutes

Fresh wet density: 2200 Kg/m3

* dependent on temperature


Preparation




Substrate priming

Pre-wet the area with clean water and remove anyexcess to leave a damp surface

Mixing

Mixing can be carried out using a spot board and shovelfor one or two bags and slow speed drill and paddle forlarger quantities. A 25 kg bag requires between 2 to 2.7litres of water. When mixing with a drill and paddle placethe water into a suitable mixing container and add thepowder slowly and mix for 2 minutes. Ensure that all thepowder is thoroughly wetted and mixed to a smoothhomogeneous consistency. Due to its rapid set charac-teristics do not mix more than can be placed and finishedin 10 minutes.


Application

At trowellable consistency apply the mixed FOSROC® XRRSC on to the primed substrate as soon as possible aftermixing. The mortar should be applied evenly by trowel andtamped in place with a wood float to ensure fullcompaction. Thoroughly compact the mortar around anyexposed steel reinforcement. FOSROC® XR RSC can beapplied from a minimum of 12 mm to a maximum of 100mm thickness in a single application.

Finishing

FOSROC® XR RSC should be struck off to the correct leveland finished with a steel trowel to fully close the surface. Ifa textured surface is required, this can be achieved usinga suitable roller or brush. The completed surface shouldnot be overworked.

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In cold conditions down to 1°C, the use of warm water (upto 25°C) is advisable to accelerate strength development.Normal precautions for winter working with cementitiousmaterials should then be adopted. The material shouldnot be applied when the substrate and/or air temperatureis 1°C and falling. At 1°C static temperature or at 1°C andrising, the application may proceed.



Curing

FOSROC® XR RSC is a cement-based repair mortar. Incommon with all cementitious materials, FOSROC®

RSCmust be cured immediately after finishing inaccordance with good concrete practice. The use ofNitobond AR or Concure WB, sprayed on to the surface ofthe finished mortar in a continuous film, is recommended.In fast drying conditions, supplementary curing withpolythene sheeting taped down at the edges must beused. In cold conditions, the finished repair must beprotected from freezing.

Cleaning

Clean any mixing equipment with water immediately aftermixing and prior to the initial set. Cured material canonly be removed mechanically.

Limitations

FOSROC® XR RSC should not be used when thetemperature is below 1°C and falling. Exposure to heavyrainfall prior to the final set may result in surface scour.The product should not be exposed to moving waterduring application or totally immersed in water for the first24 hours after application. If any doubts arise concerningtemperature or substrate conditions, consult the localFosroc office.

Estimating

Supply

25 kg bags

Coverage and yield

Approximately 12.0 litres / 25 kg bag (1.0 m² at 12 mmthickness).

Notes: The actual yield per bag of FOSROC® XR RSC willdepend on the consistency used. The coverage figures forliquid products are theoretical — due to wastage factorsand the variety and nature of possible substrates,practical coverage figures will be reduced.

Storage


Shelf life is 6 months if stored as above. If stored at hightemperatures and/or high humidity conditions the shelflife may be reduced to less than 3 months.

Health & safety


Fire

FOSROC® XR RSC is non-flammable


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Clear protective coating system forexposed concrete and masonry

Uses

To protect atmospherically exposed reinforced concretestructures from attack by acid gases, chloride ions,sulphates, oxygen and water. The product is also suitableto protect other cementitious substrates and masonry.Dekguard Clear is suitable for use on all types ofstructures, car parks, commercial and industrialbuildings, subways, underpasses and bridges. It isequally suitable for new and existing structures. DekguardClear is a component of Fosroc’s Renderoc system ofconcrete reinstatement.

Advantages

Highly resistant to weatheringGood barrier to chloride ingressBreatheability allows water vapour to escape fromstructureProvides a barrier to carbon dioxide and otheratmospheric acid gases

Description

The Dekguard Clear system comprises a singlecomponent, penetrating silane-siloxane primer and asingle component clear coating, both ready for immediatesite use.

The primer (Dekguard Primer) is supplied as a clearliquid and is based on a silane-siloxane dissolved in apenetrating organic carrier. The primer is reactive andcapable of producing a chemically-bound hydrophobicbarrier, thus inhibiting the passage of water and water-borne contaminants.

Dekguard Clear is a solvent based clear methacrylatecoating which will provide resistance to aggressiveelements, weathering and rain. A major feature of thesystem is its ability to allow water vapour to escape fromthe structure.


Clear methacrylate protective / weather resistant surfacecoating.

The protective coating shall comprise a penetratingoligomeric siloxane primer and Dekguard Clear, a singlecomponent methacrylate coating. The total dry filmthickness of the system shall not be less than 60 micronsand shall give a reduction in chloride ion penetration notless than 90%.

Properties

The values obtained are for the Dekguard Clear systemapplied at the minimum recommended application rate.

Volume solidsDekguard Clear: 35%Carbon dioxide diffusionresistance (Taywood method).Equivalent thickness of airinitial: 11 m per 18 m d.f.t.Equivalent thickness of30 N/mm² concrete cover(Taywood method): 30 mm per 18 m d.f.t.Water vapour diffusionresistance(Taywood method): SD 0.07 m @ 172 d.f.t.Reduction in chloride ionpenetration (Aston Pagemethod): > 90%Freeze/thaw salt scalingASTM C672 (50 cycles): UnaffectedReduction in waterabsorption ASTM C642: >84%


All coating work to be carried out in accordance with therelevant sections of BS6160:2006, Painting of Buildings -Code of Practice.

Preparation

All surfaces should be dry and free from contaminationsuch as oil, grease, loose particles, decayed matter,moss, algal growth, laitance, and all traces of mouldrelease oils and curing compounds. This is best achievedby lightly grit-blasting the surface. Where moss, algae orsimilar growths have occurred, treatment with aproprietary biocide should be carried out after the grit-blasting process.

Note: If Nitobond AR has been used as a curingmembrane over Renderoc patch repairs, it is notnecessary to remove this prior to the application ofDekguard Clear.

Where application over existing sound coatings isrequired, trials should be conducted to ensurecompatibility and retention of the bond between theunderlying coating and the substrate. For further advice,consult the local Fosroc office.

It is essential to produce an unbroken coating ofDekguard Clear. To ensure this is achieved, surfacescontaining blow-holes or similar areas of pitting should

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first be filled using Renderoc FC, a cementitious fairingcoat. Rougher substrates can be levelled using RenderocRP252, a cementitious reprofiling and protection mortar.Separate data sheets must be referred to beforecommencing overcoating of Renderoc RP252 withDekguard Clear.

Application

In order to obtain the protective properties of theDekguard Clear system, it is important that the correctrates of application and overcoating times are observed.

Dekguard Clear

Number of coats: As necessary to giverequired carbon dioxidediffusion resistance

Theoretical application rate: 0.316 litres/m²/coatMinimum dryfilm thickness: 60 microns per coatOvercoating time at 20°C: 6 hours

Dekguard Primer

Number of coats: Flood coatTheoretical application rate: 0.4 litre/m2

Theoretical dryfilm thickness: N/AOvercoating time at 20°C: 12 hours

Application should not commence if the temperature ofthe substrate is below 2°C.

Any areas of glass and window frames should bemasked. Plants, grass, joint sealants, asphalt andbitumen-painted areas should be protected duringapplication.

The primer should be applied in one or more coats untilthe recommended application rate of 0.4 litre per squaremetre has been achieved. This is best accomplished byusing portable spray equipment of the knapsack-type.Porous surfaces may require the application of NitoprimeDG as an alternative primer, or may require other specialtreatment. Nitoprime DG should be applied at the samecoverage rate as Dekguard Primer but in continuous,multiple coats as necessary. If in doubt about thecondition of the substrate, contact the local Fosroc office.

The primer should be allowed to dry for a minimum of 12hours at 20°C before continuing. Under no circumstancesshould the primer be overcoated with Dekguard Clearuntil the surface is properly dry.

Dekguard Clear may be applied by the use of suitablebrushes, or rollers. For further information aboutapplication techniques, please consult the local Fosrocoffice.

All primed substrates should be treated with DekguardClear top coat. The material should be applied to all areasby the use of suitable brushes or rollers to achieve auniform coating with a wet film thickness not less than300 microns.

Subsequent coats should be applied exactly as detailedabove, again achieving a uniform coating with a wet filmthickness not less than 300 microns per coat. Each coatshould be allowed to dry for not less than 6 hours at 20°C.

Cleaning

Renderoc FC and Renderoc RP252 should be removedfrom tools and equipment with clean water immediatelyafter use. Dekguard Clear and Dekguard Primer shouldbe removed from tools and equipment using FosrocSolvent 102.

Estimating

Supply

Renderoc FC: 25 kg bagsRenderoc RP252: 20 kg bagsRenderoc RP252 surface conditioner: 5 litre bottlesDekguard Primer: 25 litre drumsNitoprime DG: 25 litre drumsDekguard Clear: 25 litre drumsFosroc Solvent 102: 5 and 25 litre tins

Coverage

Renderoc FC: 15 litre (5 m² at 3 mm thick)Renderoc RP252: 12 litre (2.4 m² at 5 mm thick)Dekguard Primer: 2.5 m² per litreNitoprime DG: 2.5 m2 per litreDekguard Clear: 3.2 m² per litre per coat

The coverage figures given are theoretical — due towastage factors and the variety and nature of possiblesubstrates, practical coverage figures will be reduced.

Limitations

The Dekguard Clear system is formulated for applicationto clean, sound concrete or masonry. Where applicationover existing sound coatings or paints is required, trialsshould be conducted to ensure compatibility and retentionof the bond between the underlying coating and thesubstrate. When applied over existing coatings or paints,the performance characteristics of Dekguard Clear maybe impaired. Compatibility and soundness should beassessed on a trial area. For further advice, consultFosroc Technical Department.

The application of the Dekguard Clear System should notcommence if the temperature of the substrate is below 2°C.


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A single coat application may produce a patchyappearance due to variation in the porosity of thesubstrate.

Dekguard Clear should not be applied in windy conditionswhere early-age dust adhesion may occur, or where rainis likely within 2 hours at 20°C or 20 hours at 5°C (up to80% RH). It should not be applied when the prevailingrelative humidity exceeds 90%.

Storage

All products have a shelf life of 12 months if kept in a drystore in the original, unopened packs. Material fromdifferent batches shall be stored separately. If stored athigh temperatures and/or high humidity conditions theshelf life may be reduced.

Precautions

Health and safety


Fire

Dekguard Primer, Dekguard Clear, Nitoprime DG andFosroc Solvent 102 are flammable. Keep away fromsources of ignition. No Smoking. In the event of fire,extinguish with CO2 or foam. Do not use a water jet.

Flash points

Dekguard Clear: 7°CDekguard Primer: 38°CNitoprime DG: 38°CFosroc Solvent 102: 33°C



www.fosroc.com




Dekguard is the trade mark of Fosroc International Limited

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Crack-accommodating elastomericprotective coating for reinforced concretestructures

Uses

To protect atmospherically exposed reinforced concretestructures from attack by acid gases, chloride ions,oxygen and water, especially where there is a danger ofsubsequent cracks appearing within the substrate.Dekguard E2000 is suitable for use on all types ofstructures, including those in coastal environments.

Advantages

Can accommodate substrate cracking up to 2mm andcyclic movement up to 0.3mmExcellent barrier to carbon dioxide, chloride ions,oxygen and waterSpecial acrylic polymer minimises dirt retentionAllows water vapour to escape from the structureResistant to the effects of ultra-violet lightWater-basedRange of decorative colours

Description

The Dekguard E2000 system comprises a singlecomponent penetrating primer and a single componentelastomeric pigmented coating, both ready for immediatesite use.

The system is available with a choice of priming systems,i.e. Nitobond AR or Nitoprime DG. Nitoprime DG, a filmforming stabilising primer may be utilised when chlorideresistance is of primary importance. Nitoprime DG issupplied as a clear liquid and is based on an acrylic resinand a silane-siloxane dissolved in a penetrating organiccarrier. The primer is reactive and capable of producing achemically-bound hydrophobic barrier, thus inhibiting thepassage of water and water-bourne contaminants. A thinsurface film is produced which consolidates andstabilises porous substances.

Nitobond AR may be used where chloride resistance is ofsecondary importance to carbonation resistance.


Crack-accommodating protective/decorative surfacecoating.

The protective coating system shall comprise NitoprimeDG, an acrylic film-forming penetrating siliane-siloxaneprimer and Dekguard E2000, a single componentelastomeric coating suitable for application by brush,roller or spray.

The total dry film thickness must be capable of providingcarbon dioxide diffusion resistance equivalent to not lessthan 50 metres of air and no chloride ion diffusion after

100 days when evuated by the Taywood method. It shallexhibit a water vapour transmission resistance (SD) of notmore than 0.14 metres (by the Klopfer method) at a dryfilm thinkness of 200 microns. It must be capable ofbridging a 2mm incipient crack at 20°C before failurewhen evaluated by the UK BRE method.

Properties

The values obtained are for the Dekguard E2000 systemusing Nitoprime DG applied at the minimumrecommended application rate.

Volume solidsDekguard E2000: 50%Carbon dioxide diffusionresistance (Taywood method).Equivalent thickness of air —Initial: > 50 metresAfter 2000 hours acceleratedweathering: > 50 metresWater vapour diffusionresistance (Klopfer method): SD 0.14 m, 200 dftChloride resistance No chloride ion(Taywood method): diffusion after 100 days

Static crack accommodationcapability (UK BRE method): 2mmDynamic crackaccommodation (cyclic): 0.3mm



Preparation

All surfaces should be dry and free from contaminationsuch as oil, grease, loose particles, decayed matter,moss, algae growth, laitance, and all traces of mouldrelease oils and curing compounds. This is best achievedby lightly grit-blasting the surface. Where moss, algae orsimilar growths have occurred, treatment with aproprietary biocide should be carried out after the grit-blasting process.

If Nitobond AR has been used as a curing membraneover Renderoc patch repairs, it is not necessary to removethis prior to the application of Dekguard E2000.

Where application over existing sound coatings isrequired, trials should be conducted to ensurecompatibility and retention of the bond between theunderlying coating and the substrate. For further advice,consult Fosroc Technical Department.It is essential to produce an unbroken coating ofDekguard E2000. To ensure this is achieved, surfaces

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containing blow-holes or similar areas of pitting shouldfirst be filled using Renderoc FC, a cementitious fairingcoat. Rougher substrates can be levelled using RenderocRP252, a cementitious reprofiling and protection mortar.Separate data sheets must be referred to beforecommencing overcoating of Renderoc RP252 withDekguard E2000.

Application

In order to obtain the protective properties of the DekguardE2000 system, it is important that the correct rates ofapplication and overcoating times are observed.

Where more than one batch of material is to be used,restrict use of batch to whole separate elevations. Contactlocal Fosroc Office for further details.D

Nitoprime DG

Number of coats: Flood coatTheoretical applicationrate per coat: 0.4 litres/m2

Theoretical wet filmthickness per coat: N/AOvercoating time: 12 hours @ 20°C

Nitobond AR

Number of coats: 1 or 2Theoretical applicationrate per coat: 0.15 litres/m2

Theoretical wet filmthickness per coat: 150 micronsOvercoating time: 12 hours @ 20°C

Dekguard E2000

Number of coats: 1Theoretical applicationrate per coat: 0.4 litres/m2

Theoretical wet filmthickness per coat: 400 microns

Application of Nitoprime DG should not commence if thetemperature of the substrate is below 2°C. Application ofDekguard E2000 should not commence if thetemperature of the substrate is below 5°C.


The Nitoprime DG should be applied in one or more coatsuntil the recommended application rate of 0.4 litre persquare metre has been achieved. This is bestaccomplished by using portable spray equipment of the

knapsack-type. A uniform surface appearance (sheen)should be achieved. If any matt porous patches remain, afurther application of primer should be made.

The primer should be allowed to dry for a minimum of 12hours (at 20°C), longer at lower temperatures, beforecontinuing. Under no circumstances should the primer beovercoated with Dekguard E2000 until the surface isproperly dry.

Dekguard E2000 may be applied by the use of suitablebrushes, rollers or spray equipment. For furtherinformation about application techniques, please consultFosroc Technical Department.

All primed substrates should be treated with one coat ofDekguard E2000. It is important that no gaps or ‘rawedges’ appear in the finished coating. Special careshould be taken to provide an unbroken coating atexternal corners and similar exposed protrusions. Thisshould be applied to all areas by the use of suitablebrushes or rollers to achieve a uniform coating with a wetfilm thickness not less than 400 microns. It should beallowed to dry until firm to the touch. Typically, this will beafter about 16 hours in dry weather at 20°C.

Cleaning

Renderoc FC, Renderoc RP252, Dekguard E2000 andNitobond AR should be removed from tools andequipment with clean water immediately after use.Nitoprime DG should be removed from tools andequipment using Fosroc Solvent 102.

Estimating

Supply

Renderoc FC: 25kg bagsRenderoc RP252: 20kg bagsNitoprime DG: 25 litre drumsNitobond AR: 25 litre drumsDekguard E2000: 10 litre drumsFosroc Solvent 102: 5 litre drums

Coverage

Renderoc FC: 15 litres (5 m2 at 3mm thickness)Renderoc RP252: 12 litres (2.4 m2 at 5mmthickness)Nitoprime DG: 2.5 m2 / litre (total)Nitobond AR: 6 to 8m2 / litreDekguard E2000: 2.5m2 / litre (total)



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Limitations

The Dekguard E2000 system is formulated for applicationto clean, sound concrete or masonry. Where applicationover existing sound coatings or paints is required, trialsshould be conducted to ensure compatibility and retentionof the bond between the underlying coating and thesubstrate. When applied over existing coatings or paints,the performance characteristics of Dekguard E2000 maybe impaired and its fire rating invalidated. Compatibilityand soundness should be assessed on a trial area. Forfurther advice, consult Fosroc Technical Department.

Application of Nitoprime DG should not commence if thetemperature of the substrate is below 2°C. Application ofNitobond AR and Dekguard E2000 should not commenceif the temperature of the substrate is below 5°C.

Dekguard E2000 and Nitobond AR should not be appliedwhere there is a likelihood of exposure to frost within 48hours of the application. The product should not beapplied in windy conditions where early-age dustadhesion may occur, or where rain is likely within 2 hoursat 20°C or 20 hours at 5°C (up to 80% RH). It should notbe applied when the prevailing relative humidity exceeds90%.

The use of Dekguard E2000 should not be considered forareas subjected to ponded water. Dekguard E2000 isunsuitable for use in areas subject to direct physicalattack by vandals. Where appropriate, Dekguard S orGraffitiguard should be considered.

The manufacture of Dekguard coatings is a batch processand despite close manufacturing tolerances variation mayoccur between batches. Fosroc recommends usingmaterial from one batch only as the finish topcoat.

Storage

Store in cool, dry conditions, away from sources of heatand naked flames, in the original, unopened packs.Dekguard E2000 should be protected from frost.

All products have a shelf life of 12 months if kept in a drystore in the original, unopened packs. Material from

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different batches shall be stored separately. If stored athigh temperatures and/or high humidity conditions theshelf life may be reduced.

Precautions

Health and safety


Fire

Renderoc FC, Renderoc RP252, Nitobond AR andDekguard E2000 are non-flammable.

Nitoprime DG and Fosroc Solvent 102 are flammable.Keep away from sources of ignition. No Smoking. In theevent of fire, extinguish with CO2 or foam. Do not use awater jet.

Flash points

Nitoprime DG: 38°CFosroc Solvent 102: 33°C




www.fosroc.com




122

High performance crack-accommodatingelastomeric acrylic protective anddecorative coating for concrete andmasonry

Uses

To protect atmospherically exposed reinforced concretestructures from attack by acid gases, chloride ions,oxygen and water, especially where there is a danger ofsubsequent cracks appearing within the substrate. Theproduct is also suitable to protect other cementitioussubstrates and masonry. Dekguard Elastic is suitable foruse on all types of structures, including those in coastalenvironments. It is equally suitable for new and existingstructures. Dekguard Elastic is a component of Fosroc’sRenderoc system of concrete reinstatement.

Advantages

Can accommodate substrate cracking up to 6mm andcyclic movement up to 1mmTrue elastomeric coating with excellent elongation andrecovery properties which are maintained at sub-zerotemperaturesExcellent barrier to carbon dioxide, chloride ions,oxygen and waterSpecial acrylic polymer minimises dirt retentionAllows water vapour to escape from the structureUV-resistant with high resistance to the effects of long-term weatheringWater-basedWide range of decorative colours

Description

The Dekguard Elastic system comprises a singlecomponent penetrating primer and a single componentelastomeric pigmented coating, both ready for immediatesite use.

The film-forming, stabilising primer (Nitoprime DG) issupplied as a clear liquid and is based on an acrylic resinand a silane-siloxane dissolved in a penetrating organiccarrier. The primer is reactive and capable of producing achemically-bound hydrophobic barrier, thus inhibiting thepassage of water and water-borne contaminants. A thinsurface film is produced which consolidates andstabilises porous substrates.

Dekguard Elastic is an elastomeric, water basedprotective coating based on a special acrylic polymer. Itprovides excellent elongation and recovery, low dirt pick-up, resistance to aggressive elements, UV light and rain.It is available in a wide range of colours.


Dekguard Elastic has been approved by the British Boardof Agrément under Certificate No. 98/3461.

Fire tested to BS 476, Pt 7: 1987. Spread of flame -Class 1.

Fire tested to BS 476, Pt 6: 1989. Propagationindex I — 0.0. Sub index i1 — 0.0. Building Regulationsrating — Class 0.


Elastomeric protective/decorative surfacecoating

The protective coating system shall comprise NitoprimeDG, an acrylic film-forming penetrating silane-siloxaneprimer and Dekguard Elastic, a single componentelastomeric coating suitable for application by brush,roller or spray. The total dry film thickness of the coatingshall be not less than 400 microns and shall be capableof providing carbon dioxide diffusion resistance equivalentto not less than 125 mm of 30N/mm2 concrete cover (bythe Taywood method) and a reduction in chloride ionpenetration not less than 99% (by the Aston UniversityDiffusion Cell method).

It must exhibit a water vapour transmission resistance(SD) of not more than 0.11 metres (by the Klopfer method)at a dry film thickness of 400 microns.

The coating must be capable of withstanding 20,0000mm – 1mm – 0mm cycles at 20°C without failure. Instatic testing, it must be capable of bridging an 6 mmincipient crack @ 20°C before failure and a 4 mm incipientcrack @ 0°C before failure. When tested to BS 476, Pt 7 :1987, it must exhibit a Class 1 spread of flame andachieve a Class 0 Building Regulations rating whentested to BS 476, Pt 6 : 1989 and Pt 7 : 1987.

Properties

The values obtained are for the Dekguard Elastic systemapplied at the minimum recommended application rate.

Volume solids Dekguard Elastic: 49%Carbon dioxide diffusionresistance (BRE method).Equivalent thickness of air —Initial: > 100 metresAfter 2000 hours QUV: > 100 metresEquivalent thickness of30 N/mm2 concrete cover(Taywood method): > 125 mmWater vapour diffusion SD 0.11 m @resistance (Klopfer method): 400 microns dftReduction in chloride ionpenetration (Aston UniversityDiffusion Cell method): > 99%

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Incipient crack spanning capability@ 400 microns dft — static test(ASTM C836-84modified)

20°C: 6 mm0°C: 4 mm

–15°C: 1.3 mmDynamic crack bridging capability0 mm - 1 mm - 0 mm cycling

20°C: 20,000 cycles (no failure) 0°C: 15,000 cycles (no failure)–5°C: 4,000 cycles (no failure)

Tear resistance (ASTM D624-84): 12 N/mm2

Fire testing (BS 476, Pt 7: 1987) —Spread of flame: Class 1Fire testing (BS 476, Pt 6: 1989) —Propagation index I: 0.0Sub index i1: 0.0Building Regulations rating: Class 0



Preparation

All surfaces should be dry and free from contaminationsuch as oil, grease, loose particles, decayed matter,moss, algal growth, laitance, and all traces of mouldrelease oils and curing compounds. This is best achievedby lightly grit-blasting the surface. Where moss, algae orsimilar growths have occurred, treatment with a proprietarybiocide should be carried out after the grit-blasting process.

If Nitobond AR has been used as a curing membrane overRenderoc patch repairs, it is not necessary to remove thisprior to the application of Dekguard Elastic.

Where application over existing sound coatings isrequired, trials should be conducted to ensurecompatibility and retention of the bond between theunderlying coating and the substrate. For further advice,consult Fosroc Customer Services Department.It is essential to produce an unbroken coating of DekguardElastic. To ensure this is achieved, surfaces containingblow-holes or similar areas of pitting should first be filledusing Renderoc FC, a cementitious fairing coat. Roughersubstrates can be levelled using Renderoc RP252, acementitious reprofiling and protection mortar. Separatedata sheets must be referred to before commencingovercoating of Renderoc RP252 with Dekguard Elastic.

Application

In order to obtain the protective properties of the DekguardElastic system, it is important that the correct rates ofapplication and overcoating times are observed.

Where more than one batch of material is to be used,restrict use of batch to whole separate elevations. Contactlocal Fosroc Office for further details.

Nitoprime DG Dekguard Elastic

Number of coats: Flood coat 2Theoretical applicationrate per coat: 0.4 litres/m2 0.4 litres/m2

Theoretical wet filmthickness per coat: N/A 400 micronsOvercoating time: 12 hours @ 20°C when firm to the

touch

Application of Nitoprime DG should not commence if thetemperature of the substrate is below 2°C. Application ofDekguard Elastic should not commence if thetemperature of the substrate is below 5°C.

Any areas of glass or window frames should be masked.Plants, grass, joint sealants, asphalt and bitumen-paintedareas should be protected during application.

Apply Nitoprime DG in one or more coats until therecommended application rate of 0.4 litre per squaremetre has been achieved. This is best accomplished byusing portable spray equipment of the knapsack-type. Auniform surface appearance (sheen) should be achieved.If any matt porous patches remain, a further application ofprimer should be made.

Allow the primer to dry for a minimum of 12 hours (at20°C), longer at lower temperatures. Under nocircumstances should the primer be overcoated withDekguard Elastic until the surface is properly dry.

Dekguard Elastic may be applied by the use of suitablebrushes, rollers or spray equipment. For furtherinformation about application techniques, please consultFosroc Technical Department.

All primed substrates should be treated with two coats ofDekguard Elastic. It is important that no gaps or ‘raw edges’appear in the finished coating. Special care should betaken to provide an unbroken coating at external cornersand similar exposed protrusions. Apply the first coat to allareas until a uniform coating with a wet film thickness notless than 400 microns is achieved. Allow to dry until firm tothe touch. Typically, this will be after about 16 hours in dryweather at 20°C.

Apply the second coat of Dekguard Elastic as above.

Under poor drying conditions at low temperatures it maybe more practical to apply three thinner coats (270microns wet film thickness each) of Dekguard Elastic toachieve better ‘through-drying’. This method will achievethe correct recommended dry film thickness.

CleaningRenderoc FC and Dekguard Elastic should be removedfrom tools and equipment with clean water immediately


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after use. Nitoprime DG should be removed from toolsand equipment using Fosroc Solvent 102.

Estimating

Supply

Renderoc FC: 25kg bagsRenderoc RP252: 25kg bagsNitoprime DG: 25 litre drumsDekguard Elastic: 10 litre drumsFosroc Solvent 102: 5 litre drums

Coverage

Renderoc FC: 15 litres (5 m2 at 3 mm thickness)Renderoc RP252: 12 litres (4 m2 at 3 mm thickness)Nitoprime DG: 2.5 m2 per litreDekguard Elastic: 2.5 m2 per litre per coat


Limitations

Where application over existing sound coatings or paintsis required, trials should be conducted to ensurecompatibility and retention of the bond between theunderlying coating and the substrate. When applied overexisting coatings or paints, the performancecharacteristics of Dekguard Elastic may be impaired andits fire rating invalidated. Compatibility and soundnessshould be assessed on a trial area. For further advice,consult Fosroc Customer Services Department.

Application of Nitoprime DG should not commence if thetemperature of the substrate is below 2°C. Application ofDekguard Elastic should not commence if thetemperature of the substrate is below 5°C.

Dekguard Elastic should not be applied where there is alikelihood of exposure to frost within 48 hours ofapplication. Do not appy in windy conditions where early-age dust adhesion may occur, or where rain is likelywithin 2 hours at 20°C or 20 hours at 5°C (up to 80% RH).It should not be applied when the prevailing relativehumidity exceeds 90%.

Dekguard Elastic should not be considered for areas

subjected to exposure to ponded water. In such casesuse Dekguard S.

The elastomeric properties and high tear strength ofDekguard Elastic make it unsuitable for use in areassubject to direct physical attack by vandals. Whereappropriate, Dekguard S should be considered.

Dekguard Elastic should not be used on soffits subject topossible water ingress. In these cases use Dekguard S or W.


Storage

Store in cool, dry conditions, away from sources of heat andnaked flames, in the original, unopened packs. DekguardElastic should be protected from frost. All products have ashelf life of 12 months if kept in a dry store in the original,unopened packs. Material from different batches shall bestored separately.


Precautions

Health and safety


Fire

Renderoc FC, Renderoc RP252 and Dekguard Elastic arenon-flammable.

Nitoprime DG and Fosroc Solvent 102 are flammable. Keepaway from sources of ignition. No Smoking. In the event offire, extinguish with CO2 or foam. Do not use a water jet.

Flash points

Nitoprime DG: 38°CFosroc Solvent 102: 33°C


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125

High performance aliphatic acrylicprotective and decorative coating forconcrete and masonry

Uses

To protect atmospherically exposed reinforced concretestructures from attack by acid gases, chloride ions,sulphates, oxygen and water. The product is also suitableto protect other cementitious substrates and masonry.Dekguard S is suitable for use on all types of structures,especially those in aggressive marine and coastalenvironments. It is equally suitable for new and existingstructures. Dekguard S is a component of Fosroc’sRenderoc system of concrete reinstatement.

Advantages

Excellent barrier to carbon dioxide, chloride ions,sulphates, oxygen and waterAllows water vapour to escape from the structureHighly UV-resistant aliphatic acrylic gives exceptionalresistance to the effects of long-term weatheringHighly durable in all climatic conditionsWide range of decorative coloursExcellent resistance to dirt pick-up

Description

The Dekguard S system comprises a single component,penetrating silane-siloxane primer and a single componentpigmented coating, both ready for immediate site use.

The primer (Dekguard Primer) is supplied as a clearliquid and is based on a silane-siloxane dissolved in apenetrating organic carrier. The primer is reactive andcapable of producing a chemically-bound hydrophobicbarrier, thus inhibiting the passage of water and water-borne contaminants.

Dekguard S is an aliphatic acrylate, solvent based,protective coating, providing outstanding resistance toaggressive elements, UV light and rain. It is available in awide range of colours.


Dekguard S has been approved by the British Board ofAgrément under Certificate No. 98/3461.

Fire tested to BS 476, Pt 7:1987. Spread of flame - Class 1.

Fire tested to BS 476, Pt 6:1989. Propagation index I - 1.5.Sub index i1 - 1.3. Building Regulations rating - Class 0.


Protective/decorative surface coating

The protective coating shall comprise a penetratingsilane-siloxane primer and Dekguard S, a single

component aliphatic acrylic coating. The total dry filmthickness of the coating shall be not less than 150microns and shall be capable of providing carbon dioxidediffusion resistance equivalent to not less than 650 mm of30 N/mm2 concrete cover (by the Taywood method). Itshall provide a reduction in chloride ion penetration notless than 99% (by the Aston University Diffusion Cellmethod) and no chloride ion diffusion after 600 days (bythe Taywood method). It must exhibit a water vapourtransmission resistance (SD) of not more than 0.98metres (by the Taywood method) at a dry film thickness of150 microns. When tested to BS 476, Pt 7:1987, it mustexhibit a Class 1 spread of flame and achieve a Class 0Building Regulations rating when tested to BS 476, Pt6:1989 and Pt 7:1987.

Properties

The values obtained are for the Dekguard S systemapplied at the minimum recommended application rate.

Volume solidsDekguard S: 43%Carbon dioxide diffusion resistance(Taywood method). Equivalentthickness of air —Initial: >250 metres2,000 hours QUV weathered: >250 metresEquivalent thickness of30 N/mm2 concrete cover(Taywood method): >650 mmWater vapour diffusion resistance(Taywood method): SD 0.98 m @

150 microns dftReduction in chloride ion penetration(Aston University Diffusion Cell method) : >99%

Chloride ion diffusion coefficient No chloride ion(Taywood method): diffusion

after 6002,000 hours QUV weathered days immersionFreeze/thaw salt scaling (50 cycles) —(ASTM C672-84): UnaffectedGood quality concrete (control): Severe scalingFire testing (BS 476, Pt 7 :1987) —Spread of flame: Class 1Fire testing (BS 476, Pt 6 :1989) —Propagation index I: 1.5Sub index i1: 1.3Building Regulations rating: Class 0

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Preparation

All surfaces should be dry and free from contaminationsuch as oil, grease, loose particles, decayed matter,moss, algal growth, laitance, and all traces of mouldrelease oils and curing compounds. This is best achievedby lightly grit-blasting the surface. Where moss, algae orsimilar growths have occurred, treatment with aproprietary biocide should be carried out after the grit-blasting process.

If Nitobond AR has been used as a curing membraneover Renderoc patch repairs, it is not necessary to removethis prior to the application of Dekguard S.

Where application over existing sound coatings is required,trials should be conducted to ensure compatibility andretention of the bond between the underlying coating andthe substrate. For further advice, consult Fosroc TechnicalDepartment.

It is essential to produce an unbroken coating of DekguardS. To ensure this is achieved, surfaces containing blow-holes or similar areas of pitting should first be filled usingRenderoc FC, a cementitious fairing coat. Roughersubstrates can be levelled using Renderoc RP252, acementitious reprofiling and protection mortar. Separatedata sheets must be referred to before commencingovercoating of Renderoc RP252 with Dekguard S.

Application

In order to obtain the protective properties of theDekguard S system, it is important that the correct ratesof application and overcoating times are observed.

Where more than one batch of material is to be used,restrict use of batch to whole separate elevations. Contactlocal Fosroc Office for further details.

Dekguard Primer Dekguard SNumber of coats: Flood coat 2Theoretical applicationrate per coat: 0.4 litres/m2 0.175 litres m2

Theoretical wet filmthickness per coat: N/A 175 micronsOvercoating time —@ 20°C: 12 hours 6 hours

Application should not commence if the temperature ofthe substrate is below 2°C.


The primer should be applied in one or more coats untilthe recommended application rate of 0.4 litre per squaremetre has been achieved. This is best accomplished byusing portable spray equipment of the knapsack-type.Porous surfaces may require the application of NitoprimeDG as an alternative primer, or may require other specialtreatment. Nitoprime DG should be applied at the samecoverage rate as Dekguard Primer but in continuous,multiple coats as necessary. If in doubt about the conditionof the substrate, contact Fosroc Technical Department.

The primer should be allowed to dry for a minimum of 12hours (at 20°C), longer at lower temperature, beforeapplication of Dekguard S. Under no circumstances shouldthe primer be overcoated until the surface is properly dry.

All primed substrates should be treated with two coats ofDekguard S. The material should be stirred thoroughlybefore use. The first coat should be applied to all areas bythe use of suitable brushes or rollers to achieve a uniformcoating with a wet film thickness not less than 175 microns.This coat should be allowed to dry before continuing.

The second coat of Dekguard S should be applied exactlyas detailed above, again achieving a wet film thicknessnot less than 175 microns.

Cleaning

Renderoc FC and Renderoc RP252 should be removedfrom tools and equipment with clean water immediatelyafter use. Dekguard Primer, Nitoprime DG and DekguardS should be removed from tools and equipment usingFosroc Solvent 102.

Estimating

Supply

Dekguard S: 10 litre drumsDekguard Primer: 25 litre drumsNitoprime DG: 25 litre drumsNitobond AR: 5 and 25 litre drumsFosroc Solvent 102: 5 and 25 litre tins

Coverage

Dekguard S: 6 m2 per litre per coatDekguard Primer: 2.5 m2 per litreNitoprime DG: 2.5 m2 per litreNitobond AR: 6 m2 per litre




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Limitations

The Dekguard S system is formulated for application toclean, sound concrete or masonry. Where application overexisting sound coatings or paints is required, trials shouldbe conducted to ensure compatibility and retention of thebond between the underlying coating and the substrate.When applied over existing coatings or paints, theperformance characteristics of Dekguard S may beimpaired and its fire rating invalidated. Compatibility andsoundness should be assessed on a trial area. Forfurther advice, consult Fosroc Technical Department.

Application of Dekguard S, Dekguard Primer or NitoprimeDG should not commence if the temperature of thesubstrate is below 2°C. Nitobond AR application shouldnot commence if the temperature of the substrate isbelow 5°C.


Storage

Store in cool, dry conditions, away from sources of heatand naked flames, in the original, unopened packs.

All products have a shelf life of 12 months if kept in a drystore in the original, unopened packs. Material fromdifferent batches shall be stored separately.


Precautions

Health and safety


Fire

Renderoc FC, Renderoc RP252 and Renderoc RP252surface conditioner are non-flammable. Dekguard Primer,Nitoprime DG, Dekguard S and Fosroc Solvent 102 areflammable. Keep away from sources of ignition. NoSmoking. In the event of fire, extinguish with CO2 or foam.Do not use a water jet.

Flash points

Dekguard Primer: 38°CNitoprime DG: 38°CDekguard S: 42°CFosroc Solvent 102: 33°C




www.fosroc.com





128

Textured weather-resistant coating systemfor exposed concrete and masonry

Uses

To enhance the appearance of exposed reinforcedconcrete. Suitable for use on all types of structures bothnew and existing. Dekguard Textured is a component ofthe Renderoc system of concrete reinstatement.

Advantages

High resistance to the effects of long-term weatheringand durable in all climatic conditionsAllows water vapour to escape from the structureWater basedChoice of water based or solvented primersWide range of decorative coloursHelps disguise patchy or unsightly substratesCan be used in combination with Dekguard S toobtain protection against acid gases, chloride ions,oxygen and water

Description

Dekguard Textured is a water based coating with atextured surface profile.

The Dekguard Textured system comprises a singlecomponent, penetrating silane-siloxane primer and asingle component pigmented coating which provides atextured surface finish. Both components are ready foron-site use.

The primer (Dekguard Primer) is supplied as a clearliquid and is based on a silane-siloxane dissolved in apenetrating organic carrier. The primer is reactive andcapable of producing a chemically bound hydrophobicbarrier, thus inhibiting the passage of water andwaterborne contaminants.

Dekguard Textured is a textured water based protectivecoating based on a special acrylic polymer. It provideslow dirt pick-up, resistance to aggressive elements, UVlight and rain. It is available in a wide range of colours.

Specification Clauses

Protective/decorative surface coatings

The weather-resistant coating shall be the DekguardTextured system, comprising a silane-siloxane primerand a water based, single component, pigmentedtextured coating.

The finished coating shall be unbroken andrepresentative of the texture approved from a site appliedsample panel and/or as agreed with the ContractAdministrator.



Preparation

All surfaces should be dry and free from contaminationsuch as oil, grease, loose particles, decayed matter,moss, algal growth, laitance, and all traces of mouldrelease oils and curing compounds. This is bestachieved by lightly grit blasting the surface. Where moss,algae or similar growths have occurred, treatment with aproprietary biocide should be carried out after the gritblasting process.


It is essential to produce an unbroken coating ofDekguard Textured. To ensure this is achieved, surfacescontaining blow-holes or similar areas of pitting shouldfirst be filled using Renderoc FC, a cementitious fairingcoat. Rougher substrates can be levelled usingRenderoc RP252, a cementitious reprofiling andprotection mortar. Separate data sheets must be referredto before commencing overcoating of Renderoc RP252with Dekguard Textured.

Application

In order to obtain the full properties of the DekguardTextured system, it is important that the correct rates ofapplication and overcoating time are observed.

Where more than one batch of material is to be used,restrict use of batch to whole separate elevations.Contact local Fosroc Office for further details.

Dekguard DekguardPrimer Textured

Number of coats: Flood coat 1Theoretical applicationrate per coat 0.4 litres/m² 0.5 litres/m²Thoretical wet filmthickness per coat: N/A 500 micronsOvercoating time@ 20°C: 12 hours N/A

Any areas of glass or window frames should be masked.Plants, grass, joint sealants, asphalt and bitumen-painted areas should be protected during application.

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Fosroc®Dekguard Textured

The primer should be applied in one or more coats untilthe recommended application rate of 0.4 litre per squaremetre has been achieved. This is best accomplished byusing portable spray equipment of the knapsack-type.Porous surfaces may require the application of NitoprimeDG as an alternative primer, or may require other specialtreatment. Nitoprime DG should be applied at the samecoverage rate as Dekguard Primer but in continuous,multiple coats as necessary. If in doubt about thecondition of the substrate, consult the local Fosroc office.

The primer should be allowed to dry for a minimum of 12hours (at 20°C) longer at lower temperature, beforeapplication of Dekguard Textured. Under nocircumstances should the primer be overcoated until thesurface is properly dry.

All primed substrates should be treated with one coat ofDekguard Textured. Stir the material thoroughly beforeuse. Apply to all areas by the use of suitable brushes orrollers to achieve a uniform coating with a wet filmthickness not less than 500 microns. Achieve the desiredtexture with a suitable roller. Care must be taken toensure that a uniform coverage rate is achieved. Non-uniform coverage may provide varying textures.

Cleaning

Renderoc FC, Renderoc RP252 and Dekguard Texturedshould be removed from tools and equipment with cleanwater immediately after use. Dekguard Primer andNitoprime DG should be removed from tools andequipment using Fosroc Solvent 12.

Estimating Supply

Renderoc FC: 25 kg bagsRenderoc RP252: 20 kg bagsDekguard Primer 25 litre drumsNitoprime DG: 25 litre drumsDekguard Textured: 10 litre drumsFosroc Solvent 102: 5 litre drums

Coverage

Renderoc FC: 15 litres (5 m2 at 3 mm thickness)Renderoc RP252 : 12 litres (4 m2 at 3 mm thickness)Nitoprime DG: 2.5 m² per litre (total)Dekguard Textured: 2 m² per litre

The coverage figure given is theoretical — due towastage factors and the variety and nature of possiblesubstrates, practical coverage figures will be reduced.

Limitations

Where application over existing sound coatings or paintsis required, trials should be conducted to ensurecompatibility and retention of the bond between theunderlying coating and the substrate. When applied overexisting coatings or paints, the performancecharacteristics of Dekguard Textured may be impaired.Compatibility and soundness should be assessed on atrial area. For further advice, consult the local Fosrocoffice.

The application of Dekguard Textured should notcommence if the temperature of the substrate is below5°C.

Dekguard Textured should not be applied where there isa likelihood of exposure to frost within 48 hours of theapplication, or in windy conditions where early-age dustadhesion may occur, or where rain is likely within 2 hoursat 20°C or 20 hours at 5°C (up to 80% RH). DekguardTextured should not be applied when the prevailingrelative humidity exceeds 90%.

Dekguard Textured should not be considered for areassubjected to exposure to ponded water. Use Dekguard Swhere occasional ponded water is anticipated.

Where protection against the ingress of atmosphericacid gases is required, a single application of DekguardS should be made in between the primer and applicationof the textured top coat. For further details on DekguardS, refer to separate data sheet.

The manufacture of Dekguard coatings is a batchprocess and despite close manufacturing tolerancesvariation may occur between batches. Fosrocrecommends using material from one batch only as thefinish topcoat.

Storage

Store in cool, dry conditions, away from sources of heatand naked flames, in the original, unopened packs.Material from different batches shall be storedseparately. Dekguard Textured should be protected fromfrost.

Dekguard Textured has a shelf life of 12 months if kept ina dry store in the original, unopened container. If storedat high temperatures and/or high humidity conditions theshelf life may be reduced.



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Fosroc LimitedColeshill Road, Tamworth,Staffordshire B78 3TL. UK

www.fosroc.com



Precautions

Health and safety


Fire

Nitoprime DG: Flash Point 38 °CDekguard Primer: Flash Point 38 °C

Dekguard Textured :non-flammable



131

Water-based acrylic copolymer protectiveand decorative coating for concrete andmasonry

Uses

To protect atmospherically exposed reinforced concretestructures, cementitious substrates and masonry fromaggressive elements, weathering and rain. Dekguard Wis suitable for use on all types of structures, includingthose in coastal environments. It is equally suitable fornew and existing structures. Dekguard W is a componentof Fosroc’s Renderoc system of concrete reinstatement.

Advantages

Excellent barrier to carbon dioxide, chloride ions,oxygen and waterAllows water vapour to escape from the structureHigh resistance to the effects of long-term weatheringand durable in all climatic conditionsWater-basedWide range of decorative colours


Fire tested to BS 476, Pt 6: 1987. Spread of flame -Class 0.Fire tested to BS 476, Pt 7: 1987. Spread of flame -Class 1.

Description

The Dekguard W system comprises a single component,penetrating silane-siloxane primer and a single componentpigmented coating, both ready for immediate site use.

A range of reactive primers are available to suit substrateporosity and site conditions and inhibit the passage ofwater and waterborne contaminants.


Protective/decorative surface coating

The protective coating shall comprise a penetratingsilane-siloxane primer and Dekguard W, a singlecomponent aliphatic acrylic coating. The total dry filmthickness of the coating shall be not less than 150microns and shall be capable of providing carbon dioxidediffusion resistance equivalent to not less than 279 mm of30 N/mm2 concrete cover (by the Taywood method). Itshall provide a reduction in chloride ion penetration notless than 84% (by the Aston University Diffusion Cellmethod) and no chloride ion diffusion after 600 days (bythe Taywood method). It must exhibit a water vapourtransmission resistance (SD) of not more than 0.066metres (by the Taywood method) at a dry film thickness of150 microns.

When tested to BS 476, Pt 7:1987, it must exhibit a Class1 spread of flame and achieve a Class 0 BuildingRegulations rating when tested to BS 476, Pt 6:1989 andPt 7:1987.

Properties

The values obtained are for the Dekguard Wsystem applied in two coats at the minimumrecommended application rate.

Volume solidsDekguard W: 41%Carbon dioxide diffusion resistance(Taywood method). Equivalentthickness of airInitial: 133 metresAfter 2000 hours QUV: 91 metresEquivalent thickness of30 N/mm² concrete cover(Taywood method): 279 mmWater vapour diffusion resistance SD 0.066 m @(Taywood method): 50 microns dftReduction in chloride ionpenetration when primer is used(Aston University Diffusion Cell method): > 84%Fire testing (BS 476, Pt 7: 1987) Class 1Spread of flame:



Preparation

All surfaces should be dry and free from contaminationsuch as oil, grease, loose particles, decayed matter,moss, algal growth, laitance and all traces of mouldrelease oils and curing compounds. This is best achievedby lightly grit-blasting the surface. Where moss, algae orsimilar growths have occurred, treatment with aproprietary biocide should be carried out after the grit-blasting process.

If Nitobond AR has been used as a curing membraneover Renderoc patch repairs, it is not necessary to removethis prior to the application of Dekguard W.


Fosroc® Dekguard W constructive solutions

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It is essential to produce an unbroken coating ofDekguard W. To ensure this is achieved, surfacescontaining blow-holes or similar areas of pitting shouldfirst be filled using Renderoc FC, a cementitious fairingcoat. Rougher substrates can be levelled using RenderocRP252, a cementitious reprofiling and protection mortar.Separate data sheets must be referred to beforecommencing overcoating of Renderoc RP252 withDekguard W.

Application

In order to obtain the protective properties of the DekguardW system, it is important that the correct rates ofapplication and overcoating times are observed.

Where more than one batch of material is to be used,restrict use of batch to whole separate elevations.Contact local Fosroc Office for further details.

Dekguard DekguardPrimer W

Number of coats: Flood coat 2Theoretical applicationrate per coat: 0.4 litres/m2 0.18 litres/m2

Theoretical wet filmthickness per coat: N/A 180 micronsOvercoating time @ 20°C: 12 hours 16 hours


The primer should be applied in one or more coats untilthe recommended application rate of 0.4 litre per squaremetre has been achieved. This is best accomplished byusing portable spray equipment of the knapsack-type.Porous surfaces may require the application of NitoprimeDG as an alternative primer, or may require other specialtreatment. Nitoprime DG should be applied at the samecoverage rate as Dekguard Primer but in continuous,multiple coats as necessary. If in doubt about thecondition of the substrate, the local Fosroc office shouldbe consulted.

All primed substrates should be treated with two coats ofDekguard W. Stir material before use. The first coatshould be applied to achieve a uniform coating with a wetfilm thickness not less than 180 microns. This coatshould be allowed to dry until firm to the touch. Typically,this will be after 16 hours in dry weather at 20°C.

The second coat of Dekguard W should be applied asdetailed above, again achieving a wet film thickness notless than 180 microns and a total dry film thickness notless than 150 microns.

Semi protected surfaces

For semi-protected surfaces, such as multi storey carpark interiors, a reduced specification may be adoptedwhilst still achieving a carbon dioxide diffusion resistanceof > 50m of air.

Omit Dekguard Primer and apply two coats of DekguardW at a wet film thickness of 140 microns per coat, dilutingthe first coat with 10% v/v water, to achieve a total dry filmthickness of not less than 110 microns.

Cleaning

Dekguard W should be removed from tools andequipment with clean water immediately after use.

Limitations

When applied over existing coatings or paints, theperformance characteristics of Dekguard W may beimpaired and its fire rating invalidated. For further advice,consult the local Fosroc office.

The application of the primer should not commence if thetemperature of the substrate is below 2°C. Application ofDekguard W should not commence if the temperature ofthe substrate is below 5°C.

Dekguard W should not be applied where there is alikelihood of exposure to frost within 48 hours of theapplication. The product should not be applied in windyconditions where early-age dust adhesion may occur, orwhere rain is likely within 2 hours at 20°C or 20 hours at5°C (up to 80% RH) or when the prevailing relativehumidity exceeds 90%.

Dekguard W should not be considered for areassubjected to exposure to ponded water. Dekguard Sshould be considered where occasional ponded water isanticipated.


Estimating

Supply

Dekguard W: 10 litre drumsDekguard Primer: 25 litre drumsNitoprime DG: 25 litre drumsRenderoc FC: 25kg bagsRenderoc RP252: 20kg bagsNitobond AR: 5 and 25 litre drumsFosroc Solvent 102: 5 litre drums


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Fosroc® Dekguard W


www.fosroc.com



CoverageDekguard W: 5.5 m2 per litre per coatDekguard Primer: 2.5 m2 per litreNitoprime DG: 2.5 m2 per litreRenderoc FC: 15 litres (5 m2 at 3mm thickness)Renderoc RP252: 12 litres (2.4 m2 at 5mm thickness)Nitobond AR: 6 m2 per litre


Storage

Dekguard W has a shelf life of 12 months if kept in a drystore in the original, unopened packs. Material fromdifferent batches shall be stored separately. Store incool, dry conditions, away from sources of heat and nakedflames.

If stored at high temperatures and/or high humidityconditions the shelf life may be reduced. Dekguard Wshould be protected from frost.

Precautions

Health and safety


Fire

Dekguard W is non-flammable.

Dekguard Primer, Nitoprime DG and Fosroc Solvent 102are flammable. Keep away from sources of ignition. NoSmoking. In the event of fire, extinguish with CO2 or foam.Do not use a water jet.

Flash points

Dekguard Primer: 38°CNitoprime DG: 38°CFosroc Solvent 102: 33°C



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Damp-tolerant, solvent free epoxy resincoating

Uses

As a protective coating for concrete and mild steel. Thecured film is corrosion, chemical and abrasion resistantand is suitable for application to sewage works, marineenvironments, basements and tunnels. It is particularlyuseful where concrete surfaces are damp and cannot bedried out.

Advantages

High build applicationCan be applied directly to mild steel and concreteSmooth, glossy, easy to clean surfaceCorrosion, chemical and abrasion resistantCan be applied to damp surfacesWaterproofProvides protection against water vapour and groundgases such as radon, cabon dioxide and methane.

Description

Nitocote EP403 is a two pack, solvent free, epoxy resinmaterial. It is supplied in pre-measured quantities readyfor site mixing and use. The material cures to provide asmooth, tough and resistant finish. It is available in lightgrey.


Corrosion, chemical and abrasion resistantlining

The chemical and abrasion resistant coating shall beNitocote EP403, a solvent free epoxy, specificallydesigned for application to damp surfaces and to providea tough, impermeable and resistant film.

Properties

Volume solids: 100%Viscosity: Pourable, spreadable liquidPot life —@ 20°C: 30 to 40 minutes@ 35°C: 10 to 15 minutesThe fully cured filmis resistant to: Distilled water

PetrolXylene25% sulphuric acidSaturated sodium chloride50% sodium hydroxide

The local Fosroc office should be consulted for resistanceto specific chemicals, or operating temperatures greaterthan 20oC.



Preparation

Concrete surfaces

All surfaces must be smooth, sound and free from debris,loose or flaking material and areas of standing water.Surfaces must be free from contamination such as oil,grease, dust, loose particles and organic growth.Concrete surfaces must be fully cured, laitance free andfree from any traces of shuttering release oils and curingcompounds.

Spalled surfaces, those containing large blow holes orsurface imperfections should be repaired or renderedusing a Fosroc approved repair mortar or render. Contactthe local Fosroc office for further advice on suitablematerials.

All surfaces should then be grit blasted to remove allforeign matter and open up all blow-holes, and provide asuitable key for Nitocote EP403.

All blow-holes and imperfections should be filled withNitomortar FC. Consult the data sheet for pot life andovercoating time.

Steel surfaces

All surfaces should be grit blasted to meet therequirements of BS 7079 Sa2.5. The lining work shouldbe programmed so that newly cleaned steel is coated assoon as possible before the formation of rust or scale.

Mixing

The contents of the base can should be stirred thoroughlyto disperse any settlement. The entire contents of thehardener can should be added to the base container andmixed thoroughly until a uniform consistency is obtained,taking particular care to scrape the sides and bottom ofthe container. It is recommended that mechanical mixingbe employed, using a Jiffy mixer on a heavy duty, slowspeed electric drill.

ApplicationNumber of coats: 2Theoretical applicationrate per coat: 0.2 litres per m2

Theoretical wet filmthickness per coat: 200 micronsOvercoating times —@ 5°C: 18 to 48 hours@ 20°C: 6 to 18 hours@ 30°C: 3 to 9 hoursFully cured —@ 5°C: 14 days@ 20°C: 7 days@ 30°C: 7 days

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The minimum application temperature is 5°C.

All surfaces should be treated with two coats of NitocoteEP403.

The thoroughly mixed material should be applied with asuitable brush.

The first coat must be firmly applied and be well scrubbedinto the surface, ensuring a uniform coating with a wet filmthickness not less than 200 microns. The first coat shouldbe allowed to dry for not less than 6 hours and not morethan 18 hours at 20°C.

The second coat should be applied exactly as above,again achieving a wet film thickness not less than 200microns.

For cold weather working, it is recommended that NitocoteEP403 be stored in a heated building and removedimmediately before use, as workability deteriorates andcuring times increase at lower temperatures.

Cleaning

Nitocote EP403 should be removed from tools andequipment with Fosroc Solvent 102 immediately after use.Cured material can only be removed mechanically.

Estimating

Supply

Nitocote EP403: 2.5 kg packs (1.5 litres)Fosroc Solvent 102: 5 and 25 litre tins

Coverage

Nitocote EP403: 3 m2 per kg per coat (5 m2 per litre)

The coverage figure is theoretical — due to wastagefactors and the variety and nature of substrates, practicalcoverage figures may be substantially reduced.

Limitations

Nitocote EP403 is formulated for application to clean,sound concrete and steel. Nitocote EP403 should not beapplied over existing coatings.

Application should not be undertaken if the temperature isbelow 5°C, or is 5°C and falling, nor when the prevailingrelative humidity exceeds 90%.

Although Nitocote EP403 may be applied to dampconcrete, there must be no standing or running water.

Nitocote EP403 is not colour stable when exposed todirect sunlight nor when in contact with some chemicals.On curing Nitocote EP403, the final colour can vary withcuring conditions, and in adverse conditions such as lowtemperature and/or high humidity, a white bloom mayappear on the surface. However, this does not affect theperformance of the coating.

Storage

Store in dry conditions at temperatures between 5°C and30°C in the original, unopened containers. Material fromdifferent batches shall be stored separately. Products havea shelf life of 12 months if kept in these conditions.

If stored at high temperatures the shelf life may bereduced.

Precautions

Health and safety


Fire

Nitocote EP403 is non-flammable.


Flash point


For further information, refer to the Product SafetyData Sheet.



136

Solvent-free epoxy resin coating for waterretaining structures

Uses

For lining and waterproofing potable water retainingstructures* and surfaces subject to contact withfoodstuffs. The cured film is corrosion, chemical andabrasion resistant and is suitable for application to tanks,silos, reservoirs*, water treatment works*, breweries,dairies and meat and food processing plants. The curedfilm is non toxic and meets the requirements of BS 6920.(* See ‘Limitations’.)

Advantages

High build applicationCan be applied directly to mild steel and concreteSmooth, glossy, easy to clean surfaceCorrosion, chemical and abrasion resistantCan be applied to damp surfacesWater Regulations Advisory Service - approved product

Description

Nitocote EP405 is a two-part, solvent free, epoxy resinmaterial. It is supplied in pre-measured quantities readyfor site mixing and use and is available in blue and white.


Nitocote EP405 meets the requirements of BS 6920, theWater Regulations Advisory Service, tests of effect onwater quality.

Properties

Volume solids: 100%Viscosity: Pourable, spreadable liquidPot life —@ 20°C: 30 to 40 minutes@ 35°C: 10 to 15 minutes

The local Fosroc office should be consulted for resistanceto specific chemicals.



Preparation

Concrete surfaces

All surfaces must be smooth, sound and free fromcontamination and areas of standing water. Concretesurfaces must be fully cured, laitance free and free fromany traces of shuttering release oils and curing compounds.

All surfaces should then be grit blasted to remove allforeign matter and open up blow-holes and provide asuitable key for Nitocote EP405.

All blow holes and imperfections should be filled withNitomortar FC. Consult the local data sheet for pot life andovercoating time.


Steel surfaces

All surfaces should be grit blasted to meet therequirements of BS 7079 Sa2.5.. The lining work shouldbe programmed so that newly cleaned steel is coated assoon as possible before the formation of rust or scale.

Mixing

Thoroughly stir the contents of the base can. Empty theentire contents of the hardener can into the basecontainer and mix thoroughly until a uniform consistencyis obtained, taking particular care to scrape the sides andbottom of the container. It is recommended thatmechanical mixing be employed, using a Jiffy mixer on aheavy duty, slow speed electric drill.

Application

Number of coats: 2Theoretical applicationrate per coat: 0.2 litres per m²Theoretical wet filmthickness per coat: 200 micronsOvercoating times —@ 5°C: 18 to 48 hours@ 20°C: 6 to 18 hours@ 30°C: 3 to 9 hoursFully cured *—@ 5°C: 14 days@ 20°C: 7 days@ 30°C: 7 days

* see Limitations


All surfaces should be treated with two coats of NitocoteEP405. The thoroughly mixed material should be appliedwith a suitable stiff nylon type brush.

The first coat must be firmly applied and be well scrubbedinto the surface, ensuring a uniform coating with a wet filmthickness not less than 200 microns. The first coat should

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be allowed to dry for not less than 6 hours and not morethan 18 hours at 20°C.

The second coat should be applied exactly as above,again achieving a wet film thickness not less than 200microns.

For ease of overcoating, it is recommended that the firstcoat be white and the second coat blue, or vice-versa.

For cold weather working, it is recommended that NitocoteEP405 be stored in a heated building and removedimmediately before use, as workability deteriorates andcuring times increase at lower temperatures.

Cleaning


EstimatingNitocote EP405 is supplied in 2.5 kg packs (1.5 litres)each yielding 3 m² per kg per coat (5 m² per litre).

The coverage figure is theoretical — due to wastagefactors and the variety and nature of substrates, practicalcoverage figures may be substantially reduced.

LimitationsNitocote EP405 should not be applied over existingcoatings.

Application should not be undertaken if the temperature isbelow 5°C, or is 5°C and falling, nor when the prevailingrelative humidity exceeds 90%.

Although Nitocote EP405 may be applied to dampconcrete, there must be no standing or running water.

Nitocote EP405 is not colour stable when exposed todirect sunlight nor when in contact with some chemicals.On curing Nitocote EP405, the final colour can vary withcuring conditions, and in adverse conditions such as lowtemperature and/or high humidity, a white bloom mayappear on the surface. However, this does not affect theperformance of the coating.

* Before commencing application it is important to ensurethat Nitocote EP405 meets all current compliancerequirements. Note: Nitocote EP405 meets the

requirements of BS 6920 the United Kingdom WaterRegulations Advisery Scheme but not Regulation 31 of theWater Supply (Water Quality) Regulations 2000.

In accordance with WRAS listing, when Nitocote EP405 isused in contact with potable water, curing conditions are21 days at 7oC.

Storage

All products have a shelf life of 12 months if kept in a drystore between 5°C and 30°C in the original, unopenedcontainers. Material from different batches shall be storedseparately.

If stored at high temperatures the shelf life may bereduced.


For further information refer to appropriate Product SafetyDatasheet.

Disposal

To eliminate risk of exotherm, only mix product whenready for use and then apply without delay. Any unusedresidue should be poured on to a disposable impervioussurface to allow cure before disposal.

Fire

Nitocote EP405 is non-flammable.

For further information, refer to Product Safety Data Sheet.


Flash point


For further information, refer to the Product SafetyData Sheet.


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138

Highly chemical resistant two pack epoxysystem

Uses

To provide protection to concrete and steel structures inaggressive chemical immersion conditions. The materialis particularly suitable for applications in process plantsand sewage works.

Advantages

Excellent chemical resistanceExcellent adhesion to concrete and steelExcellent abrasion resistance

Description

Nitocote EP410 is a high build, solvent free, two packepoxy formulation. It is supplied in pre-measuredquantities ready for site mixing and use.

Nitocote EP410 is designed to be applied in one coat toachieve a minimum total dry film thickness of 250microns. When used in conjunction with glass fibrereinforcement to bridge fine cracks, it is applied in twocoats to achieve a minimum total dry film thickness of 500microns. Nitocote EP410 is designed to be used withNitoprime 25 on concrete surfaces and Nitoprime 28 onmild steel. It is green in colour. The coating shall beappliec in accordance with the Fosroc data sheet.


The chemical resistant, solent free epoxy coating shall beFosroc Nitocote EP410. It shall be applied in one coat ata dry film thickness of 250 microns or, whereincorporating fibreglass reinforcsement, in 2 coats with adry film thickness of 500 microns.

Properties

Volume solids: 100%Viscosity: Pourable, spreadable liquidPot life @ 20°C: 90 minutesPot life @ 35°C: 35 minutes

Number of coats: 1

Theoretical applicationrate per coat: 0.25 litres/0.36kg per m²Theoretical wet filmthickness per coat: 250 micronsOvercoating times@ 5°C: 16 to 72 hours@ 20°C: 16 to 24 hours@ 35°C: 6 to 18 hoursFully cured@ 5°C: 14 days@ 20°C: 7 days@ 35°C: 6 days


The fully cured coating is resistant to:Sodium hydroxide: 50%Citric acid: 50%Hydrochloric acid: 30%Lactic acid: 10%Acetic acid: 15%Sulphuric acid: 25%

The local Fosroc office should be consulted in respect ofother chemicals, or at operating temperatures greater than20°C.



Preparation

Concrete surfacesAll surfaces must be dry, smooth, free from contaminationand loose material. Concrete surfaces must be fullycured, laitance-free and free from any traces of shutteringrelease oils and curing compounds. All surfaces shouldbe grit blasted to provide a suitable key and all blow holesand imperfections should be filled with Nitomortar FC.


All surfaces should then be primed with Nitoprime 25. Mixin the proportions supplied and apply in a thin, continuousfilm. The primer should be touch dry but allowed to curefor no more than 24 hours at 20°C or no more than 18hours at 35°C before the application of Nitocote EP410.

Steel surfacesAll surfaces should be prepared to meet the requirementsof BS 7079, Sa2.5, abrasive blasting is recommended.The lining work should be programmed so that newlycleaned steel is primed before the formation of rust orscale.

All surfaces should then be primed with Nitoprime 28. Mixin the proportions supplied and apply as a thin continuousfilm. The primer should be touch dry but allowed to curefor no more than 24 hours at 20°C or no more than18 hours at 35°C before the application of Nitocote EP410.

MixingThoroughly stir the contents of the base can, then theentire contents of the hardener can should be stirred andadded to the base container and mixed thoroughly until auniform colour and consistency are obtained, takingparticular care to scrape the sides and bottom of thecontainer. Mechanical mixing is recommended using aJiffy mixer on a heavy duty, slow speed electric drill. In cold

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weather, materials should be stored between 15°C and20°C for 24 hours before use.

Application

All primed surfaces should be treated with one coat ofNitocote EP410. The mixed material should be applied bya nylon brush and finally smoothed out with a steel trowelto achieve a uniform coating with a wet film thickness notless than 250 microns. Any movement joints in thestructure should be expressed through the coating andsealed with an appropriate sealant.

Use of glass fibre reinforcement

Nitocote EP410 may be used in conjunction with glassfibre cloth to increase thickness or, where necessary,bridge fine cracks in the substrate. The cloth should belaid directly on the first coat whilst wet and should bepressed in and smoothed out with a stiff nylon brush orsplit washer roller. A second coat should then be applied,allowing no more than 24 hours at 20°C and no morethan 18 hours at 35°C between coats, and again achievinga wet film thickness not less than 250 microns.Suitablecloth is open weave 110 g/m² glass cloth.

Cleaning


Estimating

SupplyNitocote EP410: 5.6kg packsNitoprime 25: 0.95kg ‘Handy’ packs

5kg ‘Industrial’ packsNitoprime 28: 0.45kg ‘Handy’ packs

4.2kg ‘Industrial’packsFosroc Solvent 102: 5 and 25 litre tins

CoverageNitocote EP410: 15.68m2/5.6kg packNitoprime 25: 5m2/0.95kg ‘Handy’ pack

26m2/5kg ‘Industrial’ packNitoprime 28: 2.4m2/0.45kg ‘Handy’ pack

20m2/4.2kg ‘Industrial’pack

Limitations

Nitocote EP410 is formulated for application to clean,sound concrete and steel. It should not be applied overexisting coatings. Application should not be undertaken ifthe temperature is below 5°C or is 5°C and falling, norwhen the prevailing relative humidity exceeds 90%.

Nitocote EP410 is not colour stable when exposed todirect sunlight, nor when in contact with some chemicals.

Storage

Shelf life: Nitocote EP410 has a shelf life of 12 months ifkept in a dry store between 5°C and 30°C in the original,unopened containers. Material from different batches shallbe stored separately. Storage at higher temperatures mayreduce shelf life.

Precautions

Health and safety


Disposal

To eliminate risk of exotherm, only mix product whenready for use and then apply without delay. Unusedresidue should be poured on to a disposable impervioussurface to allow cure before disposal.

Fire

Nitocote EP410 is non-flammable.Nitoprime 25, Nitoprime 28 and Fosroc Solvent 102 areflammable. Keep away from sources of ignition. In theevent of fire, extinguish with CO2 or foam. Do not use awater jet.

Flash pointsFosroc Solvent 102: 33oCNitoprime 25: 55oCNitoprime 28: 27oC

For further information, consult the Product Safety DataSheet.




140

Penetrating, hydrophobic silane-siloxanetreatment for concrete and masonry

Uses

To protect atmospherically exposed reinforced concretestructures from attack by chloride ions and waterintrusion. The product is also suitable to protect othercementitious substrates and masonry. Nitocote SN502 issuitable for use on all types of structures, including thosein coastal environments. It is equally suitable for new andexisting structures.

Advantages

Penetrates into substratesNon-stainingReduces water and chloride intrusionIncreases freeze thaw resistanceMinimises efflorescenceAllows water vapour to escape from the structureChemically resistant to ice melting compounds, fuels,oils and atmospheric contaminants

Description

Nitocote SN502 is a single component penetrating silane-siloxane system which penetrates into porous substratesand then reacts to produce a bonded hydrophobic lining tothe pores. Although allowing passage of water vapourfrom the substrate it significantly reduces the absorptionof water and water borne salts.

Nitocote SN502 does not discolour most substrates andhas excellent resistance to weathering.


Silane-siloxane penetrating treatment

The penetrating treatment shall be a silane-siloxanesystem with a reduction in chloride ion penetration notless than 92% and a reduction in water absorption of notless than 85% when tested to the NCHRP 244 standard.

Properties

The values obtained are for Nitocote SN502 applied at theminimum recommended application rate.

Reduction in chloride ion penetration —To NCHRP 244 Standard: 92%Australian C.T.I. method: 98%Reduction in water absorption —To NCHRP 244 Standard: 85%Australian C.T.I. method: 94%


Preparation

All surfaces should be dry and free from contaminationsuch as oil, grease, loose particles, decayed matter,moss, algal growth, laitance and all traces of mouldrelease oils and curing compounds. This is best achievedby lightly grit-blasting the surface. Where moss, algae orsimilar growths have occurred, treatment with aproprietary biocide should be carried out after the grit-blasting process.

Application

In order to obtain the penetrating properties of NitocoteSN502, it is important that the correct rates of applicationand overcoating times are observed.

Number of coats: 2 flood coatsTheoretical applicationrate per coat: 0.2 litres/m2

Overcoating time: 2 hours @ 20°C

Nitocote SN502 should be applied in two flood coats untilthe recommended total application rate of 0.4 litre persquare metre has been achieved. This isbest accomplished by using portable spray equipment ofthe knapsack-type. If in doubt about the condition of thesubstrate, the local Fosroc office should be consulted.

Nitocote SN502 should be allowed to dry for a minimumof 2 hours (at 20°C) before continuing.

Cleaning

Nitocote SN502 should be removed from tools andequipment using Fosroc Solvent 102 immediately afteruse.

Limitations

Nitocote SN502 should not be contaminated with water.The application of Nitocote SN502 should not commenceif the temperature of the substrate is below 2°C.

Nitocote SN502 may darken some polymer modifiedsubstrates and white cement. A trial area isrecommended.

Estimating

Supply

Nitocote SN502: 25 and 200 litre containersFosroc Solvent 102: 5 and 25 litre tins

Coverage and yield

Nitocote SN502: 5 m2 per litre per coat

Fosroc®

Nitocote SN502 constructive solutions


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Fosroc®

Nitocote SN502


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Storage

Store in cool, dry conditions, away from sources of heatand naked flames, in the original, unopened containers.Nitocote SN502 has a shelf life of 12 months if kept in adry store in the original, unopened containers.


Precautions

Health and safety

For further information refer to appropriate Product dafetyData Sheet.

Fire

Nitocote SN502 and Fosroc Solvent 102 are flammable.Do not expose to naked flames or other sources ofignition. No Smoking. Containers should be tightly sealedwhen not in use. In the event of fire, extinguish with CO2 orfoam.

Flash point

Nitocote SN502: 38°C

Fosroc Solvent 102: 33oC




142

Monomeric silane water repellantpenetrant

Uses

A penetrating treatment designed to protect concrete fromboth water and chloride ingress whilst still permittingwater vapour transmission (breatheability).

Advantages

Markedly reduces water and chloride ingressDeep penetration into substratesNon-stainingIncreases freeze thaw resistanceMinimises efflorescenceChemically resistant to de-icing compounds andatmospheric contaminants

Description

Nitocote SN511 has a 95% active content of monomericalkyl (isobutyl) trialkoxy silane which penetrates deeplyinto porous substrates and then reacts to produce abonded hydrophobic lining to the pores.

This treatment markedly reduces absorption of water andwater-borne salts, but still permits passage of watervapour.

The treatment is not affected by UV light and does notproduce any discolouration of the substrate.


Conforms to DTp Specification BD43/03 and BD43/90 andBA33/90.

Properties

Specific gravity: Approximately 0.9Purity: Minimum 95%

Refractive index 1.396 +/- 0.004


Preparation

Surfaces should be dry and free from contamination suchas oil, grease, loose particles, decayed matter, moss oralgal growth, laitance and traces of mould oils and curingcompounds, or other mechanical means.

Protect plants, glass, asphalt, bitumen, plastics and allpainted surfaces prior to application.

Application

In order to obtain the penetrating properties of NitocoteSN511, it is important that the correct rates of applicationand overcoating times are observed.

Number of coats: 2 flood coatsTheoretical applicationrate per coat: 0.3 litres/m²Overcoating time at 20°C: Minimum 6 hours

Nitocote SN511 should be applied by a continuouslycirculating pumped system at a nozzle pressure of 0.06 to0.07 N/mm² (8 to 10 lbf/in²). Nitocote SN511 should beapplied evenly by saturation flooding using a wet spraywithout misting, working from the bottom up. Twoapplications shall be made, each at a minimum rate of300 ml/m². The interval between applications shall be aminimum of 6 hours (at 20°C) before continuing.

Surfaces should be protected from rain and spray duringapplication and for at least 6 hours after completion.

Cleaning

Equipment should be cleaned with Fosroc Solvent 102immediately after use. Any spillages should be absorbedwith sand or sawdust etc., and disposed of in accordancewith local regulations.

Estimating

Packaging

Nitocote SN511: 25 litre containerFosroc Solvent 102: 5 and 25 litre tins

Coverage and yield

Nitocote SN511: 0.3 litres/m² per coat (minimum)

Limitations

The application of Nitocote SN511 should not commenceif temperatures are below 5°C and falling or if the concretesurface temperature is above 25°C.

Nitocote SN511 hydrolises with atmospheric moisture.Material from opened containers should be used within48 hours or discarded.

There is a possibility of colour change on some types ofpolymer modified facing materials and white cement. Atrial area is recommended.

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Storage

Shelf life

12 months when stored in original unopened containers.

Storage conditions

Nitocote SN511 and Fosroc Solvent 102 should be storedin a cool dry place away from sources of heat or nakedflames.

Precautions

Health and safety


Overspray

Precautions must be taken to control overspray whenworking adjacent to vehicular roadways, pedestrianwalkways and water courses.

Fire

Nitocote SN511 and Fosroc Solvent 102 are flammable.

Do not expose to naked flames or other sources ofignition. No Smoking. Containers should be tightly sealedwhen not in use. In the event of fire, extinguish with CO2 orfoam.

Flash points

Nitocote SN511: 39°CFosroc Solvent 102: 33°C

(Abel closed cup method IP33)


7CI/SfB:

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144

Zinc rich cold galvanising coating

Uses

To provide a galvanic protection on iron and steel. It canbe used as a self-finish or as a durable rust inhibitingprimer beneath selected top coats. It is recommended forthe protection of structural steelwork, agricultural andconstruction plant and machinery, gates, railings, ironpipework and guttering, and the rust prevention of in-situwelding work.

Advantages

Protects ferrous metals against rustSuitable as a primer or self-finishEasily applied by brush or roller

Description

Galvafroid zinc rich coating is formulated as an easilyapplied, cold galvanising protection against corrosion onall ferrous metals. Galvafroid has a mid-grey, matt finish.

PropertiesVolume solids: 40%Solids by weight: 80%Zinc content by volume on dry film: 61%Zinc content by weight on dry film: 90%Drying times at 20°C —touch dry: 2 hourshard dry: 24 hoursrecoating time: 24 hours

minimum

Specification clause

The anti-corrosive primer shall be Galvafroid, a zinc richmaterial specifically designed to provide a rust inhibitingprotection to ferrous metalwork.


Preparation

All ferrous surfaces must be clean and free from oil,grease, mill scale, rust and existing coatings. This is bestachieved by grit blasting, although thorough wire brushingcan be sufficient. Some rust removers based on phos-phoric acid tend to leave an electrically insulating film onferrous metals and must not be used.

Mixing

Galvafroid must be thoroughly stirred to give a uniformproduct prior to application. It is recommended that the

contents are stirred periodically during application to avoidsettlement.

Galvafroid is supplied at the correct consistency for directapplication from the tin but, should it be found necessaryto thin, only Fosroc Thinner/Cleaner should be added, at arate not exceeding 1 litre of thinners to 8 litres ofGalvafroid.

Application

In order to obtain the protective properties of Galvafroid, itis important that the correct rate of application is achieved.The minimum application temperature is 5°C.All prepared surfaces should be treated with one or morecoats of Galvafroid. The material should be liberallyapplied without any attempt to brush or roll out. Therequired thickness of coating may be built up by succes-sive applications of Galvafroid when the previous coat iscompletely dry.

Overcoating

Where required, Galvafroid may be painted to improvedurability or to enhance appearance. The Galvafroidcoating should not be rubbed down to obtain a smoothsurface for finishing paints, but it should be given agenerous coat of a suitable filling primer and this, whenthoroughly dry, should be sanded to a smooth surface.

For general purposes, a good oil bound or alkyd paintshould be used. Where the work is subject to corrosiveand marine conditions, however, a non-saponifiablefinishing paint should be used, i.e. Chlorinated rubberpaint. It is advisable to allow the Galvafroid coating toweather for at least 3 days before applying the finishingcoat. Cellulose and bituminous paints are not generallysuitable for over-painting Galvafroid.

Cleaning

Galvafroid should be removed from tools and equipmentwith Fosroc Thinner/Cleaner immediately after use. Driedmaterial can only be removed mechanically.

Estimating

Supply

Galvafroid: Pack of 6 x 400 ml tinsPack of 4 x 800 ml tins1.9 litre tin

Fosroc Thinner/Cleaner: 0.5 litre tins

Coverage

Galvafroid: 16 m2/litre when used as a primer8 m2/litre when used as a self-finish

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Fosroc® Galvafroid

Limitations

Galvafroid is formulated for application to clean ferroussubstrates and should not be used on rusty, corrodedsurfaces.

Galvafroid should not be applied over existing coatings.Galvafroid should not be used on surfaces in contact withdrinking water.

Galvafroid should not be used on surfaces exposed tosoft water at temperatures above 60°C.

Galvafroid should not be used on surfaces treated withphosphoric acid based rust removers.

Galvafroid should not be overcoated with materialscontaining strong solvents such as chlorinated andaromatic hydrocarbons, esters and ethers.

Storage

Galvafroid has a shelf life of 12 months if kept in a drystore between 5°C and 20°C in the original, unopenedcontainer.

Precautions

Health and safety


Fire

Galvafroid and Fosroc Thinner/Cleaner are flammable.Keep away from sources of ignition. No smoking. In theevent of fire, extinguish with CO2 or foam. Do not use awater jet.

Flash points

Galvafroid: 41°CFosroc Thinner/Cleaner: 41°C


8CI/SfB: Vu1

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Galvafroid is a trade mark of Fosroc International Limited

146

Polymer modified, cement based, floorlevelling compounds

Uses

The Cemtop range of products includes the following:

Cemtop S: A self-smoothing underlayment for a widevariety of floor finishes, e.g. tiles, carpets and vinylsheeting. Suitable for residential and commercialbuildings, for new construction or refurbishment projects.

Cemtop GP30: A general purpose floor levellingcompound/underlayment for the preparation of floorsurfaces before the application of tiles, carpet, vinyl, etc.

Cemtop GP12: A medium duty floor surfacing systemsuitable for use in areas which will be subject to foot trafficor light commercial use. Also suitable for use as a heavyduty underlayment for the preparation of floor surfacesbefore the application of tiles, carpet, vinyl, etc.

Cemtop XD: A heavy duty, highly abrasion resistant floorsurfacing system for the reinstatement of industrial floorsurfaces.

See also ‘Uses’ table on page 3.

Advantages

Very fast application, enables large areas of floor to becompleted in a working dayCan be applied directly onto concrete floors,eliminates traditional sand-cement screedsDimensionally stable, can be installed in large areasRapid hardening and curing allows speedy access forfoot traffic and overlaying with carpets, tiles, etc., whereappropriateOne-pack product eliminates on-site batching andensures consistency of mixed product

Description

Cemtop products consist of a blend of selected cementsand aggregates modified with polymers and flow agents.The products are used in conjunction with Nitoprime 33.

The products are supplied as a grey powder whichrequires only the addition of water to produce selfsmoothing, free flowing material.


Cemtop products comply with the requirements for aClass O surface, as defined in paragraph A8 (b) ofApproved Document B, ‘Fire’, to the Building Regulations1985.

BS 476, Part 6: 1989. ‘Method of Test for Fire Propagationfor Products’ — Fire Propagation Index, I = 0.0.

BS 476, Part 7: 1987. ‘Surface Spread of Flame Test forMaterials’ — Class 1 Surface Spread of Flame.


Floor areas so designated should be covered with theCemtop product as manufactured by Fosroc. The productshould be applied in accordance with the manufacturer’sapplication instructions.

Properties

See ‘Physical properties’ table on the third page of thisdatasheet.


Although the products have been designed for applicationby pump, they can also be applied by hand.

Installation by pump

This is a specialist activity and the product must beapplied by a Fosroc recommended contractor who hasbeen fully trained in the use of the product using suitableequipment.

Installation by hand

Typically, in areas of less than 100 m² it will be morepractical to install Cemtop by hand.

Surface preparation

it is essential that both new and old concrete floors arecorrectly prepared prior to the appplication of Cemtop.

New concrete floors should have been placed for at least21 days and have a moisture content of less than 5%.They should be dry, sound and free of wax, grease, oils,fats, soil, mortar and paint splashes or curing compoundresidues, loose or foreign material and laitence. Laitenceshould be removed by light scabbling or blasting followedby washing and vacuuming to remove dust debris. Lightoil and grease staining can be removed with proprietarychemical degreaser, followed by washing with cleanwater.

In old concrete where deep seated contamination hasoccurred, mechanical methods such as blasting, grindingand scabbling should be used to provide a suitable cleansurface.

For recommendations or additional information regardingsubstrate preparation, please contact Fosroc.

Application procedure

Thoroughly prepare the floor surface as above.

Prime the surface with Nitoprime 33 (1: 5 primer to waterratio by volume) and allow to dry.

Re-prime the surface with Nitoprime 33 (1: 3 primer towater ratio by volume) and allow to dry.

Apply Cemtop to the required thickness onto the dry,primed surface.

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Priming

The objective of priming is to seal the substrate to preventrelease of air from the substrate.

MixingMixingMixingMixingMixing

Mix 25 kg of Cemtop with the required amount of cleanwater (see ‘Estimating’ table on page 3). A typical batchwould be 2 x 25 kg bags of the product.

Pour the water into a clean mixing vessel. Add the powderslowly to the water, mixing continuously with a heavy dutydrill and purpose-made paddle. Mixing should continuefor at least 3 minutes until a smooth and creamyconsistency is obtained.

Ensure that sufficient labour is available to enablecontinuous mixing and pouring.

Place the Cemtop within 2 minutes of completion ofmixing.

Pour the mixed material on to the dry primed surface,spread with trowel and allow to level.

Roll surface with a spiked roller to aid air release andlevelling properties. Do not over-roll.

To reduce the formation of seam lines, freshly mixedCemtop should be placed within 5 minutes of theprevious adjacent batch being laid.

Note: If the mix stiffens it should be discarded, do notattempt to re-mix with water.

Dual layer — Cemtop XD, Cemtop GP12 andCemtop GP30

Thoroughly prepare the floor surface.

Prime the surface with Nitoprime 33 (1: 5 primer to waterratio by volume) and allow to dry.

Re-prime the surface with Nitoprime 33 (1: 3 primer towater ratio by volume) and allow to dry.

Apply Cemtop GP30 to the required thickness onto the dry,primed surface.

At the onset of initial set, abrade the surface with a stiffbristle broom to provide a mechanical key for the nextlayer.

When hardened, prime Cemtop GP30 with Nitoprime 33(1: 3 primer to water ratio by volume).

Apply Cemtop XD or Cemtop GP12 to the primed CemtopGP30.

If Cemtop XD or Cemtop GP12 is not applied the sameday as Cemtop GP30 then the hardened Cemtop GP30should be primed on the day of application and primed

again prior to the application of Cemtop XD or CemtopGP12 (both at 1: 3 primer to water ratio by volume).

Limitations

Concrete slabs onto which the Cemtop is to be appliedmust have a surface temperature of at least +5°C with airtemperature maintained at +10°C or more duringapplication. For temperatures in excess of 25°C duringapplication refer to Fosroc Customer ServicesDepartment.

Protect from freezing for 48 hours after placement.

To prevent rapid drying protect from direct sunlight and/ordrying winds during application and the initial curingperiod.

If the substrate onto which Cemtop is applied moves orcracks, reflective cracking may occur.

Cemtop should not be applied to asphalt substrates.

Cemtop should not be applied to external surfaces orsurfaces subject to wetting.

Estimating

See ‘Estimating’ table overleaf.


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UsesCemtop S Cemtop GP30 Cemtop GP12 Cemtop XD

General-purpose underlayment beforedecorative finish, e.g. tiles: —

Heavy-duty underlayment: — — —

Final wearing surface in foot traffic areas: — —

Final wearing surface in light commercial areas: — —

Heavy-duty / industrial floor wearing coat: — — —Suitable for overcoating with Nitoflor FC130and then Nitoflor FC140: — —

Physical propertiesCemtop S Cemtop GP30 Cemtop GP12 Cemtop XD

Compressive strength at 28 days (40 mmcubes cured at 20°C, 65% RH): 20 N/mm² 20 N/mm² 25 N/mm² 30 N/mm²Flexural strength at 28 days (rectangularprisms cured at 20°C, 65% RH): 4.5 N/mm² 4.5 N/mm² 7.0 N/mm² 8.0 N/mm²C + CA accelerated wear tests at28 days* — Category: — — Normal GoodBRE impact resistance at 28 days(BS 8204, Part 1: 1987) — Category: A† A† A† A†

TRRL slip resistance test —4S rubber slider: N/A Dry: excellent N/A Dry: excellent

Wet: satisfactory Wet: satisfactoryTRRL rubber slider: N/A Dry: excellent N/A Dry: excellent

Wet: satisfactory Wet: satisfactory

Traffic time at 20°C —Foot traffic: 4 hours 4 hours 4 hours 4 hoursLight traffic: 24 hours 24 hours 48 hours 36 hoursHeavy traffic: — — — 7 days

* Refer to Concrete Society Technical Report No. 34. † Category A is the highest rating.

EstimatingCemtop S Cemtop GP30 Cemtop GP12 Cemtop XD

Application thickness: Featheredge to 10 mm 5 to 30 mm 6 to 12 mm* 6 to 12 mm*Application method: Pump/hand Pump/hand Pump/hand Pump/handTheoretical coverage: 1.7 kg/mm/m² 1.7 kg/mm/m² 1.7 kg/mm/m² 1.7 kg/mm/m²Supply: 25 kg bags 25 kg bags 25 kg bags 25 kg bagsWater addition per 25 kg bag: 5.0 litres 4.0 litres 4.5 litres 4.5 litres

* Can be taken down to a chamfered edge.

Nitoprime 33: 5 m²/litre of concentrate per 2 priming coats4 m²/litre of concentrate per 3 priming coats3 m²/litre of concentrate per 4 priming coats

Supply: 25 litre containers

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Storage

Store in unopened bags in cool dry internal conditions.

The product has a shelf life of 6 months from the date ofmanufacture if kept in a dry storage in the original,unopened bags. If stored at high temperatures and/orhigh humidity conditions the shelf life may be reduced toless than 3 months.

Nitoprime 33 has a shelf life of 12 months if stored at20°C. Protect from frost and extreme heat.

Precautions

Health and safety


Fire

Cemtop products and Nitoprime 33 are non-flammable.


Joints

Expansion joints in the existing substrate must becontinued through the Cemtop products and filled to therequired level with Expoflex 800 or Nitoseal MS300. TheCemtop system can be laid over construction joints or dayjoints. However, if these joints subsequently move,reflective cracking may occur.

Use with Nitoflor FC130 and Nitoflor FC140 floor coatings

In certain circumstances, it will be appropriate to protectCemtop GP12 and Cemtop XD with an epoxy floor coatingsuch as Nitoflor FC130 or Nitoflor FC140.

Nitoflor FC130

Being water vapour permeable, this product can beapplied to Cemtop GP12 or Cemtop XD. The first coatmust be applied within 6 hours of the Cemtop being laid.

Nitoflor FC130 provides a chemical resistant pigmentedsealing coat which is dustproof, easily cleaned andresistant to penetration of oils and liquids. Two coats arerequired. See data sheet for details.

Nitoflor FC140

If additional chemical resistance is required, NitoflorFC140 can be applied over a single coat of NitoflorFC130.

It is recommended that Fosroc’s technical departmentshould be consulted prior to the installation of a combinedproduct system such as the systems described in thisdata sheet.


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High performance epoxy resin floorcoatings

Uses

Nitoflor FC130

To provide a dust-proof easily cleaned surface which isresistant to most oils and liquids. It is suitable for use onwalls and floors in warehouses, garages, light industrialand food processing areas, kitchens and other areas ofpedestrian and light vehicular traffic.

Nitoflor FC140

To provide a hard wearing, easily cleaned, attractive floorcoating in industrial areas where high resistance tochemical attack is required. It is suitable for use inproduction assembly areas, workshops, dairies, softdrinks production and bottling plants, breweries, kitchens,showrooms, etc. It is particularly suitable in wet workingareas and where chemical spillage is likely, e.g. platingshops, processing plants, dye works, etc.

Nitoflor FC130 and Nitoflor FC140 can also be used as acoating and sealer for Cemtop industrial and commercialcementitious flooring systems. Refer to Cemtop datasheet for details.

Advantages

Hard wearing — durable, low maintenance costsHigh resistance to a wide range of industrialchemicalsHygienic — impervious finish provides easily cleanedsurfaceAttractive — available in a range of colours to improvethe working environment

Description

Nitoflor FC130

Nitoflor FC130 is a two-component water dispersed epoxyresin coating system supplied in pre-weighed packsready for on-site mixing and use. The cured film forms ahard, flexible, semi-matt seal to concrete and othersubstrates.

Nitoflor FC140

Nitoflor FC140 is a two-component solvent based, epoxyresin coating system supplied in pre-weighed packsready for on-site mixing and use. The cured film forms ahard but flexible coating with excellent adhesion to cleanconcrete, sand/cement and granolithic screeds, andcertain metal surfaces. It cures to a semi-gloss,impervious finish which is easily cleaned.

Nitoflor FC130 and Nitoflor FC140 are available in a rangeof standard colours and are also available in a clear grade.


Nitoflor FC140 has been tested according to BS 4247,Part 1 — Nuclear Decontamination parts A and B. In bothinstances a ‘good’ classification was obtained.

Nitoflor FC130 and Nitoflor FC140 comply with BS 476,Part 7 :1971 — Class 1 spread of flame.

Properties

The values given below are average figures achieved inlaboratory tests at 20°C and 35°C. Actual values obtainedon site may show minor variations from those quoted.

Physical properties

Nitoflor FC130 @ 20°C @ 35°C

Pot life*: 2 hours 1 hourTime between coats: 6 to 24 hours 4 to 16hoursInitial hardness: 24 hours 16 hoursFull cure: 7 days 7 daysDry film thickness (2 coats): 100 microns (approximate)

Nitoflor FC140 @ 20°C @ 35°C

Pot life*: 4 hours 1.5 hoursTack-free time: 4 to 6 hours 2 to 4 hoursTime between coats: 6 to 24 hours 4 to 16hoursInitial hardness: 24 hours 18 hoursFull cure: 7 days 5 daysDry film thickness (2 coats): 100 microns (approximate)

* Note that after the pot life has expired, the material,although not hardened, increases in viscosity and thecharacteristics of the product change. Excess materialshould be discarded after this point.

Chemical properties

Nitoflor FC130 and Nitoflor FC140 are resistant to a widerange of chemicals. Specific data is available on request.Good housekeeping is essential in areas where chemicalspillage is likely to occur. It is especially important thatsuch spillage should not be allowed to dry since verymuch higher concentrations of chemicals will then result.



Surface preparation

It is essential that Nitoflor FC130 and Nitoflor FC140 areapplied to sound, clean, dry substrates in order to achieve

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maximum adhesion between the floor coating andsubstrate.

Because Nitoflor FC130 and Nitoflor FC140 are relativelythin coatings, the substrate must be fine textured. Anysurface irregularities may show through causingexcessive wear on high spots and changing the perceivedcolour of the coating.

New concrete floors

Unless specially water-reduced, the floor should be atleast 28 days old and give a hygrometer reading notexceeding 80% RH for Nitoflor FC 130 or 75% RH forNitoflor FC140 when tested in accordance with BS 8203Appendix A. Dry removal of laitance by light grit-blasting ispreferable but, where this is not feasible, treat with FosrocAcid Etch, followed by thorough rinsing with water andcomplete drying. Dust and other debris should then beremoved by vacuum brush.

Old concrete floors

A sound, clean substrate is essential to achievemaximum adhesion. Light grit-blasting or acid etchingshould be carried out as for new concrete floors. Oil andgrease penetration should be removed using a watermiscible chemical cleaner.

When using Nitoflor FC140 on very porous surfaces orsurfaces which are damp prime with a single coat ofNitoprime 25.

Asphalt floors

Nitoflor FC130 can be applied to asphalt floors providedthey are at least 6 months old.

Nitoflor FC140 should not be applied to asphalt floors,PVC tiles or sheet.

Mixing

The individual components of the Nitoflor FC coatingsshould be thoroughly stirred before the two are mixedtogether. The entire contents of the small containershould be poured into the large container and the twomaterials mixed thoroughly for at least 3 minutes. The useof a heavy-duty slow speed, flameproof or air driven drillfitted with a mixing paddle is desirable.

Coating

The mixed Nitoflor FC130 and Nitoflor FC140 should beapplied to the prepared surface using a brush orlambswool roller. Ensure that the area is completelycoated and that ‘ponding’ of the material does not occur.

The second coat may be applied as soon as the first coathas initially dried (typically 12 to 18 hours). The time willbe dependent on the type of surface and the ambientconditions.

Good drying conditions are required to allow completeevaporation of the water as the resin cures. Adequateventilation and air movement is necessary.

Use with Cemtop XD

Nitoflor FC130 can be used to overcoat Cemtop XD toprovide a more easily cleaned, chemically resistantsurface. Apply two coats of Nitoflor FC130 as described,the first of which must be applied within 6 hours after theinstallation of Cemtop XD.

Anti-slip finish

A fine textured anti-slip finish for either Nitoflor FC130 orNitoflor FC140 may be achieved by the addition of one0.9 kg sachet of Nitoflor FC Anti-slip Grains stirred intowards the end of the mixing process. (Note: This willreduce overall coverag e rate.)

Cleaning

Nitoflor FC130 should be removed from tools andequipment with clean water immediately after use.

Nitoflor FC140 should be removed from tools andequipment with Fosroc Solvent 102 immediately after use.Hardened material can only be removed mechanically.

Maintenance

The service life of a floor can be considerably extended bygood housekeeping practices. Regular cleaning ofNitoflor FC130 and Nitoflor FC140 may be carried outusing a rotary scrubbing machine with a water misciblecleaning agent or by hot water washing at temperaturesup to 50oC.

Estimating

Supply

Nitoflor FC130: 5 kg packsNitoflor FC140: 5 kg packsNitoprime 25: 5 kg packs


Nitoflor anti-slip grains: 0.9 kg

Coverage

Nitoflor FC130 and FC140: 35 to 40 m²/pack (per coat)Nitoflor FC130 and FC140with Anti-slip Grains: 24 to 30 m²/pack (per coat)Nitoprime 25: 25 m²/pack



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Limitations

Nitoflor coatings should not be applied onto surfacesknown to or are likely to suffer from rising damp or have arelative humidity greater than 80% (Nitoflor FC130) or 75%(Nitoflor FC140) as measured in accordance with BS8203 Appendix A or by a Vaisala thermohygrometer typeHMI 31.

The durability of Nitoflor coatings in foot traffic areas isreduced in areas of very heavy traffic such as around workbenches, drinks machines, etc. It is advisable to specifyadditional coats in such areas.

The low odour characteristics of Nitoflor FC130 is notnecessarily an indication of non-tainting characteristics.Where tainting of foodstuffs during application is possiblewe recommend separate tests are carried out in thisinstance, please contact the local Fosroc office.

Nitoflor FC130 should not be applied at temperaturesbelow 10°C or where ambient relative humidity exceeds85%.

Nitoflor FC140 should not be installed at temperaturesbelow 5°C.

The manufacture of Nitoflor FC130 and FC140 coatings isa batch process and despite close manufacturingtolerances variation may occur between batches. Fosrocrecommends using mateiral from one batch only as thefinish topcoat.

Storage

Nitoflor FC130 should be stored in dry conditions between10°C and 30°C, away from sources of heat and nakedflames in the original, unopened packs. Material fromdifferent batches shall be stored separately.

Nitoflor FC130 and Nitoflor FC140 have a shelf life of12 months if kept in the above conditions. If stored at hightemperatures the shelf life may be reduced. NitoflorFC130 should be protected from frost.

Precautions

Health and safety


Fire

Nitoflor FC130 is non-flammable.

Nitoflor FC140 is flammable. Keep away from sources ofignition. No Smoking. In the event of fire, extinguish withCO2 or foam. Do not use a water jet.

Flash points

Nitoflor FC140: 23°C

Fosroc Solvent 102 33°C

Disposal

Spillages of component products should be absorbedonto earth, sand or other inert material and transferred toa suitable vessel. Disposal of such spillages or emptypackaging should be in accordance with local wastedisposal authority regulations.


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Nitoflor is the trademark of Fosroc International Limited

153

‘Dry shake’ floor hardener for new concretefloors

Uses

Nitoflor Hardtop S provides a highly abrasion resistantsurface to fresh concrete floors by the ‘dry shake’ methodwhich ensures that the hard wearing surface bondsmonolithically to the base concrete. It is ideally suited forall industrial areas subjected to heavy traffic, e.g. powerstations, heavy industry, agricultural buildings, warehousefloors, loading bays and workshops.

Advantages

Supplied ready to use — no additives requiredProvides a hard, abrasion resistant surfaceForms monolithic bond with fresh concrete baseNon-metallic aggregate — will not rust when wetNon dustingAnti-slip

Description

Nitoflor Hardtop S surface hardening compound is aquality controlled, factory blended powder which is readyto use on site. It consists of special hard wearingaggregates selected for their physical properties ofabrasion and wear resistance, Portland cement andspecial additives to improve workability. This combinationproduces a material which is easy to trowel into thesurface of fresh, wet concrete. Nitoflor Hardtop S cures toprovide a dense, non porous surface which is extremelyhard wearing and abrasion resistant. Monolithic cureensures that problems normally associated with thin(‘granolithic’) screeds, e.g. curling, shrinkage, cracking,etc. are completely overcome.

Nitoflor Hardtop S is available in natural (concrete grey)colour as standard.


Floors shall be surfaced where shown withNitoflor Hardtop S, a ‘dry shake’ floor hardener containingnon-metallic, rust-free aggregates. The compound shallhave the ability to improve the abrasion resistance ofconcrete by 225%.

Nitoflor Hardtop S powder shall be applied to the freshly-laid concrete floor by the ‘dry shake’ method. It shall beapplied at the point where light foot traffic leaves animprint of about 3 to 6 mm.

The powder shall be applied in two stages, in fullaccordance with the manufacturer’s instructions. Specialattention shall be paid to bay edges in accordance withthe manufacturer’s written requirements.

Properties

Abrasion resistance

Nitoflor Hardtop S First Secondapplication rate app. app. BS8204per m2 concrete Kg/m2 Kg/m2 classification

3Kg 2 1 ARI

5Kg 3 2 Special

Average wear of 0.02mm for special class. 20 timeincrease on 40N/mm2 concrete ( concrete societytechnical report no.34, 2nd edition)

Hardness (Mohs scale)

The selected aggregates contained within NitoflorHardtop S have a hardness value of 7 on the Mohsoriginal scale.


Nitoflor Hardtop S should be applied at an evenapplication rate. It is recommended that the floor bemarked off into bays of known area. Sufficient materialsshould then be laid out to meet the recommended spreadrate.

Base concrete

The base concrete should have a minimum cementcontent of 300 kg/m3. The concrete mix should bedesigned to minimise segregation and control bleeding,although some limited bleed is desirable to ensuresufficient moisture is available to wet out the NitoflorHardtop S when it is first applied.

The use of water reducing admixtures from the FosrocStructuro or Conplast range is strongly recommended inorder to achieve a water:cement ratio below 0.55. Thebase concrete should have an on-site slump of between75 and 100 mm.

The base concrete should be laid and compacted inaccordance with good concrete practice, taking care toensure accurate finished profile and minimum laitancebuild-up. Particular attention should be paid to bay edgesand corners to ensure full compaction of the baseconcrete — see application instructions.

Vacuum dewatering is not recommended.

Application of Nitoflor Hardtop S should begin withoutdelay when the base concrete has stiffened to the pointwhen light foot traffic leaves an imprint of about 3 to 6 mm.Any bleed water should now have evaporated, but theconcrete should have a wet sheen.

On large floors it will be necessary to work progressivelybehind the laying team to ensure application at the correcttime.

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Nitoflor Hardtop S

Nitoflor Hardtop S is applied in two stages.

(a) The first application (see table) is broadcast at aneven rate onto the concrete surface. When the materialbecomes uniformly dark by the absorption of moisturefrom the base concrete, this first application can befloated. Wooden floats or, on large areas, a power floatdisc may be used. It is important, however, that thesurface is not overworked.

(b) Immediately after floating, the second application ofNitoflor Hardtop S is applied evenly over the surface atright angles to the first. Again, when moisture hasbeen absorbed the surface can be floated in the sameway as before.

Final finishing of the floor using the blades of a powerfloat can be carried out when the floor has stiffenedsufficiently so that damage will not be caused.

Bay edges

Where bay edges are likely to suffer particularly heavywear or impact and where saw-cut transverse controljoints are to be located, it is desirable to give these areasadditional protection, by one of the following methodsprior to full treatment of the entire surface:

(a) Immediately after levelling the freshly placed concrete,Nitoflor Hardtop S should be sprinkled by hand at arate of 0.5 kg/lin.m. (5 kg/m2) in a strip 100 mm widealong the bay edge and hand-trowelled into thesurface.

(b) Immediately after levelling the freshly placed concrete,remove a wedge of the concrete 10 mm deep at theslab edge and tapered up to slab level. Replace thiswith a very stiff paste of Nitoflor Hardtop S, mixedthoroughly with a small amount of water. Ensure it isfully compacted on to the base concrete.

These reinforced areas will be further strengthened whenthe subsequent full treatment is applied.

Timing of the application of Nitoflor Hardtop S is importantand care should be taken to ensure adequate labour,machinery and material is available to complete the wholearea while sufficient moisture is available to fully reactwith the powder to provide a good dense finish.Conversely, the full benefit will not be achieved if thematerial is applied too early when bleed water is stillpresent.

Any addition of water to wet out the surface on either thefirst or second application of Nitoflor Hardtop S will bedetrimental to the overall quality of the floor.

It is essential that the correct recommended rate ofapplication is achieved over the entire floor area in orderto avoid possible localised variations in shading.

Cleaning

All equipment should be washed with clean waterimmediately after use and before the material hashardened.

Curing

Proper curing of concrete floors treated with NitoflorHardtop S is essential to the physical properties of thefinished floor. The most effective method of curing is touse Concure WB which should be applied on to thefinished floor 10 minutes after the power floatingoperation has been completed.

The use of polythene sheeting, wet hessian and dampsand or ponding are not recommended. The use of saltwater or brackish water should not be considered underany circumstances.

Surface treatments

Subsequent surface treatments are not normallynecessary with Nitoflor Hardtop S because of the highdensity, low porosity finish.

Estimating

Supply

Nitoflor Hardtop S: 25 kg bagsConcure WB: 20 litre container

Coverage

Nitoflor Hardtop S: 5 kg/m2 / 3 kg/m2

Concure WB: 3.5 to 5 m2/litre

Applications should comply with the recommended rate toobtain the published performance characteristics. Anyreduction may have a detrimental effect on the finishedfloor’s abrasion resistance and, in the case of pigmentedfloors, the quality and consistency of the finish.

Limitations

Do not use Nitoflor Hardtop S in areas exposed to acidsand their salts or other materials known to rapidly attackor deteriorate concrete containing ordinary Portlandcement.

Do not apply to concrete containing calcium chloride orconcrete having greater than 3% air entrainment.

Where a coloured floor is required, it is stronglyrecommended that a site trial is undertaken to assesspossible local variations caused by aggregates andsands used in the base concrete.



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Fosroc®

Nitoflor Hardtop S

Storage

Store in unopened bags in cool dry internal conditions.The product has a shelf life of 12 months from the date ofmanufacture if kept in a dry storage in the original,unopened bags.

If stored at high temperatures and/or high humidityconditions the shelf life may be reduced to less than6 months.

Precautions

Health and safety


Fire

Nitoflor Hardtop S is non-flammable.


It is strongly recommended that a heavy duty sealant suchas Nitoseal MS300 be used to seal internal joints offactory and warehouse floors to take account of theincreased capacity of the treated floor.

For further information on these products, and otherswithin the Fosroc range, please contact your local Fosrocoffice or representative.


Nitoflor is the trade mark of Fosroc International Limited

156

Permanent hardening and dustproofingcompound for concrete surfaces

UsesAs a surface hardener for new and old concrete floor toprevent dusting and to increase durability. Suitable for useon concrete and granolithic surfaces. Typical applicationsinclude industrial floors, light engineering works,warehouses, animal feed and milk parlours, abattoirs, carparks, dams, reservoirs, tanks, silos and flues.

Advantages

Highly durable, improves abrasion resistance andreduces chemical attack from oils and greasesEasy to apply, no special equipment or skills requiredEliminates dust formation from within the treatedsurfaceEconomical and low cost method of floor protection

DescriptionNitoflor Lithurin is a white, soluble, crystalline powderbased on metallic fluorosilicates and wetting agents.

When Nitoflor Lithurin is mixed with water and applied tothe floor, the solution penetrates the concrete reactingwith lime and other soluble particles to form granite hardcrystals, leaving a permanent, hard wearing and dust freesurface.

Properties

Penetration: Specially selected wetting agents inNitoflor Lithurin improve the depth ofpenetration resulting in a more durablefinish better than that of other surfacetreatments which merely form a superficialskin

Hardness: The surface hardness is achievedthrough a chemical reaction within thecementitious material. This givesin-depth protection against heavy traffic andother forms of abrasion

Anti-dust: The chemical elimination of free limeand other soluble particles creates a tightlybound surface resistant to dusting

Chemical The inert crystalline compoundsresistance: formed by Nitoflor Lithurin application

reduce the absorbency of the surface andimprove resistance to solvents, greasesand commonly used chemicals

Consult the Fosroc Customer Service Department fordetails on resistance to specific chemicals

Application instructionsPreparation

Surfaces to be treated with Nitoflor Lithurin must bestructurally sound and free from loose materials. Cracksand holes should be repaired with Nitomortar PE resinmortar (see separate data sheet).

Oil and grease contamination should be treated with asuitable chemical de-greaser and washed with cleanwater and allowed to dry. Any laitance or existing coatingmust be removed prior to application as these will preventpenetration.

New concrete floors must be allowed to cure for 14 daysprior to treatment. Coloured floors should be allowed tocure for 28 days prior to treatment and a small area testedwith Nitoflor Lithurin to assess the effect on the colour.

Nitoflor Lithurin must only be applied to dry surfaces tomaximise penetration.

Mixing

Dissolve 15 kg of Nitoflor Lithurin with 45 litres (10gallons) of water in plastic containers and stir untilcompletely dissolved. Metal containers may be usedprovided the solution is used within 24 hours.

Application

Ensure that the surface to be treated is dry and apply themixed Nitoflor Lithurin at a rate of approximately 1 litre toevery 4.5 m² using a soft broom or brush. Ensure that thesurface is thoroughly saturated with the solution and wellbrushed out to prevent ponding.

Allow the solution to be absorbed into the floor for a periodof up to 2 hours. Do not allow the floor to dry out and whilstthe floor is still damp wash the surface thoroughly withclean water. Remove all surplus solution and water asstated in disposal instructions.

Failure to do so will result in a white dusty deposit left ondrying.

Nitoflor Lithurin should not be discharged into drains andstorm tanks. (See disposal instructions.)

Two coat application is recommended for completetreatment, but very dense, well trowelled surfaces such asgranolithic toppings, power floated or vacuum dewateredconcrete will generally require only a single coat.

If required, re-apply the solution after 24 hours ensuringthat the floor is dry. All surplus solution must be removed.

EstimatingNitoflor Lithurin is supplied in 15 kg buckets. One coatapplications require approximately one bucket to coverapproximately 200 m² . Two coat applications requireapproximately one bucket per 150 m². The degree ofporosity will affect the coverage rate achieved.

Fosroc®

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LimitationsNitoflor Lithurin solution is toxic and cannot be dischargedinto drains and storm tanks. Nitoflor Lithurin must bedisposed of in accordance with the EnvironmentalProtection Act 1990.

Metal, glass or paintwork must be protected againstNitoflor Lithurin. Should any splashes occur these mustbe removed immediately and disposed of by following thedisposal instructions.

Storage

Nitoflor Lithurin has a shelf life of 12 months if stored incool dry conditions in original, unopened buckets.



Fire

Nitoflor Lithurin is non-flammable.

Disposal

Due to the Environmental Protection Act 1990 solublefluorosilicates i.e. Nitoflor Lithurin cannot be dischargedinto drains or storm tanks and the given guidelinesshould be followed.

After treatment, the surplus solution and subsequentwashings must be vacuumed up to remove all traces ofthe solution from the surface. The storage andtransportation of this solution must be in polythene,plastic or stainless steel containers that can be lidded fortransport.

The residual liquid should be treated with builders limei.e. calcium hydroxide, in order to neutralise the solution.The lime should be thoroughly mixed with the solution, leftto stand for 24 hours and pH checked with litmus paperuntil a pH7 or above is achieved. Both lime and litmuspaper can be obtained from any chemical laboratoryequipment supplier such as BDH of Poole, Dorset.Builders lime can be obtained from any good buildersmerchant. As a guideline, 10 litres of solution will require

2 kg of lime for neutralisation. The pH of the solution mustalways be checked to ensure that complete neutralisationhas occurred.

The reaction with the lime produces a white precipitate ofcalcium fluorosilicate which may be disposed of on alandfill site. The remaining liquid can be washed awaydown drains with excess water.

All health and safety procedures and precautions must beadhered to whilst handling and disposing of the solution.


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Nitoflor is the trademark of Fosroc International Limited

158

Fast setting, pure polyurea elastomericfloor coating

General Information

Fosroc Polyurea FLM is a spray-applied, 100% solids,flexible, two-component, rapid curing pure Polyureasystem, designed as a floor protective coating. Itcombines the advantages of seamless, waterproofcoating with very long life cycles and high durability.

Polyurea FLM consists of Fosroc Polyurea FLM Part A ISOand Fosroc Polyurea FLM Part B AMINE and a pigmetedcolour pot. The system offers excellent surfaceproperties and overall physical properties.

Uses

Protective coating for flooring applications in a widerange of environmental conditions. Typical applicationsinclude:

Industrial floorsProcessing plantsFood processing areasStadiaWorkshops & production facilitiesManufacturing plantsPlant rooms

Note: Anti-slip and other coating properties may beprovided by the introduction of fillers or fibres by modifiedspray gun. Refer to the Fosroc Polyurea MethodStatement, and contact Fosroc for further advice.

Advantages

Environment friendly - zero VOCExcellent chemical resistance, thermal stability andUV Resistance *Very fast turn-around time. The coated substrate canbe put into service within an hourExcellent impact, abrasion and puncture resistanceSeamless and monolithic, including day jointsSignificantly enhances the durability of reinforcedconcreteLow permeability valuesDesigned for service temperatures from -30oC to+135oC

*See Limitations

Specification

The protective and/or wateproofing coating shall be FosrocPolyurea FLM, a 100% solids, flexible, two component,

rapid curing pure Polyurea coating system providing highcorrosion, abrasion and thermal shock resistance. It shallmeet the values under the section “ Properties”.

Properties

Typical Physical properties at 23oC

Solids by Volume : 100%Volatile organic compounds : 0 g/litreViscosity : A ISO =1000 mPas

: B AMINE <1500 mPasDensity at 23oC : 1.01 g/mlTensile strength ASTM D412 : >16 Nmm-2

Modulus 100%/ 200%/ 300%ASTM D412 : >9/ 12/ 15 Nmm-2

Tear Resistance ASTM D624C : 85 ± 5 N/mmElongation ASTM D412 : >300%Shore D ASTM D2240 : 47Abrasion (1kg,H22 wheels)ASTM D4060 : 29 mg /1000 cyclesAbrasion (1kg,CS17 wheels)DIN EN ISO 5470 : < 0.02mg /1000 cyclesService temperatureASTM D4060 : -30oC to +135oCColour : RAL 7005 GreyOther colours available to order

Chemical Resistance(ASTM D3912, 72 hours immersion)

Chemical Result Max service temp.Hydraulic Oil R 50oCMotor Oil R-DIS 50oCDiesel Fuel R 25oCPetrol R-DIS 25oCSkydrol NRSodium Hydroxide (50%) R 50oCAmmonia (0.880) 33% R 25oCSugar solution conc. R 50oCBleach (5%) R-DIS 50oCButanol R-C 25oCLactic Acid (20%) R 50oCPhosphoric Acid (10%) R 50oCHydrochloric Acid (20%) R-C 50oCNitric Acid (30%) R-C 25oCSulphuric Acid (10%) R 50oCR : RecommendedR-DIS : Recommended – Discolouration onlyR-C : Recommended – Conditional; discolouration

and/or slight softening or swelling – wash downwithin one hour to avoid effects

NR : Not Recommended

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Note: The chemical resistance recommendations givenabove apply to spillage and secondary containmentapplications with up to 72 hours contact duration; forany other requirements / chemicals contact Fosroc forfurther advice.

Clarification of property values

The typical physical properties given above are derivedfrom independent testing of Fosroc Polyurea FLM sprayapplied in accordance with the Fosroc Polyurea MethodStatement, in controlled laboratory environment. Resultsderived from testing field-applied samples may vary.

Processing and cure parameters

Block Temperature : +70o C to +80oCHose Temperature : +70o C to +80oCVolume ratio : 1:1Pressure : 120 - 150 barGel Time : 5 - 10 secWalkable : 2 minsTrafficable (light duty) : 15 - 20 minutesTrafficable (medium duty) : 24 hoursTrafficable (heavy duty) : 7 days


Refer to Application section below and Fosroc PolyureaMethod Statement for further detail.

Surface preparation

All surfaces must be clean, dry and free fromcontamination.

ConcreteDry abrasive blasting, wet abrasive blasting, vacuum-assisted abrasive blasting, and centrifugal shot blasting,as described in ASTM D4259, must be used to removecontaminants, laitance, and weak concrete, to exposeblow holes, and to produce a sound concrete surfacewith adequate profile and surface porosity.

Blow holesAll blow holes and minor surface imperfections shall befilled with Nitomortar FC prior to application of Primer. Seeseparate product data sheet. Nitomortar FC should beallowed to cure for 12 - 18 hours at 20oC. Lightly abrade thesurface and wipe with a cloth lightly wetted with FosrocEquipment Cleaner and allowed to dry prior to priming.

SteelThe steel must be of first class quality and must not havebeen allowed to rust more than corresponding to grade B

of BS EN ISO 8501-1:2007. Any laminations must beremoved.

Blast cleaning to Sa 2½. (ISO 8501-1:2007). Roughness:using abrasives suitable to achieve a coarse surface ofGrade Medium G (50-85μm, Ry5) (BS EN ISO 8503-2:2001).

All welding seams must have a surface finish whichensures that the quality of the paint system will bemaintained. All sharp edges must be removed orrounded off to ensure that the specified film thicknesscan be built-up on all surfaces. The radius of therounding must be minimum 2 mm.

Priming

Following correct preparation, the substrate must beprimed. Fosroc Primer 195 should be used.

For concrete, suggested application rate is 2.5 - 4 m2 perlitre; dependant on concrete porosity. On very porousconcrete higher application rates may be required.Consult Fosroc for further recommendations.

For steel substrates, a suggested rate of 6.5 m2 per litreis recommended.

Add the entire content of Part B into Part A and mix with aslow speed drill and paddle for 3 minutes untilhomogeneous.

Apply by brush, roller or squeegee to a uniformthickness. Initial spreading may be caried out by spraybut a final rolling shold be carried out to ensure fullwetting and even distribution of the primer.

A broadcast of 0.2 - 0.5 mm kiln-dried sand onto theuncured primer should be carried out to ensure optimumadhesion properties. Excess sand shold be removedprior to application of the Fosroc Polyurea FLM.

The primer shall be allowed to become touch-dry prior toapplication of Fosroc Polyurea FLM. Typically 1.5 hours at20oC, 2 hours at 10oC

Pot life Primer 195: 30 minutes at 25oC, 60 minutes at 15oC.

Application

Spray Equipment

A high pressure spray proportioning machine/ spray gunfor plural heated polyurea components such as thosemanufactured by GlasCraft or Graco should be used forthis product.

A list of appropriate equipment is provided in the FosrocPolyurea Method Statement.


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Application Method

Add the pigment paste, to the Part B AMINE drum andmix with a slow speed 300-400rpm bunghole mixer for20 minutes until homogeneous.

If pigmented material is stored it should be mixed with abunghole mixer for 20 minutes prior to use.

Avoid moisture contamination of bulk material, sealdrums for storage. Do not add solvent.

Heat the spray lines to 70 – 80oC.

Apply the Fosroc Polyurea FLM at the specified thickness(1.5 – 3.0 mm ) to the primed substrate in a cross hatchpattern with a minimum of two alternate directional passes.

If non slip surfaces are required consult Fosroc PolyureaMethod Statement.

Day joints : when overcoating material applied for morethan 12 hours. Remove any dirt / dust contamination. Wipesurface of cured coating with NEP (N-ethyl pyrrolidone).Apply Polyurea when surface is dry, typically 30 minutes witha 100mm overlap.

Due to the fast cure rate of Fosroc Polyurea FLMoverspray can only be removed mechanically.

Estimating

Supply:

Fosroc Polyurea FLMPart A ISO component : 200 ltr drumsFosroc Polyurea FLM PartB AMINE component : 200 ltr drums

: 195 ltr drums + separate colour pack

Fosroc Primer 195Part A Base : 12.5kg in 25 litre pailFosroc Primer 195Part B Hardener : 7.5kg in 10 litre pailFosroc Equipment Cleaner: 5 litre

Coverage:

Fosroc Polyurea FLM : 1.5 – 3.0 ltrs per m2

(1.5 - 3.0 mm) depending onspecification

Fosroc Primer 195 : Concrete : 2.5 - 4 m2 / litre: Steel : 6.5m2 / litre

Storage

Fosroc Polyurea FLM and Primer 195 have a shelf life of12 months if kept in a dry, air conditioned store between+5°C and +30°C in the original unopened containers.

Limitations

Fosroc Polyurea FLM should not be applied over existingcoatings.

Fosroc Polyurea FLM is not colour stable when exposedto sunlight and UV. This will not affect the cured physicalproperties of the product. If longterm aestheticsregarding colour stability is of critical importance, contactFosroc for further advice.

Application should not be undertaken by the methodsdescribed if the temperature is below 5oC or is 5oC andfalling or where the prevailing relative humidity exceeds90% or the dew point is less than 3oC above the surfacetemperature. Consult Fosroc if these conditions are notmet for specific advice.

Precautions

Health and Safety


Flash Point

Fosroc Polyurea FLM and Primer 195 are non-flammable.

Flash Point Fosroc Equipment Cleaner: 44oC


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Water based concrete curing compound

Uses

As a spray applied membrane to retain moisture inconcrete for effective curingSuitable for all general concreting applications and ofparticular benefit for large area concrete surfaces,such as airport runways, roads and bridgeworks

Advantages

Improved curing of concrete enhances cementhydration and provides a more durable concreteControl of moisture loss improves surface quality,reducing permeability, producing a hard wearing, dust-free surface and minimising potential for surfacecracking and shrinkageFugitive colour provides visual guide duringapplicationWater based, therefore, non-flammableSpray application reduces labour costs and eliminatesthe need for alternative curing systems


Concure WB gives 75% or greater curing efficiency whentested to BS 7542 and complies with ASTM C309 andAASHTO M148 as Type 1.

Description

Concure WB is a water based concrete curing compoundbased on a low viscosity wax emulsion. It is supplied as awhite emulsion which forms a clear film on drying.

When first applied to a fresh cementitious surface theemulsion breaks to form a continuous, non-penetratingwhite coating. This dries to form a continuous clear filmwhich provides a barrier to moisture loss, ensuring moreefficient cement hydration, improved durability andreduced shrinkage.


Minimum application temperature: 5°C

Concure WB should be spray applied to the surface offresh concrete. Application should begin immediately theconcrete is free from surface water. Do not apply if bleedwater is forming or present on the concrete surface.

The spray nozzle should be held approximately 450 mmfrom the concrete surface and passed back and forth toensure complete coverage. The fugitive white colourduring application provides a guide to the area covered.Pump pressure should be maintained to give an even,fine spray.

After spraying, no further application of water is necessaryto ensure continued curing. The concrete surface shouldnot be disturbed until it has sufficient strength to bearsurface loads. The applied film should not be walked onbefore it is fully dry and care should be taken to ensurethat the film is not broken.

Concure WB may also be applied to the surface of newlyhardened concrete immediately after demoulding. In suchcases the concrete surface must be damp and not dry.Dry surfaces may prevent correct film formation and causeabsorption of the Concure WB which may lead to stainingand difficulty in later removal.

Coverage rate

The recommended coverage rate is between 3.5 and5.0 m²/litre (0.200 to 0.285 litres/m²). Coverage ratesoutside this recommended range may be used ifnecessary and suitable to meet specific requirements.Contact the Fosroc Customer Service Department foradvice in such cases.

Equipment

Spray equipment producing a fine mist without damagingthe emulsion may be used for Concure WB, such asknapsack or motorised sprayers. The suitability ofequipment should be ensured by an application trial.

Equipment cleaning

Spray equipment should be cleaned immediately afteruse by flushing through with water. If spray nozzlesbecome blocked with wax particles these may be easilycleared with white spirit.

Overcoating and removal

Concure WB must be removed from a concrete surfacebefore application of a subsequent coating to ensure agood bond of the coating material to the concrete.Concure WB will be slowly removed by physical abrasionin normal trafficking and exposure. To ensure completeremoval use high pressure steam, water jet or light sandblasting.

Limitations

Concure WB should not be continuously re-circulated inhigh shear pumps in concrete train or similar applicationsas this may cause a breakdown of the emulsion beforespraying. If continuous recirculation is necessary, thesprayer should be fitted with a low shear diaphragmpump.

In extreme drying conditions additional curing usingpolythene or wet muslin may be required.

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Estimating

Supply

Concure WB is supplied in 200 litre and 20 litre drums.

Storage

Concure WB has a minimum shelf life of 12 monthsprovided the temperature is kept within the range of 4°C to35°C. Freezing and prolonged exposure to heat or directsunlight should be avoided. Should the temperature of theproduct fall outside this range then the Fosroc CustomerService Department should be contacted for advice.

Containers should be kept sealed and airtight to preventloss of moisture by evaporation.

Precautions

Health and safety


Fire

Concure WB is water based and non-flammable.

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163

Concrete remover, cleaning and etchingagent

Uses

For the removal of mortar and plaster runs, droppings andstains from brickwork and concrete surfaces. Also forremoval of hardened concrete from tools, machinery andequipment, or rust and mill scale from steelwork.

Suitable for etching of concrete floors and surfaces priorto application of resin or other surface coatings.

Advantages

Rapid concrete etching actionNo corrosive action with glass, plastic and rubberCleans hardened concrete from tools and mechanicalequipment

Description

Fosroc Acid Etch is a concrete remover, cleaning andetching agent. It is a combination of acid based material,corrosion inhibitors and dispersing agents and issupplied as a clear green solution.

Properties

Specific gravity: Typically 1.08 at 20°C


Cleaning brickwork and rust stains fromconcrete

A small trial area should be cleaned first to determine themost suitable Fosroc Acid Etch dilution. Pre-wet thesurface, then, using a sponge, rub the affected areas witha solution of Fosroc Acid Etch and water. Strength of thesolution required will vary but should be between 1:1 and1 : 4 (by volume) Fosroc Acid Etch to water. When theaction has finished, wash down thoroughly with cleanwater. As treatment with Fosroc Acid Etch can alter thesurface finish of concrete, the minimum concentrationnecessary for effective removal of stains should beemployed. The surface should be washed down withwater immediately treatment is complete.

Cleaning large items of equipment

(Examples are readymix trucks, concrete mixers orbarrows.)

Fosroc Acid Etch should be liberally applied to thedeposits by a soft broom and allowed to soak overnight ifpossible. If the surfaces of the deposit can be cracked bymechanical means this will speed up the operation. Insevere cases more than one application may benecessary. On completion, dissolved deposits and loosematerial should be brushed and washed away with cleanwater.

Cleaning small tools

Use Fosroc Acid Etch as a dip. The tools should besoaked overnight, then taken out and washed with cleanwater to remove all loosely adhering materials. Careshould be taken to avoid prolonged contact betweenFosroc Acid Etch and zinc or aluminium parts of tools,such as rivets, etc.

Cleaning concrete floors

Pre-wet the floors, then, using a stiff bristle broom, brushthe affected areas with a solution of Fosroc Acid Etch andwater. Strength of the solution required will vary but shouldbe between 1:1 and 1 : 4 Fosroc Acid Etch to water. Whenthe action has finished, wash down thoroughly with cleanwater.

Oil or grease should be removed by treatment with asuitable chemical degreaser followed by water or steamcleaning. Where heavy contamination occurs, as ingarages or workshops, pre-treatment with Fosroc AcidEtch assists in freeing oil or grease and renders theaction of the degreaser used more effective.

Removal of rust and mill scale

After wire brushing to remove loose material, apply asolution of Fosroc Acid Etch and water using a soft broomor brush and leave to act for 20 to 40 minutes. Strength ofthe solution required will normally be between 1:1 and1 : 4 Fosroc Acid Etch to water. Wire brush again to removeremaining loose material and finish by thoroughlywashing down with clean water. Repeat if necessary.

Etching concrete floors

For etching surfaces to remove laitance and give amechanical key before applying resin or other coating,Fosroc Acid Etch should be diluted with water and appliedat the rate of approximately 1 litre per 2 square metres.The dilution will depend on the condition of the floors andthe degree of etching required, but normally it will bebetween 1 : 2 and 1 : 4. When the action has finished,wash down thoroughly with clean water.

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Spillage

Spillages should be hosed down with plenty of water.

Caution

Fosroc Acid Etch is acid based and should be handledwith care. Acid vapours from undiluted product candamage nearby surfaces, notably causing rusting ofunprotected steel. If in doubt about its effect on a material,test a small area before general application.

Estimating

Supply

Fosroc Acid Etch: 25 litre drum210 litre drum

Storage

Store in original unopened packaging, in cool dryconditions, away from sunlight.

Precautions

Health and safety


Fire

Fosroc Acid Etch is non-flammable.


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165

Biodegradation resistant sealant

Uses

Nitoseal 12 is a two-part sealant designed to meet manyof the requirements of the water industry in water retainingstructures, sewage treatment and sea defence works. It isresistant to the bacteriological conditions associated withsewage treatment and silt accumulations in waterstorage. The abrasion resistance of Nitoseal 12 makes italso appropriate for use for sealing movement joints inconcrete sea walls subject to tidal scour.

The principal applications for Nitoseal 12 are:

Sludge digestion tanksFiltration and aeration tanksCulvertsRaw water reservoirsSea walls

Advantages

Resistant to aerobic and anaerobic bacteriologicalattackExcellent adhesion under immersed conditionsAbrasion resistantSeparate component for accelerating the initial cure

Description

Nitoseal 12 is a two-part, elastomeric joint sealant basedon polyurethane technology. It is supplied in packscontaining base compound and curing agent in thecorrect proportions which, when mixed, cure to form atough rubber-like material. Adhesion to most commonlyused construction materials is excellent.

The use of appropriate primers is essential to ensureproper adhesion. Fosroc Primer 7 is for use on poroussurfaces and Fosroc Primer 4 is for use on non-poroussurfaces.

In special circumstances, such as sealing sea defenceworks in tidal areas, a special Nitoseal 12 acceleratorcomponent is available, to be added when mixing toenhance the initial cure rate, so that work can becompleted between tides. At 10°C the seal can besubjected to tidal immersion approximately 60 minutesafter application, without adverse effect.


Joints shall be sealed, where designated, using Nitoseal 12,two-part biodegradation resistant sealant manufacturedand supplied by Fosroc. The sealant shall be mixed andapplied strictly in accordance with the manufacturer’sprinted instructions.

Design criteria

Example of an expansion joint in a reservoir wall is shownbelow

1 Nitoseal 12 4 Supercast Hydrofoil*2 Hydrocell XL* 5 Thioflex 600*3 Water face 6 External face

* Also available from Fosroc

Properties

Technical data — Nitoseal 12

Form: Two-part compoundBase: White pasteCuring agent: Dark-grey paste

Storage life: 12 months in original containers incool, dry conditions

Solids content: 100%Density: 1.44 kg/litreColour: GreyPhysical/chemicalchange: Chemical cureApplicationtemperature: 5°C to 50°CPot life: 2 to 3 hours at 25°C

With accelerator 20 minutes at 25°CCure rate: 48 hours at 25°C

With accelerator 24 hours at 25°CCure time: 48 hours at 25°C

96 hours at 10°CPermanent immersion in watershould not occur until full cure hastaken place

Note: The above times will be reduced by approximately50% if the accelerator is used.In a tidal situation, the sealant should incorporate theaccelerator and the sealing operation should becompleted at least 1 hour at 10°C prior to immersion.

Hardness shore‘A’ at 25°C: 35° to 40°

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Flammability: Burns but does not readily supportcombustion

Biological: Good resistance to both aerobic andresistance anaerobic conditions normally

occurring in sewage treatment worksMovementaccommodationfactor: 20% in butt joints

Technical data — Nitoseal 12 accelerator

Flash point: Over 65°CStorage life: 12 months in original containers in

cool, dry conditionsPack size: 50 ml


Joint preparation

Joints to be sealed must be accurately formed. They mustbe dry, clean and frost free. Dust, dirt, weak laitance, oldfailed sealant and other foreign substances must beremoved.

Ensure that expansion joint fillers are tightly packed andthat no voids are left at the base of the sealing slot.

Insert a self-adhesive polyethylene bond breaking tape atthe base of the joint. (Soft foam back-up material shouldnot be used.)

Priming

Prime the sides of the sealing slot using the appropriatesurface conditioner. Apply by brush, working well in,ensuring complete coverage.Porous surfaces: Fosroc Primer 7.Non-porous surfaces: Fosroc Primer 4.NB: Avoid using too much primer resulting in pools in thebase of the joint.

Allow the primer to dry. The sealant may be applied withinthe time period 30 minutes to 3 hours. That is after theprimer solvent has evaporated but before the film has fullyreacted. Any primed surfaces left longer than 3 hoursmust be re-primed before applying the sealant.

Mixing

Add the curing agent to the base component tin. Slit theend of the curing agent sachet, place it on the top edge ofthe tin and press with the lid to squeeze all the contentsinto the tin.

Note: If Nitoseal 12 accelerator is used it should be stirredwell before adding to the base with the curing agent priorto mixing.

Mix using a slow speed drill (300 to 500 rpm) fitted with aFosroc Sealant Mixing Paddle for not less than 4 minutesuntil a uniform colour is achieved with no streakiness.

Application

Load the mixed Nitoseal 12 into a Fosroc ‘G’ gun using aFollower Plate. Compact the Nitoseal into the primed joint.Tool off leaving a smooth finish.

Finishing

Nitoseal 12 can be finished by tooling-off smooth using ametal or wooden spatula. A minimum amount ofdetergent may be used to ease this operation. Remove allmasking tapes immediately after tooling. Excessivetooling can cause surface drag, this should be avoided.

Cleaning

Clean equipment immediately after use with FosrocEquipment Cleaner.

Estimating

Packaging

Nitoseal 12 accelerator is supplied in small, lever lid tinsin packs of 12. One tin of accelerator is required for each2 litre tin of Nitoseal 12.

Guide to Nitoseal 12 quantities

Joint size Litres per Metre runin mm (w x d) metre run per 2 litre5 x 5 0.025 80.010 x 5 0.050 40.020 x 10 0.200 10.025 x 15 0.375 5.330 x 15 0.450 4.440 x 20 0.800 2.550 x 25 1.300 1.6

Guide to primer quantities

1 litre of Fosroc Primer 7 to 30 litres of Nitoseal 12.

1 litre of Fosroc Primer 4 to 150 litres of Nitoseal 12.

Storage

Fosroc Primer 4 and Fosroc Primer 7 must be stored inaccordance with the Highly Flammable Liquids andLiquefied Petroleum Gases Regulations 1972.


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www.fosroc.com



Precautions

Health and safety

Nitoseal 12, Nitoseal 12 accelerator, Fosroc Primer 7,Fosroc Primer 4, Fosroc Equipment Cleaner:


Fire

Nitoseal 12 and Nitseal 12 accelerator are non-flammable.

Fosroc Primer 4, Primer 7 and Fosroc Euqipment Cleanerare highly flammable. See below for more details.

Fosroc FosrocPrimer 4 Primer 7

Flash point: 14°C 23°CCoverage: 60 m²/litre 12 to 15 m²/litreApplicationtemperature: 5°C to 50°C 5°C to 50°CDrying time: 2 to 15 minutes 20 to 60

minutesPack size: 250 ml 500 ml

5 litres

FosrocEquipment Cleaner

Flash point: 44°CStorage life: IndefinitePack size: 5 litres


Nitoseal is a trade mark of Fosroc International Limited

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One part, civil engineering sealant forimmersed conditions

Uses

Nitoseal MS600 is suitable for sealing movement joints inbuildings and civil engineering structures including jointsthat will be subject to intermittent or permanentimmersion.

Typical applications include:

ReservoirsSewage tanksSea walls (non-tidal)BasementsSubwaysParapetsBridgesSuperstructures

Advantages

Approved for use in contact with potable waterMeets key international standardsResistant to aerobic and anaerobic bacteriologicalattackExhibits excellent water resistanceExcellent resistance to dilute acids and alkalisCures to a tough, elastic rubber sealAccommodates continuous and pronounced cyclicmovementHigh resistance to ageing, reduces physical damagedue to climatic extremesSingle component yet fast rate of cureEasy to apply at low temperatureCan be applied to damp substratesIsocyanate free technology

Description

Nitoseal MS600 is a one part medium modulus sealantbased on hybrid silyl modified polyether technology. It hasa fast rate of cure and forms a tough, highly durable andwater resistant elastomer. Conforms to the Water Supply(water quality) Regulations 2000 and 2001 Regulations31(4b) for products having a small surface area in contactwith water for public supply.


ASTM C920-94:Type S, Grade NS, Class 25Conforms with the performance criteria ofBS4254 (1991)British Standard BS 6920 : Part 1:2000Water Regulations Advisory Service listed product.

Design criteria

Nitoseal MS600 should be applied to joints between 5and 35mm wide. Joints which are expected to experiencecyclic movements should be designed to an optimumwidth : depth ratio of 2:1, subject to the overridingrecommended minimum sealant depths set out below:5mm for metals, glass and other non-porous surfaces;8mm for all porous surfaces; 20mm for joints subject tohydrostatic pressure.

To ensure that the sealant remains within its statedmovement capacity (25% MAF), sealing slot widths shouldbe designed in accordance with the recommendations ofBS 6093.1993. The Movement Accommodation Factor is afigure quoted indicating the ability of a sealant toaccommodate joint movement throughout the service lifeof that sealant, expressed as a percentage of the jointwidth at time of sealing.

To calculate the theoretical minimum joint width knowingthe expected maximum working movement of the joint:

W = M __ + MMAF/100

W = Joint width

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The use of a bond breaker is not required in expansionjoints containing cellular polyethylene joint filler such asHydrocell XL or Expandafoam. For construction orcontraction joints a bond breaker tape or back-up stripshould be used.

Where a particularly neat finish is required, mask the faceedges of the joint before sealing and remove immediatelyafter tooling is completed.

Priming

Fosroc Primer MS2 is required for all joints.

When using primer, empty the entire contents of thehardener tin into the base tin and replace the base tin lid.Mix thoroughly by shaking for at least 2 minutes. Prime thejoint face using a clean, dry brush. Avoid over applicationof primer causing puddles in the bottom of the joint.

Nitoseal MS600 should be applied between 30 minutesand 4 hours after priming.

If a joint is left unsealed for more than 4 hours, the primershould be removed by grit blasting or grinding and thejoint re-primed.

Do not split packs of Fosroc Primer MS2.

Application and finishing

Cut the end off the sachet and place in the Fosroc GX gun.Fit the nozzle and cut at 45 degrees at a suitable size forsealing the joint.

Extrude the sealant firmly in to the joint. Tool flush within5 minutes of application to ensure good contact betweenthe sealant and the substrate.

Cleaning

Clean tools immediately after use with Fosroc EquipmentCleaner.

Estimating

Guide to quantities

Joint Litres per Metre run per metre run 600 ml sachet 6 x 10 0.06 10.00 12 x 10 0.12 5.00 20 x 20 0.40 1.50 25 x 12 0.30 2.00 30 x 15 0.45 1.33

Approximately 0.75 litres of Fosroc Primer MS2 will be

Fosroc®

Nitoseal MS600

M = Expected maximum working movement of jointMAF = Movement Accommodation Factor of that sealant

PropertiesForm: Smooth, non-slumping pasteColour: Grey

For special colours contactFosroc for further Information

MovementAccommodation 25% butt jointsfactor: 50% lap jointsSkinning time at20 C / 50% RH: 30 minutesCure rate at 24 hours: 3mm20 C / 50% RH: 48 hours: 6mm

72 hours: 8mmApplication 5°C to 50°CService Dry –30°C to +80°Ctemperature: Wet up to 40°CHardness shore‘A’ 20°C: 32Chemical Resistant to occasional spillage ofresistance: many chemicals: see limitationsBiological Nitoseal MS600 has been evaluatedresistance: in microbiologically active situations

and has been shown to haveresistance to aerobic and anaerobicconditions

UV resistance: ExcellentWater immersion: Nitoseal MS600 must be fully cured

before permanent immersion inwater


Joint surfaces must be clean, dry and free from frost.Remove all dirt, laitance, loose material and foreignmatter. Remove all rust, scale and protective lacquersfrom metal surfaces. Removal can be achieved byrigorous wire brushing, grinding or grit blasting.

Joints in concrete should preferably be sawn. Aftersawing, all saw slurry must be flushed away and the jointallowed to dry.

When resealing, the existing sealant should be removedfrom the joint and the arris cleaned back to sound cleanconcrete. All debris should be removed.

Any expansion joint filler must be checked to ensure it istightly packed and no gaps or voids exist at the base of thesealing slot before positioning a bond breaker.



170

Fosroc®

Nitoseal MS600


www.fosroc.com



sufficient for 90m of joint. No allowance has been madefor joint size or wastage.

Limitations

Should not be applied at temperatures below 5oCNot suitable for contact with bituminous materialsNot suitable for contact with solvents, oil or petrolWhilst Nitoseal MS600 has excellent adhesion tomany types of residual sealant, its use should not beconsidered a substitute for a good standard of jointpreparation

Packaging

Nitoseal MS600 – 10 no x 600ml sachets per box

Fosroc Primer MS2 – 0.75 litre packs

Storage

Store in original packaging in cool, dry conditions. Shelflife 12 months. Storage outside of these conditions mayreduce shelf life.

Precautions

Health and safety

Nitoseal MS600 is considered safe in normal use. Forfurther information refer to appropriate Product Safety DataSheet.

Fosroc Primer MS2 is highly flammable, see materialsafety data sheet for details.


Nitoseal is the trade mark of Fosroc International Limited


171

Hand applied flexible bituminous putty

Uses

Plastijoint is recommended for sealing joints, particularlyvertical and inclined joints, in most types of water retainingstructures.

Sewage disposal worksCulvertsSea wallsRetaining walls (brickwork and concrete)Subways and basement structures

Advantages

Designed for permanent immersion in waterTough, weather resistant sealExcellent slump resistanceEasily applied by handSuitable for joints up to 40 mm wideResistant to bacteriological attack

Description

Plastijoint is a thermoplastic bitumen based putty whichrequires heating to make it workable. On cooling it gives aslump-free, flexible seal.

Plastijoint is suitable for immersed joints including thosewhere biological activity occurs.

Plastijoint is suitable for sealing joints, including lowmovement expansion joints, in retaining walls andbasements. It is also suitable for sealing around pipe orcable entries into buildings.

Plastijoint may be applied to joints between 20 and 40mm wide. In most cases it is advisable to form a sealingslot approximately square in cross-section.

Where expansion joints are subject to hydrostatic head,Plastijoint seals require support from a compressiblefiller such as Hydrocell.

PropertiesForm: Stiff puttyColour: BlackMovementaccommodationfactor BS 6093: 10% for butt jointsApplication 5°C to 50°C (Plastijoint heated totemperature: 45°C to 55°C)Chemical Dilute acids resistantresistance to Dilute alkalis resistantoccasional Petroleum solvents non resistantspillage: Mineral oils non resistant

Vegetable oils non resistantBiological Plastijoint is resistant to the aerobicresistance: and anaerobic conditions normally

occurring in sewage treatment worksSolids content: 100%


Preparation

Plastijoint is applied by hand after it has been heated to45°C to 55°C by placing in a field oven or in boiling waterfor approximately 1 hour. When using water, the waterlevel should only come almost to the top of the tin (leavethe lid on). Plastijoint must not be subjected to directheating.

Joint preparation

Ensure that the joint surfaces are completely dry, cleanand frost-free. Remove all dirt, dust, laitance and loosematerial by rigorous wire brushing. Remove all rust, scaleand protective lacquers from metal surfaces. Remove anyoil or grease with Fosroc Equipment Cleaner. Inexpansion joints, Plastijoint must always be supported bya firm backing which allows free movement. Where aparticularly neat finish is required, cover face edges ofjoint with masking tape before priming and removeimmediately after sealing work is completed.

Priming porous surfaces

On concrete, stone, brickwork and timber, Fosroc Primer 3is required. The applied primer should be touch dry beforesealing.

Priming non-porous surfaces

Primer not normally required. Ferrous metals should betreated with an anti-corrosion primer.

Application

Take a convenient quantity of material from the tin andmould in gloved hand into a strip. While still hot, push thiswell down into the cavity to fill all crevices, ensuring goodcontact with the sides and base of the joint. If necessarycaulk home with a piece of damp wood.

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Fosroc® Plastijoint


www.fosroc.com



Note: If there is honeycombed concrete in the immediatevicinity of the joint, there is the risk that water underpressure may percolate behind the seal and pass into thejoint. In such cases, prime the area concerned and applyadditional sealant, working well into all cavities to give a‘mushroom’ finish. Joints subject to flowing water shouldbe finished flush or slightly concave.

Finishing

Heat a stripping knife and, working along the joint, cutaway excess material to present a neat finish. In coldweather a gas blowtorch may be run down the seal beforetrimming. Plastijoint requires no special tools, but the useof a caulking iron is recommended for easy consolidationand to give a neat finish to the seal.

Cleaning


Estimating

Guide to Plastijoint quantitiesJoint Litre Metre Joint Litre Metresize per per size per perin mm metre 5 litre in mm metre 5 litre20 x 20 0.40 13.0 30 x 50 1.50 3.3

25 0.50 10.0 35 x 25 0.88 5.730 0.60 8.3 30 1.10 4.8

25 x 20 0.50 10.0 40 1.40 3.625 0.63 8.0 50 1.80 2.930 0.75 6.7 40 x 25 1.00 5.040 1.00 5.0 30 1.20 4.2

30 x 25 0.75 6.7 50 2.00 2.540 1.20 4.2

Plastijoint is avaiable in 5 litre containers.

1 litre of Fosroc Primer 3 is sufficient for 75 metres of joint.Yields are theoretical and no allowance has been madefor variations in joint dimensions, substrate or wastage.

Storage

Shelf life

2 years stored in cool dry conditions in unopened originalcontainers.

Precautions

Health and safety


Fosroc Primer 3 is highly flammable, see material safetydata sheet for details.


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Plastijoint is the trade mark of Fosroc International Limited

173

Cold applied, high performance, pitch free,pavement joint sealant

Uses

For the sealing and maintenance of joints in concreteroads, concrete runways and hard standings. Colpor200PF is particularly suitable for sealing areas where fueland oil spillage might occur such as aircraft fuellingareas, oil terminals, garage forecourts, parking and cargoareas.

Advantages

Pitch freeCold applied — no heating equipment requiredFuel, oil and hydraulic fluid resistanceHigh durability and long service lifeHigh movement accommodation


British Standard 5212 :1990 — types N, F and FB.

U.S. Federal Specification SS-S-200E :1984.

Description

Colpor 200PF retains its movement accommodation of25% on butt joints throughout the extremes oftemperature, it does not harden in cold weather norbecome excessively soft or pick up in hot conditions.

In trafficked areas the maximum expansion joint widthshould be limited to 30 mm. It is necessary to recess thelevel of the sealant 5 to 8 mm below the pavement surfacedependent on the time of year and temperature prevailingat the time of sealing.

The width/depth ratio of the Colpor 200PF seal should be1:1 to 1½ :1 subject to a minimum 10 mm depth ofsealant (example, contraction joint: 15 mm wide x 13 mmdepth; expansion joint: 25 mm wide x 20 mm depth).

Properties

Form: Two part compoundBase compound: viscous liquidCuring agent: liquid

Colour: BlackMAF (BS 6093): Butt joints 25%Physical orchemical change: Chemical cureSetting time: After 16 to 24 hours Colpor 200PF

will be tack free and accept traffic.Full cure and maximum hardnessare attained in approximately 3 to 4days at 25°C

Application To avoid unacceptably prolongedtemperature: cure times, do not apply at

temperatures below 5°CHardnessshore ‘A’ at 25°C: 15 ± 5Chemical Aviation fuels Synthetic oilsresistance to Hydraulic fluids Mineral oilsoccasional Skydrol White spiritspillage: Kerosene Mild alkalis

Petrol Dilute acidsDiesel fuels

Solids content: 100%Flash point: Over 65°CFlammability: Burns but does not readily support

combustion


Joint preparation

Joint sealing slots in concrete should be accuratelyformed and must be dry, sound, clean and free from frost.Remove all dust and loose material by grit blasting orgrinding. Avoid polishing the joint sides when grinding.The prepared sealing slot should be blown out with dry,oil-free compressed air.

Ensure that any expansion joint filler is tightly packed inthe joint and insert a bond breaker or cord caulked tightlyinto the base of the sealing groove to prevent sealantadhering to the base of the slot and provide the specifieddepth of sealant.

Priming

Concrete joint faces should be primed with FosrocPrimer 20 or Primer 19.

Primer 20Decant sufficient primer into a clean dry tin for the daysusage. Do not return unused primer to the supply tin atthe end of the day. Prime the joint faces with a thinuniform coat of primer and allow solvent to evaporatebefore sealing. This takes between 30 minutes and 2hours depending on climatic conditions. If sealant is notapplied within 2 hours the joint face should be reprimed.

Where concrete joints are exposed or subject toconditions of prevailing damp or where the concrete isunusually dense or porous, (e.g. in parts of Scandinaviaand Northern Europe) the use of Primer 19 isrecommended. Contact the local Fosroc office for furtherdetails.

Primer 19Empty the entire contents of the Primer 19 hardener tininto the base tin, and replace base tin lid. Mix thoroughly

Fosroc® Colpor 200PF constructive solutions

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Fosroc® Colpor 200PF

by shaking tin for 2 minutes. Prime the joint face using aclean dry brush. Avoid over application of primer causingpuddles in the bottom of the joint. Colpor 200PF shouldbe applied between 30 minutes and 4 hours after priming.If the joint is not sealed overnight the primer film shouldbe removed by grit blasting and the joint reprimed.

The mixed Fosroc Primer 19 should be applied within oneworking day. Do not split packs of Fosroc Primer 19.

Mixing

Drain totally the contents of the curing agent tin into thelarge base component tin. Using a hand held, slow speeddrill (300 to 500 rpm) fitted with a Fosroc paddle bladestirrer mix for 1 minute. Stop and scrape around the top ofthe tin to remove any remaining curing agent. Continue tomix for 3 minutes until the material is thoroughly mixed.

In cold weather, Colpor 200PF mixes more easily if storedovernight at room temperature.

Application

Pour mixed sealant into a Fosroc G Gun after removing thenozzle end cap, pulling back the plunger rod and replacingend nozzle. In joints of 25 mm and above, the mixed sealantmay be poured directly from the tin by bending the side to forma pouring lip. Apply mixed sealant so that the finished levelof the seal is recessed below the trafficked surface asspecified.

Cleaning

Clean equipment immediately after use with FosrocEquipment Cleaner. Remove mixed material from thehands with ‘Swarfega’ or similar industrial hand cleanser.

Estimating

Packaging

Colpor 200PF is supplied in cartons containing 2 x 5 litreunits, comprising a tin of base and a tin of curing agent.

For machine application Colpor 200PF is available in 20litre units. Where a fast cure machine application isrequired refer to Nitoseal 888 data sheet.

Guide to Colpor 200PF quantities

Joint size Litre per Metre perin mm metre 5.0 litre pack10 x 10 0.100 50.0013 x 13 0.169 29.5815 x 15 0.225 22.2220 x 15 0.300 16.6620 x 20 0.400 12.5025 x 20 0.500 10.0025 x 25 0.625 8.0030 x 25 0.750 6.66

1 litre of Fosroc Primer 20 or Fosroc Primer 19 will besufficient for 25 litres of Colpor 200PF. Yields aretheoretical, no allowance has been made for variations injoint dimensions or wastage.

Limitations

For the sealing of industrial floor joints, higher modulussealants such as Thioflex 600* or Expoflex 800* (seeseparate data sheets) are recommended.

Colpor 200PF is not compatible with bituminoussurfaces. Where Colpor 200PF could come into contactwith pavement asphalt, please contact the local Fosrocoffice for advice.

Storage

Store Colpor 200PF in original containers in cool, dryconditions i.e. not exceeding 25°C. Storage life in theseconditions is 12 months. Storage above this temperaturemay reduce storage life.

Precautions

Health and safety


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Colpor is the trade mark of Fosroc International Limited


www.fosroc.com




175

Hot poured ‘N1’ polymer modified bitumensealant

Uses

For the sealing and maintenance of joints in concreteroads and asphalt surfacing

Advantages

Complies with the Department of TransportSpecification for Highway Works Clauses 1016and 1017Resists dirt and ingress of grit associated withtrafficked pavementsGood adhesion to concrete and asphalt surfaces

Description

Nitoseal 333 is a hot poured, high extension polymermodified bitumen sealant complying with therequirements of BS 2499 :1993 Type N1.

Nitoseal 333 has a movement accommodation factor of25% in butt joints. For optimum performance,consideration should be given to the possibility that themovement accommodation will not be evenly distributedbetween joints provided.

To ensure the sealant operates within the statedmovement capacity of 25%, the width of the sealing slotshould be designed in accordance with therecommendations of BS 6093.

Reference should also be made to Specification forHighway Works 1991, Table 10/6.


BS 2499 :1993 Type N1.

Nitoseal 333 has been independently tested toBS 2499 : N1 in accordance with the Department ofTransport Specification for Highway Works.


Where so designated on the drawing, joints are to besealed using Nitoseal 333 pavement sealantmanufactured by Fosroc to BS 2499 :1993 andindependently certified to Type N1 of this specification.Joints shall be prepared and the sealant applied inaccordance with the manufacturers current data sheet.

Joint size

Nitoseal 333 can normally be applied to a maximum jointsize of 30 mm width and 25 mm depth. Minimum jointwidth and depth dimensions should not be less than13 x 15 mm respectively except for longitudinal joints.Reference should be made to Specification for HighwayWorks 1991, Table 10/6 and BS 2499.

Properties

Form: Plastic solidColour: BlackMovementaccommodationfactor (BS 6093): Butt joints 25%Applicationtemperature: Over 5°CSafe heatingtemperature: 185°CPouring temperature: 165°C to 175°CChemical resistance: Not resistant to petrol, diesel,

lubricating oils or greasesSolids content: 100%Density: 1.15 ± 0.05Flash point: Over 65°C

Applications instructions

Joint preparation

Joint sealing slots in concrete should be accuratelyformed and must be dry, sound, clean and free from frost.Remove all dust and laitance by grit-blasting or grinding.Avoid polishing the joint sides when grinding. Theprepared sealing slot should be blown out with dry, oil-free compressed air. BS 2499 :1993 Pt 2 sets out a codeof practice for the application and use of hot applied jointsealants for concrete pavements.

Priming

Prime concrete surfaces with Fosroc Primer B2 and allowthe solvent to evaporate before sealing. Metal surfaces donot require priming but should be warmed with a gastorch immediately before sealing to promote adhesion.

Application

It is essential that the correct equipment is used formelting Nitoseal 333 to ensure that the subsequentperformance is not impaired by damage through over-heating or pouring at the wrong temperature. The heatingapparatus must be fitted with a thermometer, an oil jacketand a means of stirring the molten compound.

Remove Nitoseal 333 from outer cardboard packing. Nocardboard should be put into the heater. Cut Nitoseal 333and inner plastic bag into small pieces, melt a few piecesin the melting vessel, and gradually add more to themolten material, stirring occasionally. Heat until Nitoseal333 reaches its correct pouring temperature of 165°C to175°C.

Extra care must be taken in cold weather. The coldsurfaces of the joints may cause rapid chilling of thecompound. To help compensate for this, Nitoseal 333should be poured at the top limit of the pouring



176


temperature range. Frost may give concrete a deceptivelydry appearance.

Nitoseal 333 should be poured to a level 5 to 7 mm belowthe traffic surface, or to the level specified.

Nitoseal 333 which has been heated and then allowed tocool below 95°C must be discarded.

Cleaning

Equipment should be emptied immediately after use.Nitoseal 333 which has been heated and allowed to coolcompletely must be discarded.

Ancillary materials

Fosroc Primer B2Fosroc FibreboardFosroc Equipment Cleaner

Estimating

Packaging

Nitoseal 333 is supplied in 15 kg packs.

Guide to Nitoseal 333 quantities

Joint size Kg per Metres perin mm metre 15 kg pack10 x 10 0.12 12010 x 13 0.15 10010 x 15 0.18 8310 x 20 0.24 6213 x 15 0.23 6515 x 15 0.26 5715 x 20 0.36 4015 x 25 0.43 3520 x 20 0.48 3120 x 25 0.58 2625 x 25 0.72 2130 x 25 0.86 17

1 litre of Fosroc Primer B2 will be sufficient for 50 kg ofNitoseal 333.

These are theoretical yields. No allowance has beenmade for variations in joint dimensions or wastage.

Storage

Nitoseal 333 must be stacked flat not more than six highand covered if stored outside.

Fosroc Primer B2 should be stored in accordance with theHighly Flammable Liquids and Liquefied PetroleumGases Regulations 1972.

Limitations

Nitoseal 333 is not suitable for use in contact with tar orpitch based materials.

Nitoseal 333 should not be used in contact with potablewater.

Precautions

Health and safety


Fire

Fosroc Primer B2 is flammable. Keep away from sourcesof ignition. No Smoking. In the event of fire, extinguish withCO2 or foam. Do not use a water jet.


Technical data — ancillary materials

Fosroc Primer B2

Flash point: 0°CSpecific gravity: 0.9Coverage: 12 m²/litreApplication temperature: 5°C to 50°CPack size: 5 litre



www.fosroc.com





177

High performance, elastomeric, pavementjoint sealant

Uses

For the sealing and maintenance of joints in concreteroads, concrete runways and hard standings. Nitoseal878 is particularly suitable for sealing areas where fueland oil spillage might occur such as aircraft fuellingareas, oil terminals, garage forecourts, parking andcargo areas.

Advantages

Fuel, oil and hydraulic fluid resistanceHigh durability and long service lifeHigh movement accommodation

Standards

British Standard 5212:1990 - types N, F and FB.

Description

Nitoseal 878 is a two component product designed toretain its movement accommodation of 25% on buttjoints throughout temperature extremes. It does notharden in cold weather nor become excessively soft orpick up in hot conditions.

In trafficked areas the maximum expansion joint widthshould be limited to 30mm. It is necessary to recess thelevel of the sealant 5-8 mm below the pavement surfacedependent on the time of year and temperature prevailingat the time of sealing.

The width/depth ratio of the Nitoseal 878 seal should be1:1 to 1½:1 subject to a minimum 10mm depth of sealant(example, contraction joint: 15mm wide x 13mm depth;expansion joint: 25mm wide x 20mm depth).

Properties

Form: Two component productcomprising liquid base and curative

Colour: GreyMAF (BS 6093): Butt joints 25%Cure process: Chemical cureApplicationtemperatures: 5°C - 35°CSetting Time: After 6 hours @ 25o C Nitoseal 878

will be tack free and accepttraffic. Full cure and maximumhardness will be achieved in 3-4days at 25oC

Shore A Hardness: 20

Chemical Aviation fuels Synthetic oilsresistance to Hydraulic fluids Mineral oilsoccasional Skydrol White spiritspillage: Kerosene Mild alkalis

Petrol Dilute acidsDiesel fuels De-icing salts

UreaSolids content: 100%Flash point: Over 65°CFlammability: Burns but does not readily support

combustion


Joint preparation

Joint sealing slots in concrete should be accuratelyformed and must be dry, sound, clean and free from frost.

Remove all dust and laitance by grit blasting or grinding.Avoid polishing the joint sides when grinding. Theprepared sealing slot should be blown out with dry, oil-free compressed air.

Ensure that any expansion joint filler is tightly packed inthe joint and insert a bond breaker or Expandafoam cordcaulked tightly into the base of the sealing groove toprevent sealant adhering to the base of the slot andprovide the specified depth of sealant.

Priming

Concrete joint faces should be primed with FosrocPrimer 20.

Decant sufficient primer into a clean dry tin for the day’susage. Do not return unused primer to the supply tin.Prime the joint faces with a thin uniform coat of primerand allow solvent to evaporate before sealing. This takesbetween 30 minutes and 2 hours depending on climaticconditions. If sealant is not applied within 2 hours thejoint face should be reprimed.

Where concrete joints are exposed, or subject toconditions of prevailing damp, or where the concrete isunusually dense or porous, the use of Primer 19 isrecommended. Contact the local Fosroc office for furtherdetails.

Empty the entire contents of the Primer 19 hardener tininto the base tin, and replace base tin lid. Mix thoroughlyby shaking tin for 2 minutes. Prime the joint face using aclean dry brush. Avoid over application of primer causingpuddles in the bottom of the joint. Nitoseal 878 should beapplied between 30 minutes and 4 hours after priming. Ifsealant is not applied within 4 hours the joint face shouldbe reprimed.

The mixed Fosroc Primer 19 should be applied within oneworking day. Do not split packs of Fosroc Primer 19.


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Mixing

Drain totally the contents of the curing agent tin into thelarge base component tin. Using a hand held, slow speeddrill (300 to 500 rpm) fitted with a Fosroc paddle bladestirrer mix for 1 minute. Stop and scrape around the top ofthe tin to remove any remaining curing agent. Continue tomix for 3 minutes until the material is thoroughly mixed.

In cold weather, Nitoseal 878 mixes more easily if storedovernight at room temperature.

Application

Pour mixed sealant into a Fosroc G Gun after removingthe nozzle end cap, pulling back the plunger rod andreplacing end nozzle. In joints of 25 mm and above, themixed sealant may be poured directly from the tin bybending the side to form a pouring lip. Apply mixedsealant so that the finished level of the seal is recessedbelow the trafficked surface as specified.

Cleaning

Clean equipment immediately after use with FosrocEquipment Cleaner. Remove mixed material from handswith ‘Swarfega’ or similar industrial hand cleanser.

Estimating

Packaging

Nitoseal 878 is supplied in cartons containing 2 x 5 litreunits, comprising a tin of base and a tin of curing agent.

Guide to Nitoseal 878 quantitiesJoint size Litre per Metre perin mm metre 20.0 litre pack10 x 10 0.100 20013 x 13 0.169 11815 x 15 0.225 8920 x 15 0.300 6720 x 20 0.400 5025 x 20 0.500 4025 x 25 0.625 3230 x 25 0.750 26

1 litre of Fosroc Primer 19 or 20 will be sufficient for 20litres of Nitoseal 878. Yields are theoretical, noallowance has been made for variations in jointdimensions or wastage.

Limitations

Apply at temperatures of 5°C and rising. Do not warmmaterial above 35°C.

Do not apply direct heat to product.Nitoseal 878 is not compatible with bituminous surfaces.Where Nitoseal 878 could come into contact withpavement asphalt, please contact the local FosrocTechnical Department.

For the sealing of industrial floor joints, higher modulussealants such as Nitoseal MS300* or Expoflex 800* arerecommended. *See seperate data sheet

Storage

Nitoseal 878: 12 months in original containers stored incool, dry conditions i.e. not exceeding 25°C. Highertemperatures may reduce storage life.

Precautions

Health and safety


12CI/SfB:

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www.fosroc.com




179

Hot-poured rubber bitumen horizontaljoint sealant

Uses

For sealing movement and construction joints inpavements, floor slabs, water retaining and waterexcluding structures

Advantages

An economic sealant for horizontal and inclined jointsup to 1 in 20Resists dirt and ingress of grit associated withtrafficked pavementsGood adhesion to concrete and asphalt surfaces


BS 2499 :1993 — Pliastic N2.

Description

Pliastic sealants are available in a choice of two grades:

Pliastic N2

Complies with BS 2499 :1993. A low extension grade forsealing joints in concrete pavements, etc.

Pliastic 77

A hard grade for sealing low movement joints in factoryfloors and areas where joints are closely spaced andresistance to grit and traffic is of prime importance.

Design criteria

Joint size

Pliastic compounds are suitable for joints up to 30 mmwide in trafficked surfaces, but joints up to 65 mm widecan be sealed with Pliastic where the joints are horizontaland are not subject to trafficking. The depth of Pliasticcompounds should not exceed 50 mm and for mostnormal uses, 25 mm is recommended.

Pliastic can be used on inclined surfaces up to about 1 in20. Extra care must be taken, however, when pouring.Vertical joints e.g. kerbs, upstands, etc, should be sealedwith Plastijoint.

Road and traffic surfaces

When sealing joints in reinforced and unreinforcedconcrete roads and airfield runways ensure the joint isrecessed 3 to 5 mm below the traffic surface.

Water retaining structures

When sealing joints in water retaining structures allimmersed joints should contain waterstops. All roof jointsshould also include a supplementary means of sealing.

Water excluding structures

All joints which extend below the high water table levelshould contain a waterstop in addition to the Pliastic seal.

Services and internal finishes

Pliastic 77 is suitable for sealing joints in factory floorsother than those subjected to petrol, oils or fats. Pliasticsoftens when heated and should not be used in floorswith under-floor heating or in areas where it would besubjected to heat from factory plant or steam cleaningoperations.

Ensure the joint is recessed 3 to 5 mm below the trafficsurface.

Properties

Form: Plastic solidFlash point: Over 65°CSolids contents: 100%Density: 1.02 kg/litreColour: BlackApplicationtemperature: Over 5°CProduct pouring Pliastic N2: 175°C to 185°Ctemperature Pliastic 77: 180°C to 190°Crange:Safe heating Pliastic N2: 190°Ctemperature: Pliastic 77: 195°CChemical Dilute acids: resistantresistance to Dilute alkalis: resistantoccasional Petroleum solvents: not resistantspillage: Mineral oils: not resistant

Vegetable oils: not resistantGreases: not resistant

Movement Total joint range, butt joints:accommodation Pliastic N2: 12%factor: Pliastic 77: 10%

Maintenance

No special requirement, damage should be repaired ifand when it occurs.


Joint preparation

Ensure that the joint surfaces are completely dry, cleanand frost free. Remove all contamination preferably by gritblasting or by rigorous wire brushing.

Immediately prior to priming blow out all remaining loosedust with dry, oil-free compressed air.

Where applicable, care must be taken to ensure thatcompressible filler, such as Fosroc Fibreboard, willprovide adequate support for the Pliastic compound.

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Fosroc® Pliastic


Use Fosroc Primer B2 on concrete, stone and brickpaving. Allow primer to become touch dry before sealing,normally 1 to 4 hours.


Metal surfaces do not require priming but should bewarmed to ensure satisfactory adhesion. Ferrous metalsshould be treated with an anti-corrosion primer.

Stripping of sacks

Lay sack on flat surface and cut bottom seam with a sharpknife. Tear away outer layers and then strip off inner layerof paper, working from the bottom of the sack. No papershould be put into the heater.

Heating

The use of a heating vessel with an oil jacket and fittedwith stirrer and thermometer is essential.

Cut the compound into small pieces, melt a few piecesthen gradually add more pieces to the molten material,stirring continuously. Heat until the compound reachescorrect pouring temperature.

Pouring temperatures:Pliastic N2: 175°C to 185°C.Pliastic 77: 180°C to 190°C.

Do not overheat. Use as soon as possible after heating,preferably within 2 hours.

Safe heating temperatures:Pliastic N2: 190°C.Pliastic 77: 195°C.

Caution: Heating of compound should be carried out inwell ventilated areas.

Extra care should be taken in cold weather. The coldsurfaces of the joints may cause rapid chilling of thecompound. To help compensate for this, the compoundshould be poured at the top limit of the pouringtemperature range. Frost may give concrete a deceptivelydry appearance.

Compound which has been heated and then allowed tocool below 95°C must be scrapped. It must not beremelted for use. In expansion joints, Pliastic should bepoured to a level 3 to 5 mm below the traffic surface toallow for upward displacement when the joints close.

Note: For small jobs, Pliastic 77 may be used with asmall, directly heated vessel, but great care must be takento avoid over-heating the Pliastic compound. In suchcases limited quantities of the material should be cut upinto small lumps and melted by gradually adding thepieces to the molten mass whilst continually stirring.

Application

Joints should be filled to the surface of the concrete or tothe level specified. Joint seals in carriageways arenormally recessed 3 to 5 mm to avoid extrusion. Aconcave finish due to shrinkage on cooling is normal butin a deep or narrow joint the compound may be poured intwo layers to produce a uniform finish.

Cleaning

Equipment should be emptied immediately after use.Compound which has been heated and allowed to coolcompletely must be scrapped.

Estimating

Packaging

Pliastic N2 and Pliastic 77 are supplied in the UK in papersacks containing 15 kg. All grades of Pliastic are suppliedoverseas in steel drums containing 50 kg.

Fosroc Primer B2 is supplied in 5 or 25 litre cans.


5 litres Fosroc Primer B2 for 250 kg of Pliastic.

Guide to Pliastic quantities

Joint size Kg per Metre per Metre perin mm metre run 15 kg sack 50 kg drum10 x 20 0.20 76 255

25 0.25 61 20430 0.29 51 17040 0.39 38 127

15 x 20 0.29 51 17025 0.37 41 13630 0.44 34 11340 0.59 26 8550 0.74 20 68

20 x 20 0.39 38 12825 0.49 31 10230 0.59 26 8540 0.78 19 64

30 x 25 0.74 20 6830 0.88 17 5740 1.18 13 4350 1.47 10 34

40 x 25 0.98 15 5140 1.57 10 3250 1.96 8 26


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Limitations

Pliastic compounds are suitable for sealing againstbituminous asphalt surfaces. Pliastic compounds do notcomply with the fuel resistant requirements ofBS 2499 :1993 and should not be used in airfieldhardstandings, cargo handling areas, garage forecourtsor other paved areas subject to fuel and oil spillage. Forthese applications Colpor 200PF should be used.

Water excluding substructures

Pliastic compounds are suitable for use in joints inbuilding basements, subways, etc. All joints which extendbelow the high water table level should containwaterstops in addition to the Pliastic seal.

Storage

Pliastic must be stacked flat not more than six high andcovered if stored outside.

Fosroc Primer B2 must be stored in accordance with theHighly Flammable Liquids and Liquefied PetroleumGases Regulations 1972.

Storage life is 2 years if kept in the above conditions.

Precautions

Health and safety



Pliastic is a trade mark of Fosroc International Limited

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182

Heavy duty epoxy urethane joint sealant

Uses

For sealing internal joints subject to, heavy loading, andabrasion or where chemical resistance is required. Canbe used in factories, warehouses and distributioncentres. It is, particularly effective where there is forklifttruck traffic. Expoflex 800 can also be used where jointswould be subject to stiletto heels, shopping centres,podium etc.

Advantages

Cures to a tough sealAbrasion resistantHigh modulusResistant to chemical, fuel and oil spillageEasily installed to give a flush finish

Description

Expoflex 800 is a two-component elastomeric sealant forlimited movement joints. After mixing, the resultantcompound will cure to provide an exceptionally robustseal, while retaining a degree of flexibility. Expoflex 800 isabrasion resistant and withstands spillage of fuel oils,mineral acids and vegetable oils. Expoflex 800 can beused in joints between 5 mm and 50 mm wide.


The joint sealant shall be Fosroc Expoflex 800, an epoxyurethane, heavy duty sealant. It shall be applied strictly inaccordance with the Fosroc data sheet.

Properties

Expoflex 800

Form: Two-part compoundBase: White pasteCuring agent: Grey paste

Colour: Light greyMAF (BS 6093): 10% for butt jointsCure: Chemical curePot life: 1 hour at 25°CTrafficking time: 24 hours at 20°C: light traffic

48 hours at 20°C: heavy trafficApplication To avoid prolonged cure timetemperature: apply Expoflex 800 above 5°CHardness Shore ‘A’: 65 to 80

Chemical resistance Resistant to alcohols, alkalis,to occasional mineral oil, hot detergentspillage: solution,

60% live steam, 25% mineralacids, vegetable oils andkerosene

UV resistance: Some surface discolouration andslight surface hardening

Solids content: 100%Density: 1.4 g/cm³Flash point: Over 65°C


Joint Design

Joints should be designed so that joint changes do notexceed the 10% MAF of Expoflex 800.

We would recommend that joints in new concrete slabsare left to the final stages of construction whentemperatures have stabilised and the initial shrinkagehas taken place.

Where joints are less than 25 mm and are fullysupported by a solid backing, minimum depth should be10 mm to 15 mm. Where a resilient backing, minimumdepth should be 20mm. For wider joints a squaresection is preferable

Preparation

Joint surfaces shall be clean, dry and free fromcontamination. Any voids or gaps at the base of thesealing slot should be filled and a suitable bond breakershould be pushed into construction and contraction jointslots. Where a particularly neat finish is required maskedges of joint before priming (if required) and sealantapplication.

Priming

Where surface shall be subject to submersion orpermanently damp, joints should be primed using FosrocPrimer 13X. Decant the entire contents of primer curingagent into the primer base and stir thoroughly until mixed.Apply the primer using a clean dry paint brush workingwell in to ensure complete coverage. Allow to dry for 30minutes prior to application of the sealant. If the primercoating is left for more than2 hours, re-prime.

Mixing

In cold weather Expoflex 800 mixes more easily if storedovernight at room temperature. Transfer the contents ofthe small tin into the base tin and mix thoroughly using aslow speed drill (300 to 500 rpm) fitted with a FosrocPaddle Stirrer until a uniform colour is achievedthroughout. Immediately after mixing load the Expoflex

Fosroc® Expoflex 800 constructive solutions


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800 into a “G” gun using a follower plate. Extrude thesealant firmly into joint to ensure complete contact withthe joint face.

Finishing

Expoflex should be tooled off flush with adjacentsurfaces. A minimum of surface lubrication such as dilutedetergent solution may be used to assist the process.Remove masking immediately after tooling.

Cleaning


Estimating

Expoflex 800 is supplied in 2 litre tins in cartons of two.

Guide to quantities

Joint size Litres per Metre run perw x d in mm metre run 2.0 litre pack5 x 15 0.075 26.675 x 20 0.100 20.0020 x 10 0.200 10.0020 x 25 0.500 4.0025 x 25 0.625 3.2030 x 25 0.750 2.6730 x 30 0.900 2.2240 x 25 1.000 2.0040 x 40 1.600 1.2550 x 25 1.250 1.6050 x 50 2.500 0.80

200 ml tin of Fosroc Primer 13X is sufficient for 2m2 ofExpoflex 800. These are theoretical yields. No allowancehas been made for variations in joint width or wastage.

Storage

Storage life of 12 months in original containers when keptin dry conditions between 5°C and 27°C.

Precautions

Health and safety




Expoflex is the trade mark of Fosroc International Limited

184

One-part, low modulus neutral cure siliconesealant

Uses

For sealing joints in building structures, uPVC windowsand door frames.

Advantages

Neutral cure system — appropriate for porous andnon-porous surfacesElastic low modulus sealGood adhesion to a variety of substrates includinguPVCGood application properties

Description

Hilastic LM is a one-part neutral curing silicone sealantsuitable for sealing around uPVC windows andmovement joints in concrete, brickwork and a variety ofother substrates. Hilastic LM cures on exposure to air andhumidity to form a flexible seal that requires nomaintenance throughout its service life.

Hilastic LM may be applied to joints between 5 and 25mm wide and 5 and 12 mm deep. For joints over 10 mmwide, a width to depth ratio of 2 :1 should be applied up toa maximum depth of 12 mm.

Properties

Form: Thixotropic pasteColours: White, brown, grey, buff, brick red,

portland, black, dark greyCure: Chemically cures to a solid rubberSkinning time@ 23°C: 30 minutesCure rate @ 20°C /65% RH: 1 mm / dayApplicationtemperature: 5°C to 40°CTypical hardnessshore @ 20°C /60% RH: 30Movementaccommodationfactor (MAF): 50%


Preparation

Joint surfaces must be clean, dry and free from frost.Remove all dirt, laitance, loose material and foreignmatter. Remove all rust, scale and protective lacquersfrom metal surfaces. Non-porous surfaces should bedegreased using Fosroc Solvent 102.

In movement joints Hilastic LM must be supported byExpandafoam cord backing which will allow freemovement. If insufficient depth is available use a selfadhesive bond breaking tape.

Where a particularly neat finish is required, cover faceedges with a masking tape and remove immediately aftersealing work is completed.

Application

Extrude the sealant firmly into the joint to ensure completecontact with joint faces. Smooth finish if necessary with aspatula wetted with detergent solution. Joint should betooled within 5 minutes of application.

Cleaning

Clean tools immediately after use with Fosroc EquipmentCleaner. Clean hands with a proprietary hand cleaner.

Limitations

Not suitable for trafficked joints or for permanentlyimmersed conditions.

Should not be used on substrates which bleed oils,plasticisers or solvents.

Not to be used with bitumen compounds.

Cure may be retarded in conditions of very low humidityand temperature.

Hilastic LM should not be overcoated or painted evenwhen fully cured.

Like most silicone sealants, Hilastic LM should not beused on natural stone.

Estimating

Packaging

380 ml plastic cartridges with separate screw-on nozzles,packed in cartons of 20. Total contents approximately7.6 litres.

Fosroc® Hilastic LM constructive solutions


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Guide to sealant quantities

Joint size Litre per Metre perin mm metre run 380 ml cartridge5 x 5 0.025 15.205 x 10 0.050 7.6010 x 10 0.100 3.8015 x 10 0.150 2.5320 x 10 0.200 1.9025 x 12 0.300 1.27

These are theoretical values. No allowance has beenmade for variation in joint dimensions or wastage.

Storage

Storage life 12 months. Store in original containers incool, dry conditions. Storage outside these conditionsmay reduce shelf life.

Precautions

Health and safety




Hilastic is the trademark of Fosroc International Limited

186

One part, general purpose building sealant

Uses

Nitoseal MS50 is suitable for sealing joints in Concrete,Brickwork, Blockwork, Perimeter sealing around doorsand windows, Non-trafficked floor joints.

Advantages

Excellent adhesion to most common buildingmaterialsSingle component with fast rate of cureEasy to apply at low temperatureCan be applied to damp substratesEnvironmentally friendlyPrimer-less for most applications (see “Priming”)Available in a range of colours (see “Properties”)Isocyanate free technologyActs as an acoustic sealant

Description

Nitoseal MS50 is a one part, medium modulus sealantbased on hybrid silyl modified polyether technology.

PropertiesForm Smooth, non-slumping pasteColour White, Grey, Black, Magnolia,

Buff, Portland,Rustic Red,Brown, Anthracite

Flash point > 65oCSkinning time at 30 minutes20 C / 50%RHCure rate at 20 C, 24 hours 3mm50% RH 48 hours 6mm

72 hours 8mmApplication temperature 5oC to 50oCTypical hardness Shore 28“A” at 20 CMovement accommodation 20%factor (MAF)UV resistance GoodService temperature range -30oC to 70oC


Joint surfaces must be clean dry and free from frost.Remove all dirt, laitance, loose material and foreignmatter. Remove all rust, scale and protective lacquersfrom metal surfaces.

Removal can be achieved by rigorous wire brushing,grinding or grit blasting.

Joints in concrete should preferably be sawn. After sawingall saw slurry must be flushed away and the joint allowedto dry.

When resealing, the existing sealant should be removedfrom the joint and the arris cleaned back to sound cleanconcrete. All debris should be removed.


The use of a bond breaker is not required in expansionjoints containing cellular polyethylene joint filler such asHydrocell XL or Expandafoam. For construction orcontraction joints a bond breaker tape or back-up stripmust be used.

Where a particularly neat finish is required, mask the faceedges of the joint before sealing and remove immediatelyafter tooling is completed.

Priming

In joints where limited movement is expected, a primer isnot normally required. In joints subjected to highmovement or where intermittently immersed duringservice Fosroc Primer MS1 is recommended.

Prime the joint face using a clean, dry brush. Avoid overapplication of primer causing puddles in the bottom of thejoint.


If a joint is left unsealed for more than 4 hours, the primershould be removed by grit blasting or grinding and thejoint reprimed.

(For further advice on priming required please contactyour local Fosroc Technical Service Department.


Sachets

Cut the end off the sachet and place in the Fosroc GX gun.Fit the nozzle and cut at 45 degrees at a suitable size forsealing the joint.

Cartridges

Cut end off threaded stub on cartridge, Fit the nozzle andcut at 45 degrees at a suitable size for sealing the joint.

Extrude the sealant firmly in to the joint. Tool flush within5 minutes of application to ensure good contact betweenthe sealant and the substrate.

Cleaning


Fosroc®



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Estimating


Joint size Litres/ Metres/ Metres/ mm metre run 380ml crtdge 600ml sachets

6 x 10 0.06 6.33 10.00 12 x 10 0.12 3.17 5.00 20 x 10 0.20 1.90 1.00 25 x 12 0.30 1.27 2.00 30 x 15 0.45 0.84 1.33

0.5 litres of Fosroc Primer MS1 will be sufficient for 60m ofjoint. No allowance has been made for joint size orwastage.

Packaging

Nitoseal MS50 10x600ml sachets per box in Grey

20x380ml cartridges per box in allcolours

Fosroc Primer MS1 0.5 litre packs

Limitations

Should not be applied at temperatures below 5oCNot suitable for water immersed conditions. NitosealMS600 should be used for this applicationNot suitable for contact with bituminous materialsNot suitable for trafficked floor joints. Nitoseal MS300should be used for this applicationMay cause staining to decorative stone. For anon-staining sealant use Nitoseal MS100Not suitable for contact with solvents, oil or petrolNitoseal MS50 should only be over-painted with acompatible, flexible coating capable ofaccommodating the envisaged movement in the joint.Overcoating may reduce the MAF of the sealant.

Storage

Store in original packaging in cool, dry conditions. Shelflife 12 months. Storage outside of these conditions mayreduce shelf life.

Precautions

Health and safety

Nitoseal MS50 is considered safe in normal use. Forfurther information refer to appropriate Product Safety DataSheet.

Fosroc Primer MS1 is flammable, see Material SafetyData Sheet for details.



www.fosroc.com





188

One part, primer-less, non-staining facadesealant

Uses

Nitoseal MS100 has been formulated for stain-freesealing of joints in and around concrete, brick, masonry,pre-cast panels, stone cladding, windows, doors and fibrecement sheeting.

Advantages

Will not stain masonry, marble or other surfaces.Excellent primer-less* adhesion to most commonbuilding materials.Can be applied to damp substratesFast neutral cure.Highly flexible with excellent applicationcharacteristics.Low odour, environmentally friendly.Low modulus and high movement capabilities.Excellent UV and weather resistance

Nitoseal MS100 may be used as a sealant to assistwith sound insulation.

Good adhesion to silicone, polysulphide orpolyurethane contaminant.

* Refer to Priming section.

Standard compliance

ISO 11600 Type F 25LM

Description

Nitoseal MS100 is a tough, durable elastomeric jointsealant. It is based upon hybrid silyl modified polyethertechnology. It is suitable for use over a wide range ofexternal and internal building applications and hasexcellent weather resistance.

Nitoseal MS100 has excellent primer-less adhesion to awide range of common building substrates and does notstain concrete, marble and other masonry surfaces.

Properties

Uncured sealant:

Form: Smooth, non slump pasteFlash point: >65oCSolids content: 100% approximatelyApplication temperaturerange: 5oC to 50oCSkinning time: 25 mins, 20oC/50% RHCure rate: 3 mm in 24 hrs, 8mm in 7 days

20oC/50% RH

Cured sealant:

Form: Elastic solidColour: White, Grey, Black, Portland,

Buff, Rustic RedTypical hardnesssShore 'A' @ 20oC: 20Modulus classification: LowU.V. resistance: ExcellentService temperaturerange: -40oC to 70oCMAF: Butt joints 25% unprimed

50% primedLap joints 50% unprimed

100% primed

Application Instructions

Preparation

Joint surfaces must be clean and free from frost and ragdry, preferably completely dry. Remove all dirt, laitence,loose materials and foreign matter. Remove all rust,scale and protective lacquers from metal surfaces. Nonporous surfaces should be degreased using FosrocEquipment Cleaner.

In all joints an Expandafoam or Hydrocell XL polyethylenefoam backing should be used to prevent sealant contactwith the back of the joint, and hence allow optimumperformance.

In shallow joints self adhesive debonding tape can beused.

Fosroc®


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Priming

Good adhesion can be gained on concrete, timber,metals, ceramics, brickwork and most coating surfaceswithout the use of primers. On some porous surfacessuch as GRC, adhesion will be improved by the use of aprimer - refer Fosroc Technical Service for further advice.

Application

Cartridge: Cut the end off threaded stub on cartridge,screw on nozzle and cut nozzle to desired bead size at a45o angle.

Extrude the sealant firmly into joint to ensure completecontact with joint faces. Smooth finish if necessary with aspatula wetted with a dilute detergent solution.

Cleaning


Overpainting

The practice of overpainting sealants which experience ahigh degree of movement is discouraged as it can resultin premature failure of the sealant.

However, Nitoseal MS100 may be overcoated with water-based elastomeric coatings such as Dekguard Elasticand exterior emulsion paints such as Dekguard W. Testsshould be carried out to confirm compatability of sealantand proposed paint systems.

Nitoseal MS100 should be allowed to cure fully before theapplication of the coating or paint. For best results thesealant should be allowed to weather prior to overcoating.

Estimating

Nitoseal MS100 is supplied in 380 ml cartridges.

To work out quantities (excluding wastage) use thefollowing formula:

S__ = Lineal metres per packW x D

S = Packaging size in millilitresW = Sealant profile width in millimetresD = Sealant profile depth in millimetres


Joint size Litre per Metre perin mm metre run 0.38 litre cartridge

3 x 5 0.015 25.33 x 10 0.030 12.665 x 5 0.025 15.25 x 10 0.050 7.610 x 5 0.050 7.610 x 10 0.100 3.815 x 10 0.150 2.5420 x 10 0.200 1.925 x 15 0.380 1.0

These are theoretical yields. No allowance has beenmade for variation in joint dimensions or wastage.

Design criteria

Movement Accommodation Factor (MAF)

The Movement Accommodation Factor is a figure quotedindicating the ability of a sealant to accommodate jointmovement throughout the service life of that sealant,expressed as a percentage of the joint width at time ofsealing.

To calculate the theoretical / minimum joint width knowingthe expected maximum working movement of the joint:

W = M + M MAF/100

W = Joint widthM = Expected maximum working movement of jointMAF = Movement Accommodation Factor of that sealant

For further advice on joint design see BS 6093 :1993.

Nitoseal MS100 may be applied to joints between 5 and35 mm wide. To minimise stresses imposed on the jointsealant, all moving joints should be designed to anoptimum width to depth ratio of 2:1.

This ratio is subject to these overriding minimumsealant depths:

5 mm minimum sealant depth at any point.

5 mm minimum bonding depth against metals, glassand other non-porous surfaces, providing that joint facesare in good condition.

8 mm minimum bonding depth against masonry or otherporous surfaces, or any non-porous surfaces where jointfaces are in poor condition.

Shear joints shall be a minimum joint width to depth ratioof 1:2 up to a maximum of 1:1. The total movement inshear should not exceed 80% of joint depth at time ofsealing in these joints.


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Sealants are now commonly used as weatherseals inplace of flashings and scribers around window and dooropenings. These areas require greater attention to detailand standards of workmanship to perform successfully.

Example of sealed perimeter joint of plastic ormetal frame

1 Nitoseal MS100 2 Secofoam

Example of brickwork expansion joint

1 Nitoseal MS 100 2 Hydrocell 3 DPM

Example of sealed movement joint in externaljoint panels

1 Nitoseal MS100 2 Expandafoam cord

Limitations

Nitoseal MS100 must not be used as follows:

Where adhesion is required to polyethylene,polypropylene, polybutylene, polycarbonate andbitumen.Where it is subjected to permanent immersion inwater.With structural glazing or floor joints.With pipes or in other applications where it may besubjected to hydrostatic or pneumatic pressures(other than wind pressure).Where continual exposure to aggressive solvents orchemicals will occur.Where timber or wood based products have beenpainted.Nitoseal MS100 is a combustible material. Do notseal around chimney or flues.Do not overpaint with oil based alkyd paint systems.Should not be considered a substitute for a goodstandard of joint preparation.Joint arrises should be primed where movement inexcess of 25% is expected.

Storage

Cartridges: Shelf life 12 months when sealed and storedin cool, dry conditions.

Health and safety

No significant hazard. For additional information seeappropriate Product Safety Data Sheet.

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1 2 3

191

One part, floor joint sealant

Uses

Nitoseal MS300 is suitable for sealing saw-cut andmovement joints in internal floors, and external jointswhere abrasion resistance is required.

Factory floors

Sports stadia terracingShopping centresWarehouse and distribution depotsConcrete hardstanding areas

Advantages

Suitable for forklift truck trafficSuitable for saw cut and perimeter jointsCures to a tough sealAbrasion resistantWithstands vehicular trafficSingle componentFast rate of cureEasy to apply at low temperatureCan be applied to damp substrates

Primer-less for most applications (see "Priming"section)

Description

Nitoseal MS300 is a one part, high modulus sealantbased on hybrid silyl modified polyether technology. It hasa rapid rate of cure and forms a tough elastomer capableof supporting heavy wheel loads.

Nitoseal MS300 may be applied between 6mm and20mm wide, for trafficked joints (up to 40mm non-trafficked). In most cases it is recommended to form asealing slot with a square cross-section, subject to aminimum 10mm depth. To ensure the sealant operateswithin its stated movement accommodation capacity thesealing slot widths should be designed in accordancewith the recommendations of BS6093.

Properties

Nitoseal MS300

Form PasteFlash point >65ºCColour Grey

For special colours contactFosroc for further Information

Movement Butt joints 25%accommodation factor Lap joints 50%Skinning time at20ºC/50% RH 25 minutes

Cure rate at 20ºC, 50% RH24 hours 3 mm48 hours 6 mm72 hours 8 mmApplication temperature 5ºC to 50ºCTypical hardnessShore "A" at 20ºC 45Trafficking time at 20ºCLight traffic 24 hoursHeavy traffic 4 daysModulus HighUV resistance ExcellentService temperature range -20ºC to 70ºC


Preparation

Joints in concrete should preferably be sawn. Aftersawing all saw slurry must be flushed away and the jointallowed to dry.

When resealing the existing sealant should be removedfrom the joint and the arris cleaned back to sound cleanconcrete. Remove all debris. The joint surfaces must bedry, clean and frost free. Remove all contaminants byrigorous wire brushing, grinding or grit blasting.


Note: The use of a bond breaker is not required inexpansion joints containing Hydrocell XL cellularpolyethylene expansion joint filler. For construction orcontraction joints a bond breaker tape or back-up stripshould be used.

Where a particularly neat finish is required, mask the faceedges of the joint before priming/sealing and removeimmediately after tooling is completed.

Priming

Fosroc Primer MS2 is required for joints that are to beintermittently or permanently immersed, or where thesubstrate is likely to be saturated (for example, externally).

When using a primer, empty the entire contents of thehardener tin into the base tin and replace the base tin lid.Mix thoroughly by shaking for at least 2 minutes. Prime thejoint face using a clean, dry brush. Avoid over applicationof primer causing puddles in the bottom of the joint.


If a joint is left unsealed for more than 4 hours, the primershould be removed by grit blasting or grinding and thejoint re-primed.

Fosroc®

Nitoseal MS300constructive solutions

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Do not split packs of Fosroc Primer MS2.


Cut end off sachet and place in Fosroc GX Gun. Fit nozzleand cut at 45º to a suitable size. Extrude the sealant firmlyinto the joint. Tool flush within 5 minutes of application toensure good contact between the sealant and thesubstrate.

Cleaning


Estimating

Guide to sealant quantities in traffic joints

Joint size Litre per Metre perin mm metre run 600 ml sachet

6 x 10 0.06 1012 x 12 0.144 4.1720 x 20 0.40 1.5025 x 20 0.50 1.230 x 20 0.60 1.0040 x 25 1.00 0.60

0.75 litres of Fosroc Primer MS2 will be sufficient for 90mof joint. No allowance has been made for joint size orwastage.

Packaging

Nitoseal MS300 - 600 ml sachets. 10 no. sachets perbox.

Fosroc Primer MS2 – 0.75 litre packs

Limitations

Do not apply at temperatures below 5oC.Not suitable for contact with bituminous materials.Whilst Nitoseal MS 300 has excellent adhesion tomany types of residual sealant its use should not beconsidered a substitute for a good standard of jointpreparation.In large joints ensure sealant is sufficiently curedbefore trafficking. In 40 mm joints this could be up to10 days.

Storage

Store in original containers in cool, dry conditions. Shelflife is 12 months if stored as above. Storage outsidethese conditions may reduce shelf life.

Precautions

Health and safety

Nitoseal MS300: This product is non-hazardous innormal use. For further infromation refer to appropriateProduct Safety Data Sheet.

Fosroc Primer MS2 is highly flammable, see ProductSafety Data Sheet for details.

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193

Rubber-bitumen gun applied sealant

Uses

For sealing joints in flashings, guttering and sheetlapsAn integral part of the Proofex waterproofing system

Advantages

Firm flexible weather resistant sealExcellent slump resistanceExcellent immersed adhesionCompatible with asphalt or bituminous surfacesUnaffected by alkalis or sulphatesEasily gunnedSuitable for joints up to 40 mm wide

Description

Plastiseal is a flexible rubber-bitumen joint sealant withexcellent slump resistance. Plastiseal stiffens to form afirm seal after application. A tack free surface will formwithin 1 or 2 days depending upon the conditions ofexposure and ventilation, however the nature of bitumenmeans a slight 'sticky' feel will persist.

Design criteria

Joint size: Joints should be of a size to permit adequateapplication of Plastiseal. Very narrow joints are difficult toseal effectively and for most applications 10 mm shouldbe considered the minimum width. Maximumrecommended width is 40 mm. A minimum seal depth of15 mm must always be maintained.

To ensure that the sealant operates within its statedmovement capacity (MAF 10% in butt joints) the sealingslot widths should be designed in accordance with therecommendations of BS 6093.

The use of Fosroc Primer 3 is always recommended onporous surfaces.

Example of a sealed roof perimeter joint is show below

1 Plastiseal2 Asphalt, bituminous or other roof finish

Example of sealed joint in guttering is shown below

1 Plastiseal2 Gutter

Fosroc® Plastiseal constructive solutions

2

1

2

1

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Properties

Form: Semi-stiff pasteColour: BlackMovementaccommodationfactor (BS 6093): 10% for butt joints, 20% for lap jointsPhysical orchemical change: Solvent releaseApplicationtemperature: 5°C to 50°CChemical Dilute acids resistantresistance Dilute alkalis resistantto occasional Solvents not resistantspillage: Petroleum not resistant

Lubricants not resistantWater immersion: Before permanent immersion in

water Plastiseal must be left for aminimum period of 14 days to permitevaporation of its solvent content,this is dependent upon the ambientconditions and depth of Plastiseal

Solids content: 90% minimumFlash point: 61°C

Maintenance

No special requirement, damage should be repaired ifand when it occurs.


Joints shall be sealed, where designated, usingPlastiseal, a rubber-bitumen sealant, manufactured andsupplied by Fosroc. The sealant shall be applied strictly inaccordance with the manufacturer’s current technical datasheet.


Joint preparation

Ensure that the joint surfaces are completely dry, cleanand frost-free. Remove all dirt, dust, laitance and loosematerial by rigorous wire brushing. Remove all rust, scaleand protective lacquers from metal surfaces. Remove anyoil or grease with Fosroc Equipment Cleaner.

Gun loading

Cut conical tip off cartridge and thread, screw on nozzle,cut at 45 degrees to required size and fit into a Fosroc‘W’ Gun.

Expansion joints

Plastiseal must always be supported by a firm backing to

allow free movement. Where a particularly neat finish isrequired, cover face edges of joint with masking tapebefore priming and remove immediately after sealingwork is completed.


Use Fosroc Primer 3 on concrete, stone, brickwork, timberand unglazed edges of ceramic tiles. Allow primer tobecome touch-dry before sealing, normally 1 to 4 hours.


Not normally required. Ferrous metals should be treatedwith an anti-corrosion primer.

Cleaning

Clean up equipment immediately after use with FosrocEquipment Cleaner.

Estimating

Packaging

Plastiseal is supplied in boxes of 20 x 380ml cartridges,7.6 litres approximately.

Alternatively, 180 litre drums can be supplied to specialorder.

Primer 3 is supplied in 5 litre cans.

Guide to Plastiseal quantities

These are theoretical yields without allowance for jointsize variation or wastage.

Joint size Litre per Metre per Metre perin mm metre 0.38 litre boxw x d run cartridge (7.6 litre)10 x 15 0.15 2.50 51.0

20 0.20 1.90 38.015 x 15 0.23 1.70 33.8

20 0.30 1.30 25.320 x 20 0.40 1.00 19.0

25 0.50 0.80 15.225 x 15 0.38 1.00 20.3

25 0.63 0.61 12.230 x 25 0.75 0.51 10.1

30 0.90 0.42 8.435 x 25 0.88 0.43 8.740 x 25 1.00 0.3 7.6

Coverage

Fosroc Primer 3: 12.5m2 per litre


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www.fosroc.com



Limitations

Plastiseal should not be used in closed tanks where poorventilation will seriously inhibit evaporation of solvent fromthe Plastiseal. Plastiseal is not suitable for traffickedsurfaces. Wide joints are liable to mechnical damage.

Storage

Storage life of 12 months in original containers when keptin dry conditions between 5°C and 27°C.

Precautions

Health and safety


Fosroc Primer 3 is highly flammable, see material safetydata sheet for details.


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Plastiseal is the trade mark of Fosroc International Limited

196

One-part, high modulus, silicone acetoxycure, sealant - specification grade

Uses

Silicone Sealant 33HM is ideal for sealing joints on glassand ceramic surfaces. Principal applications include:

Glazing (not structural glazing)Hygienic areasHospitalsKitchensShowersBaths and basinsSanitary wareIn-situ draughtproofing to casement windows anddoors

Advantages

Silicone Sealant 33HM is a one-part sealant which cureson exposure to atmospheric moisture to form a tough,elastic seal providing excellent, long service life adhesionto glass, ceramic tiling and sanitary ware.

Fast rate of cureRobust elastic sealExcellent adhesion


BS 5889 :1989 Type ‘B’.

Description

Silicone Sealant 33HM is a moisture activated, acetoxycure sealant having a very fast rate of cure, forming atough elastic seal with excellent adhesion to glass,ceramics, aluminium, polycarbonate and acrylic surfaces.It is particularly recommended for use as a sealant fortiled surfaces, glass and sanitary ware.

Technical support

Fosroc offers a comprehensive range of highperformance, high quality technical products. In addition,Fosroc offers a technical support package to specifiersand contractors which includes computer-aided design(CAD), standard details as well as on-site technicaladvice from staff with unrivalled experience in the industry.

Design criteria

Example of capped beading glazing system

1 Silicone Sealant 33HM2 Glazing Strip3 Butyl glazing and bedding compound

Example of sealed stress relief and expansion joint inceramic tiled finishes

1 Silicone Sealant 33HM2 *Fosroc Debonding Tape3 *Expandafoam* Also available from Fosroc.

Note: Silicone Sealant 33HM can be used as a formed inplace draughtproofing gasket to rectify ill-fittingcasement window and door openings. For furtherinformation contact Fosroc Technical Service Department.

Joint size: Silicone Sealant 33HM may be applied in jointsbetween 3 and 25 mm wide and 5 and 10 mm deep. Foroptimum performance in joints with significant movementthe depth of sealant should be between one-half andone-third of the joint width. The joint should also include asuitable back-up strip.

Fosroc® SiliconeSealant 33HM constructive solutions

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2 3

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197

Fosroc® SiliconeSealant 33HM

Properties

Form: Thixotropic pasteColours: White, translucentMovementaccommodationfactor (BS 6093): 15% butt joints

30% lap jointsCure: Chemically cures to a solid rubberSkinning time, 20°C: 10 to 45 minutesCure rate20°C, 65% RH: 96 hours to 5 mm depthApplicationtemperature: 5°C to 50°CTypical hardnessshore ‘A’ at 25°C: 24100% modulus: 4.0 kg/cm²Chemical Sulphuric acid 25% resistantresistance Hydrochloric acid 10% resistantto occasional Acetic acid 10% resistantspillage: Lactic acid 2% resistant

Caustic soda 10% notresistant

Ammonia 10% resistantKerosene not

resistantMineral oil resistant

Continuous servicetemperature range: –40°C to 120°CSolids content: 100%Flash point: Over 65°CFlammability: Burns

Maintenance

No special requirements, any damage identified duringnormal building inspections should be repaired orreplaced as appropriate.


Joints shall be sealed using Silicone Sealant 33HMcomplying with BS 5889 Type ‘B’ manufactured by Fosroc.Joints shall be prepared and the sealant applied inaccordance with the manufacturer’s current data sheet.


Preparation

Joint surfaces must be clean, dry and free from frost.Remove all dirt, loose materials and foreign matter.Remove all rust, scale and protective lacquers from metalsurfaces. Glass and metal surfaces should be degreasedusing Fosroc Equipment Cleaner.

In movement joints Silicone Sealant 33HM must alwaysbe supported by a firm back-up strip such asExpandafoam which will allow free movement. Ifinsufficient depth is available use an adhesive bondbreaking tape. A bond breaker is not required whereHydrocell or Expandafoam is used as the joint filler.

Where a particularly neat finish is required, cover faceedges of joint with masking tape before priming andremove immediately after sealing work is complete.

Priming

No priming required for glass, ceramics, aluminium,stainless steel, polycarbonate and acrylic surfaces. Forplastics other than those listed above contact FosrocTechnical Department.

Gun loading

Cut conical tip off cartridge end thread, screw on nozzle,cut at 45° to required size and fit into a Fosroc W gun.

Application

Extrude the sealant firmly into joint to ensure completecontact with joint faces. Smooth finish if necessary with aspatula wetted with a detergent solution.

Cleaning

Clean tools immediately after use with Fosroc EquipmentCleaner. Clean hands with a proprietary hand cleaner.

Limitations

Silicone Sealant 33HM is not intended for use in structuralglazing applications.

Not suitable for use on concrete and other alkalinesurfaces. Use Hilastic LM.

White Silicone Sealant 33HM contains a fungicide and isunsuitable for use in the assembly of aquaria.

Estimating

Packaging

310 ml plastic cartridges with separate screw-on nozzles,packed in cartons of 20. Total contents approximately 6.2litres.



198

Fosroc® SiliconeSealant 33HM


www.fosroc.com




Joint size Litre per Metre perin mm metre run 0.31 litre cartridge3 x 5 0.015 20.73 x 10 0.030 10.35 x 5 0.025 12.45 x 10 0.050 6.210 x 5 0.050 6.210 x 10 0.100 3.215 x 10 0.150 2.120 x 10 0.200 1.6


Storage

12 months minimum storage life for product stored inoriginal container kept in cool, dry conditions.

Precautions

Health and safety

Please refer to MSDS.

As well as joint sealants and ancillary products, Fosrocalso manufactures a wide range of complementaryproducts which includes waterstops, waterproofingmembranes, grouting, anchoring and specialised flooringmaterials. In addition, a wide range of productsspecifically designed for the repair and refurbishment ofdamaged reinforced concrete is available. This includeshand-placed and spray grade repair mortars, fluid micro-concretes, chemical-resistant epoxy mortars and acomprehensive package of protective coatings.


Silicone Sealant 33HM is a trade mark ofFosroc International Limited


199

Multi-component, gun and pouring grade,polysulfide sealant

Uses

Sealing movement joints in building and civil engineeringstructures, including superstructures, floors, basementsand subways.

Advantages

Meets key international standardsForms a tough, elastic, rubber-like sealAccommodates continuous and pronounced cyclicmovementExcellent adhesion to most common substrates,including primed concrete, glass, aluminium andstainless steelHigh resistance to ageing reduces physical damage dueto climatic extremes

Description

Thioflex 600 is available in gun and pouring grades. The gungrade is ideal for general application. It is packed in a readyto mix, 2.5 litre tin containing the base and curing agent in thecorrect proportions. The pouring grade for joints in horizontalsurfaces is supplied in 5 litre packs with the base and curingagent in separate tins.

Thioflex 600 is particularly recommended for use in high-risebuildings and other applications where access forsubsequent maintenance will be difficult and the risk of earlymovement failure must be minimised. It is also suitable forsealing joints in brickwork, retaining walls, basements andsubways.

Thioflex 600 pouring grade is recommended for initial sealingof expansion joints and stress relief joints in floors andsealing other horizontal surfaces.

Design criteria

Thioflex 600 may be applied to joints between 5 and50 mm wide. Joints which are expected to experience cyclicmovements should be designed to an optimum width : depthratio of 2 :1, subject to the overriding recommended minimumsealant depths set out below:5 mm for metals, glass and other non-porous surfaces;10 mm for all porous surfaces;20 mm for trafficked joints and those subject to hydrostaticpressures.

To ensure that the sealant remains within its stated movementcapacity (25% MAF), sealing slot widths should be designedin accordance with the recommendations of BS 6093.

The use of a surface primer is always required on poroussurfaces. On non-porous surfaces a primer is not normallyrequired except where glass or glazed surfaces are to bepermanently immersed in water.


British Standard BS 4254 :1983.

U.S. Federal Specification TT-S-00227E November 1969(amended 1970).

DTp specification for Highway Works December 1991 series1000 clause 1017.

ASTM C920-87: Type M, Grade NS, Class 25.

Properties

Form: Multi-part, paste compoundColours: Gun grade: grey

Pouring grade: greyMovementaccommodation 25% butt jointsfactor (BS 6093): 50% lap jointsPhysical orchemical change: Chemical curePot life: 2 hours @ 25°CSetting time: 72 hours at 5°C

36 hours at 15°C18 hours at 25°C

Cure time: 4 weeks at 5°C2 weeks at 15°C1 week at 25°C

Applicationtemperature: 5°C to 50°COperatingtemperature: –20°C to +60°CHardness shore Gun grade grey: 20 to 25‘A’ 25°C: Pouring grade: 15 to 23Water immersion: Thioflex 600 must be fully cured before

permanent immersion in waterChemical Dilute acids resistantresistance Dilute alkalis resistantto occasional Petrol resistantspillage: Aviation fuels resistant

Diesel fuel resistantKerosene resistantLubricating oils resistantSkydrol resistantWhite spirit resistantChlorinated solvents not resistantAromatic solvents not resistantDilute oxidising acids not resistant

Fosroc® Thioflex 600 constructive solutions

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Fosroc® Thioflex 600

Biological Thioflex 600 has been evaluated inresistance: microbiologically active situations and

has been shown to have resistance toaerobic conditions

Solids content: 100%Density: 1.62 kg/litreFlash point: Over 65°CFlammability: Burns but does not readily support

combustion


Joint preparation

The joint surfaces must be thoroughly dry, clean and frostfree. Remove all dust and laitance by rigorous wire brushing,grinding or grit blasting. Remove all rust, scale and protectivelacquers from metal surfaces. Remove any oil or grease withFosroc Equipment Cleaner.

Any expansion joint filler must be checked to ensure it is tightlypacked and no gaps or voids exist at the base of the sealingslot before positioning a bond breaker.

Note: The use of a bond breaker is not required in expansionjoints containing Hydrocell XL or Expandafoam cellularpolyethylene expansion joint fillers. For construction orcontraction joints a bond breaker tape or back-up strip shouldbe used. Where hydrostatic pressure exists, only bondbreaking tapes must be used, not foamed back-up strips.

Where a particularly neat finish is required, mask the faceedges of the joint before priming and remove immediatelyafter tooling is completed.

Priming

When Fosroc Primers 4 or 7 are required, these should beused as follows:

Fosroc Primer 4: For use on glass and ceramics which areto be permanently immersed in water. It is a one part chemicallyactive clear liquid for brush or pad application. One thin coatshould be applied and allowed to dry for 2 to 5 minutes priorto sealant application.

Fosroc Primer 7: It is a one part chemically active clear liquidfor brush application to concrete, stone, brickwork, timberand unglazed edges of ceramic tiles. One thin coat should beapplied using a clean, dry brush, ensuring complete coverage.Avoid over priming resulting in an excess of primer in the baseof the joint or application beyond faces. The mixed Thioflex600 must be applied when the primer is tack free, that is afterthe evaporation of the solvent but before the primer film hascompletely reacted. After 3 hours the surfaces must be re-primed before applying the sealant.

Iron and steel must be protected with an anti-corrosionprimer prior to sealing.

Mixing

Gun grade: The base component and curing agent aresupplied ready for mixing in a single tin. Mix thoroughly usinga slow speed drill (300 to 500 rpm) fitted with a Fosroc SealantMixing Paddle for 5 minutes. Only thorough mixing, includingmaterial right at the bottom of the tin, will result in propercuring. In cold weather Thioflex 600 mixes more easily ifstored overnight at room temperature.

Immediately after mixing, load the sealant into a Fosroc ‘G’Gun using the Follower Plate, and apply to the joint.

Pouring grade: Thioflex 600 pouring grade is supplied in twoseparate containers, the base in the larger tin and the curingagent in a sachet. The sachet contents should be transferredto the tin, and mixed as per the gun grade instructions. Thepouring grade may be poured directly into horizontal joints orfor application to horizontal joints less than 15 mm wideloaded into a Fosroc ‘G’ Gun.

Finishing

Thioflex 600 should be tooled to a smooth finish. A minimumof surface lubricant such as dilute detergent solution may beused to assist the process. Any masking tape should beremoved immediately after tooling.

Cleaning


Contract application

The designer or contractor may wish to use the services ofa specialist sub-contractor for joint sealing work. Names ofpreferred sub-contractors are available from Fosroc.

Maintenance

No special requirements, any damage identified duringnormal building inspections should be repaired or replacedas appropriate.

Estimating

Packaging

Thioflex 600 gun grade is supplied in 2.5 litre tins in cartonsof four.

Thioflex 600 pouring grade is supplied in a 5 litre tin, curingagent included in a sachet inside the tin.


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Fosroc® Thioflex 600


www.fosroc.com



Guide to quantities

Joint size Litres per Metre run per Metre run perin mm metre run 2.5 litre pack 5 litre pack5 x 5 0.025 100.00 200.005 x 10 0.050 50.00 100.0010 x 10 0.100 25.00 50.0020 x 10 0.200 12.50 25.0020 x 15 0.300 8.33 16.6720 x 20 0.400 6.25 12.5040 x 20 0.800 3.12 6.2540 x 25 1.000 2.50 5.0040 x 30 1.200 2.00 4.0040 x 40 1.600 1.56 3.1250 x 25 1.250 2.00 4.0050 x 30 1.500 1.67 3.3350 x 40 2.000 1.25 2.2550 x 50 2.500 1.00 2.00

1 litre of Fosroc Primer 4 to 300 litres of Thioflex 600.

1 litre of Fosroc Primer 7 to 30 litres of Thioflex 600.

These are theoretical yields. No allowance has been madefor variation in joint width or wastage.

Limitations

Over-painting of sealants is not recommended because ofthe inability of paint films to accept movement. However, ifdefinitely required, trials should be carried out to determinecompatibility.

Thioflex 600 should not be used in direct contact with materialscontaining pitch or bitumen.

Thioflex 600 is not suitable for use in contact with potablewater; Nitoseal MS600 should be used.

Storage

Storage life of 12 months in original containers when kept indry conditions between 5°C and 27°C.

Precautions

Health and safety



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202

Flexible intumescent sealants

Uses

For fire protection in expansion and construction joints inwalls, floors and ceilings, confining smoke and fire, givingextra time for people to escape from a fire situation.

Advantages

Extensively fire tested in accordance with BS 476 Pt:20:1987.Fire tested in overhead joints as well as in wall jointsOver 4 and 5 hours insulation and longer integrityrating, depending on joint designSuitable for fire stopping of joints as defined byApproved Document B of the Building RegulationsPrevents the passage of smoke through joints underfire conditionsEffective as normal building sealants and allowsstructural movementFlamex Two is resistant to a range of chemicals

Standard complance

Tested in accordance with BS 476 Pt. 20: 1987.

Description

Under fire conditions Flamex One and Flamex Twointumesce, forming a foam-like structure which insulatesand provides a barrier to hot gas and flame.

Flamex One emulsion based sealant sets quickly andgives excellent adhesion to most building materials. It hasa 10% movement accommodation factor for lowmovement joint sealing and gap filling applications suchas fire door frames. Flamex One is also suitable forsealing around fire protection boards. It can be used injoints from 5 to 20 mm. The minimum depth of sealshould be 15 mm. Acts as an acoustic sealant.

Flamex Two high performance sealant forms a tough,flexible rubber-like seal with a movement accommodationfactor of 25% for high movement situations. Flamex Two issuitable for expansion joints in building superstructuresand may be used in both internal and external joints.Flamex Two can be used in joints from 5 mm upto 50 mmwide. The width of sealant should ideally be twice thedepth, with a minimum depth of 12 mm. In traffickedjoints, sealant depth should be a minimum of 20 mm. Theuse of a surface primer is always required.

Fire performance test data

Extensive fire testing has been carried out on the Flamexrange in accordance with BS 476 Pt.20: 1987 at theTechnical Centre of the Loss Prevention Council (LPC).

Sealant was assessed in terms of insulation and integrity.

Insulation is defined as the ability to restrict excessiveheat transfer through the joint, preventing ignition fromconduction on the cold side.

Integrity is the ability to remain intact during the test,thereby withstanding the pressures and stressesdeveloped during a fire situation.

Results summary

Flamex One — intumescent sealant

Joint size Backing material Insulation Integrityw x d (mm)

Wall jointsSingle seal in lightweight blocks:10 x 15 Expandafoam 30 mins 3 hrs20 x 15 Expandafoam > 30 mins > 2.5 hrs20 x 20 Expandafoam > 1 hr > 2 hrs20 x 15 Ceramic strip 2.5 hrs > 4 hrsLightweight blocks sealed both sides:10 x 15 Expandafoam > 4 hrs > 4 hrs20 x 15 Expandafoam > 4 hrs > 5 hrs20 x 20 Expandafoam > 5 hrs > 5 hrsLightweight blocks to concrete lintel sealed both sides:15 x 15 Expandafoam 3.5 hrs > 4 hrsLightweight blocks to hardwood frame sealed both sides:15 x 15 Expandafoam 2 hrs 2 hrsSingle seal: lightweight block to building board:10 x 15 Expandafoam 30 mins 70 mins

Conduit wall penetration20 mm conduit in nominal 50 mm hole:15 x 15 Expandafoam > 2.5 hrs > 4 hrs25 mm conduit in nominal 50 mm hole:12 x 15 Expandafoam 3.5 hrs > 4 hrs

Flamex Two — polysulphide intumescent sealant


Wall jointsSingle seal in lightweight blocks:10 x 12 Expandafoam > 15 mins > 1.5 hrs20 x 12 Ceramic strip > 2 hrs > 4 hrsLightweight blocks sealed both sides:10 x 12 Expandafoam > 5 hrs > 5 hrs25 x 12 Expandafoam > 3 hrs 3.5 hrsLightweight blocks to concrete lintel sealed both sides:20 x 12 Expandafoam > 5 hrs > 5 hrs40 x 20 Expandafoam > 4 hrs > 4.5 hrs

Fosroc® FlamexFire Protection constructive solutions

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Fosroc® FlamexFire Protection

Flamex Two — polysulphide intumescent sealant contd.


Soffit joints

Joints in concrete sealed both sides:15 x 12 Expandafoam 4 hrs 4 hrs20 x 12 Expandafoam > 4 hrs > 4 hrs25 x 12 Expandafoam > 4 hrs > 4 hrs30 x 15 Expandafoam 3.5 hrs > 5 hrs30 x 15 Ceramic strip > 5 hrs > 5 hrs45 x 25 Ceramic strip > 5 hrs > 5 hrs50 x 25 Expandafoam 2 hrs 2 hrs50 x 25 Ceramic strip > 5 hrs > 5 hrs

Properties

Flamex One

Form: PasteColours: White and grey as standard coloursMAF: Butt joints 10%Physical change: Cures by loss of waterSkinning time: 20 to 40 minutes, but will depend on

temperature and relative humidityCure time As a guide a 20 x 15 mm joint is fully(typical rates): cured in 28 days at 25°C, 50% RH.

Smaller joints will cure more quickly.A fairly advanced state of cure isreached at 7 days

Applicationtemperature: 5°C to 40°CHardness 30 to 50, typical 45Shore ‘A’ at 25°C: (28 days cure at 25°C, 50% RH)Solids content: 85%Density: 1.48 kg/litre

Flamex Two

Form: Multi-component paste in one tin;requires mixing

Colour: Mid greyMAF: 25% butt joints

50% lap jointsPhysical orchemical change: Chemical curePot life: 2 hours at 25°CSetting time 96 hours at 5°C(typical rates): 48 hours at 15°C

24 hours at 25°CFull cure 4 weeks at 5°C(typical rates): 2 weeks at 15°C

1 week at 25°C

Applicationtemperature: 5°C to 30°CHardness 20 to 30Shore ‘A’ at 25°C: (7 days cure at 25°C, 50% RH)Density: 1.61 kg/litreFlash point: Over 65°C

Chemical Refer to Fosroc Technicalresistance: Department for specific information

For supplies of ceramic strip please contact the FosrocCustomer Service Department.

Maintenance

No special requirements, but damage identified duringnormal building inspections should be repaired orreplaced as appropriate.


Joint preparation

The joint surfaces must be thoroughly dry, clean and frostfree. Remove all contamination by rigorous wire brushing,grinding or grit blasting. Remove all rust, scale andprotective lacquers from metal surfaces. Remove any oilor grease with Fosroc Joint Cleaner.

The Flamex sealant shall be backed or supported withExpandafoam* cord, Hydrocell XL*, a ceramic strip or abond breaker tape. The choice will be dependent upon theperformance level required and the type of joint beingsealed.

In open joints where Expandafoam is to be used ensurethat an appropriate diameter cord is selected to givesufficient compression and support to the sealant.

In construction or contraction joints, a bond breaker tapeshould be applied to the base of the sealing slot toprevent adhesion of the Flamex sealant.

Where the ceramic strip is required it should be installedbefore priming, by folding and inserting into the joint usingtwo thin metal plates to compress the strip and push itinto the joint at the same time. Expandafoam is then placedover the ceramic strip before joint sealing takes place.

When gunning the sealant ensure good contact is madewith the joint sides. For very wide joints it may benecessary to apply the sealant in two or more passes.

Where an especially neat finish is required, mask the faceedges of the joint with masking tape before priming andremove after tooling is complete.

Priming

Flamex One

In many cases priming is not required. On very poroussurfaces such as lightweight blocks, priming with a dilutesolution of Flamex One 1: 3 with water is recommended.


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Flamex Two

Fosroc Primer 4 and Fosroc Primer 7 are required andshould be used as follows:

Fosroc Primer 4:

For all non-porous surfaces.

The sealant should be applied after the primer has dried,approximately 5 minutes and within 3 hours.

Iron and steel must be treated with an anti-corrosionprimer prior to sealing.

Fosroc Primer 7:

For all porous surfaces such as concrete, stone,brickwork, blockwork and timber.

Apply by brush, working in well, ensuring completecoverage. Avoid over priming resulting in an excess ofprimer in the base of the joint or beyond the joint faces.

The mixed Flamex Two should be applied when FosrocPrimer 7 is tack free, normally within 20 minutes to 1 hour— that is after the evaporation of the solvent but before theprimer film has completely reacted. After 3 hours thesurfaces must be re-primed before applying the sealant.

Excessively porous surfaces may need a second coat,applied over the first coat which must be thoroughly dry.

Mixing

Flamex Two base component and curing agent aresupplied ready for mixing in a single tin. Mix thoroughlyusing a slow speed drill (300 to 500 rpm) fitted with aFosroc Sealant Mixing Paddle for 5 minutes. Onlythorough mixing will result in proper curing. In coldweather Flamex mixes more easily if stored overnight atroom temperature. Immediately after mixing, load thesealant into a Fosroc ‘G’ Gun using a follower plate andapply to the joint.

Finishing

Flamex One is applied using a Fosroc ‘W’ Gun andshould be tooled off within 15 minutes of sealing usingclean water. The use of dilute detergent solution is notrecommended.

Flamex Two should be tooled to a smooth finish. Aminimum of surface lubricant such as dilute detergentsolution may be used to assist the process.

Any masking tape should be removed immediately aftertooling. Normally joints in Flamex will be flush finishedand left unpainted.

Cleaning equipment

Uncured Flamex One may be cleaned from tools andneighbouring surfaces using a damp cloth and water.

Uncured Flamex Two should be cleaned from equipmentusing Fosroc Equipment Cleaner.

Contract application

The designer or contractor may wish to use the servicesof a specialist sub-contractor for joint sealing work.Names of preferred sub-contractors are available fromFosroc.

Limitations

The fire rating of Flamex sealants is specific to the testsquoted on this data sheet. Users should satisfythemselves that the test results are applicable to theirown installations.

Over-painting of Flamex sealants is not recommended.

The chemical resistance of Flamex One is limited. Referto Fosroc Technical Department for chemical resistanceof Flamex Two. Spillages must be cleaned from thesealants as soon as is practical.

Flamex sealants should not be used in direct contact withmaterials containing pitch or bitumen or in situationswhere water cannot freely drain away. Flamex One is notsuitable for any joints subject to trafficking.

Estimating

Packaging

Flamex One is supplied in 380ml cartridges packed incartons of 20.

Flamex Two is supplied in 2.5 litre tins in cartons of 4.

Guide to Flamex One quantities

Joint size Litres per Metre run perin mm metre run 380 ml cartridge10 x 15 0.150 2.515 x 15 0.225 1.720 x 15 0.300 1.2

Guide to Flamex Two quantities

Joint size Litres per Metre run perin mm metre run 2.5 litre pack10 x 12 0.12 20.8015 x 12 0.18 13.8020 x 12 0.24 10.4025 x 12 0.30 8.330 x 15 0.45 5.540 x 20 0.80 3.1050 x 25 1.25 2.00



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www.fosroc.com




1 litre of Fosroc Primer 4 to 300 litres of Flamex Two.1 litre of Fosroc Primer 7 to 30 litres of Flamex Two.

Actual usage will depend on joint dimensions and otherfactors.

Storage

Flamex sealants have a storage life of 12 months inoriginal containers when kept in dry conditions between5°C and 25°C.

Precautions

Health and safety


* See separate data sheet.


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One-part low modulus neutral cure firerated silicone sealant

Uses

For fire protection of curtain walling, building façades,expansion joints and penetration seals, where pipes andcables pass through fire rated structures.

Advantages

Tested to BS 476 Part 22:1987 (ISO 834)Up to a 4 hour fire rating in specified joint andpenetration configurationsExcellent adhesion50% MAF allowing structural movementMeets BS 5889 Type APrevents the passage of smoke through joints in fireconditionsActs as an acoustic sealant


Flamex S has been tested to the following standards:

BS 476 Part 22 :1987 (ISO 834) in expansion jointsachieving up to a 4 hour fire rating (fire rating table A).

BS 476 Part 22 :1987 (ISO 834) in pipe and cablepenetration systems achieving up to a 4 hour fire rating(fire rating table B).

ISO 834 achieving over 1 hour (A - 60) fire resistance injoints, pipe and power cable penetrations (fire ratingtable C).

Centre Scientifique que du Bâtiment (CSTB) Testachieving 1 hour fire rating in pipe and power cablepenetrations (fire rating table D).

Description

Flamex S is a fire rated silicone sealant which curesquickly and gives excellent adhesion to most buildingmaterials. The minimum width for joints when usingFlamex S should be 6 mm. For joints between 6 and 12mm wide a seal depth of 10 mm is recommended.

Attainment of a specific fire rating is dependent on thejoint configuration. For detailed information see fire ratingtable A.

Attainment of a specific fire rating is dependent onpenetration configurations. For detailed information seefire rating tables B, C and D.

Properties

Form: Thixotropic pasteColour: White/Grey

Movement accommodationfactor (MAF): 50% butt joints

100% lap jointsPhysical orchemical cure: Chemical cureSkinning time(23°C at 50% RH): 2 hoursCure rate(23°C at 50% RH): 2 mm per dayApplicationtemperature: 5°C to 30°CTypical Shore ‘A’ hardness: 20

Fire ratings

The fire rating tables give times for insulation and integrityratings, These are defined as:

Insulation: The ability to restrict excessive heat transferthrough the joint, preventing ignition from conduction onthe cold side.

Integrity: The ability to remain intact during the test,thereby withstanding the pressures and stressesdeveloped during a fire situation.

Fire rating table AMethod: BS 476 Part 22 :1987

Joint size Joint Integrity Insulationwidth x depth configuration mins mins

Polyethylene backed sealsingle sided - on fire side of test furnace10 x 10 mm A 120 n/a15 x 10 mm A 90 3020 x 10 mm A 60 3025 x 20 mm A 120 60

Polyethylene backed sealsingle sided - on non-fire side of test furnace10 x 10 mm A 240 24015 x 15 mm A 240 24020 x 20 mm A 240 24025 x 25 mm A 240 240

Polyethylene backed sealdouble sided10 x 10 mm B 240 24015 x 10 mm B 240 24025 x 20 mm B 240 240

Fosroc® Flamex S constructive solutions

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Fosroc® Flamex S

Rock fibre backed sealsingle sided - on fire side of test furnace25 x 10 mm A 120 30Rock fibre backed sealsingle sided - on non-fire side of test furnace25 x 10 mm A 240 240

Rock fibre backed sealdouble sided25 x 10 mm A 240 240

Example of test joint configurations

1 Flamex S2 Backing material

Fire rating table BMethod: BS 476 Part 22 :1987

Services Insulation Integrity rating rating

10 mm Flamex S and 75 mm mineral wool150 x 150 mm penetration100 mm diameter steel pipe 1 hr 4 hrs25 mm diameter cable 2.5 hrs 4 hrs1 x 25 mm cable; 4 x 12.5 mm cable 1.5 hrs 4 hrsNone 1.5 hrs 4 hrs

20 mm Flamex S and 25 mm mineral wool150 x 150 mm penetration25 mm diameter cable 1 hr 2 hrs

20 mm Flamex S and 75 mm mineral wool150 x 150 mm penetration25 mm diameter steel pipe 4 hrs 4 hrs1 x 25 mm cable; 4 x 12.5 mm cable 4 hrs 4 hrs

20 mm Flamex S and 50 mm mineral wool150 x 150 mm penetrationNone 1.5 hrs 4 hrs

20 mm Flamex S and 25 mm mineral wool50 mm penetration25 mm cable 4 hrs 4 hrsNone 4 hrs 4 hrs

Fire rating table CMethod: ISO 834

Penetration size Penetrant Backing Firematerial rating

Gypsum board, lightweight wall: Flamex S depth of12 mm, ceramic fibre backingTested non-fireside of test furnaceSleeve 160 mm 2 cables EKKJ 114 mm 60 minsdiameter galvanised 3 x 10 x 10 mm²steel 0.8 mm thick 1KV Cu Core

Gypsum board, lightweight wall: Flamex S depth of2 x 12 mm, ceramic fibre backingTested fireside and non-fireside of test furnaceSleeve 160 mm 2 cables EKKJ 102 mm 60 minsdiameter galvanised 3 x 10 x 10 mm²steel 0.8 mm thick 1KV Cu Core450 mm diameter Ventilation duct 98 mm 60 mins

400 mm diametergalvanised steel0.8 mm thick

Penetration size Penetrant Backing Firematerial rating

Gypsum board to concrete: Flamex S depth of12 mm, ceramic fibre backingTested fireside or non-fireside of test furnace30 mm wide joint None 110 mm 60 mins

Concrete floor: Flamex S depth of 12 mm, ceramicfibre backingTested non-fireside of test furnace400 x 400 mm 48.3 mm o.d. 138 mm 60 mins

mild steel pipe2.6 mm thick


Joint type A Joint type B

Dep

th

Width

2

1

2 1

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Fire rating table DMethod: Centre Scientifique que du Bâtiment

Penetration size Penetrant Insulation Integrityrating rating

Concrete substrate: Flamex S depth of 12 mm, 110 mmceramic fibre backingTested non-fireside of test furnace333 x 200 mm Cables — 60 mins > 120 mins

2 x type88-448/88 Cu1 x type88-224/4 Cu

330 x 200 mm Cables — 60 mins > 120 mins1 x type88-448/88 Cu1 x type88-224/4 Cu

200 mm diameter NB80 mild 60 mins > 120 minssteel pipe60 mm o.d.

The fire ratings given are specific to the conditions of thetest and provide a good indication of the expectedperformance of the sealant in a fire situation. Usersshould satisfy themselves that the test results areapplicable to their own installations. Testing of a particularsystem may be required. To achieve any specific firerating, all substrates being used must have at least anequivalent fire rating.


Joint preparation

Joint surfaces must be thoroughly dry, clean, and freefrom frost and contamination. Remove all laitance byrigorous wire brushing, grinding or grit blasting. Removeall rust, scale and protective lacquers. Any oil or greaseshould be removed with Fosroc Equipment Cleaner.

Application

Flamex S should be backed or supported with a closedcell polyethylene foam of nominal density 35 kg/m³, aceramic fibre blanket of nominal density 128 kg/m³, ormineral wool of nominal density 100 kg/m³. The choice isdependent upon the performance level required and thetype of joint being sealed. Contact the local Fosroc officefor details.

Where using a closed cell polyethylene foam ensure thediameter cord selected will give sufficient compressionand support to the sealant. In construction or contractionjoints a bond breaker tape should be used.

Extrude sealant firmly into the joint ensuring completecontact with joint faces.

Mask the face edges of the joint with masking tape beforesealing to prevent contamination of the substrate andremove the masking tape immediately after tooling.

Priming

On cement and concrete, priming with Flamex S Primer isrecommended.

Sufficient primer should be transferred to the workingcontainer. Do not decant more primer than can be used in1 hour. Apply by brush to give a thin uniform layer.Flamex S should be applied after 30 minutes. Themaximum sealant application time is 3 hours. Applicationtemperatures for the primer are 5°C to 30°C.

Any unused decanted primer should not be returned to theoriginal container but disposed of in the appropriatemanner. Any brushes and containers should be cleanedwith Fosroc Equipment Cleaner.

Finishing

Flamex S should be tooled within 5 minutes of sealing toensure good contact between the sealant and thesubstrate.

Cleaning

Uncured Flamex S can be removed from tools and non-porous surfaces using Fosroc Equipment Cleaner.Sealant adhering to porous surfaces should be left to cureand then removed by abrasion.

Limitations

Flamex S should not be applied to surfaces that are below5°C.

Flamex S should not be used against substrates thatbleed oils, plasticisers or solvent.

Flamex S is not intended for use as the structural seal inany application.

Estimating

Guide to Flamex S quantities

Joint size Litres per Metre run perin mm metre run 380 ml cartridge10 x 15 0.150 2.515 x 15 0.225 1.720 x 15 0.300 1.3

Packaging

Flamex S is supplied in 380 ml plastic cartridges packedin cartons of 20.


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Storage

Flamex S has a storage life of 9 months if kept in a drystore in the original, unopened container, at between 5°Cand 25°C.

Flamex S Primer should be stored in accordance with theUK Highly Flammable Liquids and Liquefied PetroleumGases Regulations 1972.

Precautions

Health and safety


Fire

Flamex S is non-flammable.

Flamex S Primer: Highly flammable liquid. Keep awayfrom all sources of ignition — No Smoking. Avoid contactwith skin and eyes and inhalation of vapours. Wearsuitable gloves and eye/face protection. Use only in well-ventilated areas.

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www.fosroc.com




Flamex is the trade mark of Fosroc International Limited

210

Closed-cell polyethylene joint filler, back-upstrips and cord

Uses

Expandafoam is a closed-cell polyethylene joint filler foruse as an expansion joint filler in brick and blockwork,isolation joints and hinge joints where a readilycompressible low load transfer joint filler is required.

Strip and cord sections are also available. These areused as back-up strips for elastomeric sealants.

Back-up / bond breaker strip to support sealantsBridge decks, abutments, pier hinge jointsBrick and blockwork in building superstructures

Advantages

Readily compressibleLow load transferExcellent recovery after compressionNon-absorbentRot-proofCFC-free


BS 5628 Part 3 ‘Use of Masonry’ paragraph 20.4.

DTp Specification for Highway Works, December 1991series 1000. Clause 1015.

Description

Expandafoam is a flexible, readily compressible, closed-cell polyethylene joint filler supplied in sheet form and asrectangular strips or circular section cords.

Properties

Technical data — (sheets and strips)

Form: Cross-linked, compressible, closed-cell foamed sections and sheet

Weathering test: No disintegrationRecovery: Greater than 70%Water absorption: NegligibleEffects of fire: Being a thermoplastic material,

Expandafoam will melt. It iscombustible but rate of flame spreadwill be reduced when confined withina joint

Technical data — (cord)

Form: Compressible closed-cell foamcircular cords

Storage life: IndefiniteWater absorption: Negligible

Colour: GreyTemperaturestability: –40°C to +60°CDensity: 30 +/- 5 kg/m³


The joint filler / back-up strips as detailed shall beExpandafoam supplied by Fosroc. Whether in sheet formor in strip or cord form, Expandafoam shall be installedstrictly in accordance with the relevant Fosroc technicaldata sheet.


Joint sealing slots

When used as an expansion or isolation joint filler inbrickwork, Expandafoam should be positioned to provide fora surface sealing slot of the required dimensions ensuringthat the sealing slot is free from mortar droppings or slurrybridging.

Expandafoam sheets may be fixed into position using asuitable adhesive. Care should be taken not to contaminatethe surfaces of the sealing slot with adhesive.

Where Expandafoam is used as the joint filler no additionalbond breaker is necessary.

Used as a back-up / bond breaker strip Expandafoamserves both to regulate the depth of the sealing slot requiredand ensures that the movement of the joint sealant is notrestricted by three-sided adhesion.

The size of the back-up strip should be approximately 20%greater than the joint width and depressed sufficiently toprovide the required sealing slot dimensions. Circular cordsections provide a convex face giving an optimum sealconfiguration, they also overcome any problem of twistingwhich can occur with square or rectangular sections.

Estimating

Sheet size: 1.0 x 2 metresSheet thickness: 10, 12, 15, 20 and 25 mmStrip sizes: 15 metres longStrip dimensions: 10 x 75 mm

10 x 100 mm10 x 150 mm12 x 75 mm*12 x 100 mm20 x 150 mm20 x 200 mm

Note: sizes marked with * are supplied to order.

All 10 and 12 mm strips have a 10 mm deep tear-outsection and all 20 strips have a 20 mm tear-out section toensure uniform depth of sealant cover.

Fosroc® Expandafoam constructive solutions

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Guide to cord quantities

Cord diameter in mm Linear metres per carton10 1150†12 75015 550, 100†20 350,10025 20030 16040 270†50 180

Note: size marked with † supplied to order

Storage


Precautions

Health and safety

There are no known health hazards associated withExpandafoam in normal use.


Expandafoam is the trade mark of Fosroc International Limited

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Impregnated fibreboard filler

Uses

Fosroc Fibreboard is a compressible, non-extruding,bitumen impregnated, fibreboard expansion joint fillersuitable for forming joints between in-situ and pre-castconcrete components.

Forming structural expansion and separation joints in:

Concrete pavements and floorsRoads, ramps and runwaysPedestrian areasConcrete retaining wallsConcrete basement structures and subways

Advantages

Easy to handle, cut and tampResilientWill not extrude under compression

Description

Fosroc Fibreboard is a compressible joint fillermanufactured from bitumen impregnated wood fibres. It issupplied in sheet form and is used to form and fillexpansion joints in in-situ and pre-cast concreteconstruction.


DTp Specification for Highway Works, May 2005 series1000 Clause 1015 (joint filler boards).

American Association of State Highway Officials, StandardSpecification M 153-54.

US Federal Specification HH-F-341a: Type 1, Class B.


The expansion joint filler as detailed shall be genuineFosroc Fibreboard supplied by Fosroc and installedstrictly in accordance with the relevant Fosroc data sheet.

Properties

Form: Compressible sheetSolids content: 100%Recovery: Greater than 70%Weathering test: No disintegration

Design criteria

Typical sealed expansion joints in roads, runways andother trafficked surfaces

1 Pliastic* or Colpor 200PF* 3 Fosroc Fibreboard2 Bond breaker tape 4 Recessed seal

* Also available from Fosroc.

Example of a sealed subway expansion joint is shownbelow.

1 Thioflex 600* 4 Blinding concrete2 Bond breaking tape 5 Proofex Engage*3 Supercast Rearguard 6 Fosroc Fibreboard

‘S’ waterstop** Also available from Fosroc.

Fosroc® Fibreboard constructive solutions

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Slabs

Where used to form an expansion joint in in-situ concrete,Fosroc Fibreboard shall be placed against the shutteringon the concreting side before the pour begins. Coppernails may be used to prevent displacement in joints insuspended slabs.

Alternatively, Fosroc Fibreboard may be bonded to theexisting slab or previous pour using a suitable adhesivesuch as Plastiseal. Care should be taken not tocontaminate surfaces of the sealing slot with theadhesive.

1 Shuttering 3 Copper nails2 Fosroc Fibreboard

Joint sealing

A joint sealing slot can be formed by placing a removabletimber former on top of the Fosroc Fibreboard.Alternatively, Fosroc Fibreboard can be installed to the fulldepth of the slab and cut back to the required depthsubsequently using a power brush machine. This lattermethod is generally used for housing estate roads whichcannot be cleaned and sealed until all building hasfinished. Fosroc Fibreboard should be tamped down toensure that it fills the joint completely and providescontinuous support for the joint sealant.

Fosroc® Fibreboard

Estimating

Nominal sheetthicknesses: 10mm 12.5 mm 20 mm 25 mmSheet sizes: 1200 x 2440 mm

Fibreboard Strips12.5mm thick Pack of 10 100mm x 2.44m

Pack of 10 150mm x 2.44m20mm thick Pack of 5 200mm x 2.44m

Pack of 10 150mm x 2.44m

Storage

As with all organic materials there is a very slight risk ofspontaneous combustion if stored long term in wetconditions. Store under cover, in the dry.

Precautions

There are no known health hazards associated withFosroc Fibreboard in normal use.

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Fosroc Fibreboard is the trade mark of Fosroc InternationalLimited

214


The joint filler shall be cross linked, non-absorbent, semi-rigid, cellular polyethylene. It shall have a recovery of 98%after 50% compression and a compressive strength of0.15 N/mm² when tested in accordance with ASTM D3575.It shall have a water absorption of less than 0.05% byvolume when tested in accordance with ASTM D3575 andbe resistant to weathering and chemical attack.

Properties

Property Test method Typical values

Recovery: ASTM D3575 98% after 50%compression

Compressivestrength: ASTM D3575 0.15 N/mm²Waterabsorption: ASTM D3575 Less than 0.05% by

volume

Weatheringtest: DTp Clause 1015 No disintegrationChemicalresistance: Excellent resistance

to acids, alkalis,oxidising agents andbiologicaldegradation

Compression loading

The load compression curve shown below gives typicalcompression values achieved in accordance with ASTMD3575.

Typical load/compression curve

Cross linked, non-absorbent, closed cell,polyethylene joint filler

Uses

Hydrocell XL is a cross linked, non-absorbent, semi-rigid,cellular polyethylene joint filler used for forming expansionjoints in concrete, brickwork and blockwork. The productprovides excellent support to sealants subject tohydrostatic pressure and is particularly recommended forwater retaining or water excluding structures.

Potable water reservoirsCulverts and canalsSewage tanksRoadways and hardstandingsRetaining wallsBasement structures and subwaysRunways, taxiways and aprons

Advantages

Cross linked to resist lateral and hydrostatic pressureHigh density support of sealant to prevent adhesionfailureNon-absorbent closed cell structureHigh compression recoveryNon-extrudingLow load transfer to joint edgesNon-tainting and rot proofChemically resistantBitumen freeNatural bond breaker

Description

Hydrocell XL is a cross linked, semi-rigid, closed cellpolyethylene sheet material used for forming or fillingexpansion joints between adjacent in-situ or precastcomponents. Hydrocell XL provides excellent supportbacking to elastomeric sealants and is especiallyrecommended for use in expansion joints in brickworkand in the construction of water retaining and waterexcluding structures.


DTp Specification for Highway Works, December 1991,Series 1000, Clause 1015.

BS 5628, Part 3: Code of Practice for the Use of Masonry.

The compressive strength of Hydrocell XL prevents thetransfer of load across movement joints.

Each cell is cross linked thereby preventing breakdownunder hydrostatic pressure. The closed cell formationprevents the absorption of water.

Fosroc® Hydrocell XL constructive solutions

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% compression

Load

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Joint sealing slots

When forming expansion joints with Hydrocell XL in in-situconcrete, joint sealing slots can be readily formed in thefollowing manner.

Before installing, simply cut off a strip to the requireddepth. Pin the strip back by using 50 mm nails atapproximately 100 mm intervals. Then install the fillerflush with the finished surface.

Prior to sealing, the top strip can then be pulled easilyfrom the joint to provide an uncontaminated sealing slotready for preparation and sealing.

As elastomeric sealants will not bond to Hydrocell XL theadditional need for bond breaker strips is eliminated.

Estimating

Hydrocell XL is supplied in the following sheet sizes andcan be easily cut to the required size with a Stanley knifeor saw.

10 mm x 1000 mm x 2000 mm15 mm x 1000 mm x 2000 mm20 mm x 1000 mm x 2000 mm25 mm x 1000 mm x 2000 mm

Limitations

Hydrocell XL should not be used when the operationaltemperature is continuously below -70°C or above 100°C.

Storage

Hydrocell XL should be stored in original unopenedpackaging, in cool dry conditions, away from sunlight.

Precautions

Health and safety

There are no known health hazards associated withHydrocell XL in normal use.

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www.fosroc.com




Hydrocell is the trademark of Fosroc International Limited

216

Multi purpose expanding polyurethanefoam gap filler

One-part foam gap filler, insulant and fixative, supplied ina disposable aerosol canister for easy application.

Uses

Secofoam is used for fixing and filling gaps around thefollowing:

New and replacement windows and door framesPipe and duct work entriesThresholds and sillsWall chasesRoof eaves and ridgesFoam insulation slabs

Advantages

Highly flowable — fills irregular gapsProvides a barrier to draughts and water penetrationHigh thermal insulation properties prevents heat lossthrough gapsEasy and quick to applyFast curingGood adhesionOzone friendly — contains no CFC’sNon shrinking

Description

Secofoam is a one component moisture cured rigidpolyurethane foam which are available in pressuriseddisposable aerosol canisters.

The major use of Secofoam is in the installation of newand replacement window and door frames as an easyand quick method of filling gaps and clearances betweenthe surrounding structures. The strong bond obtained andthe high density cellular structure of Secofoam assists inthe strength of the frame fixing and reduces the number ofmechanical fixing points required. Door frames can befixed by Secofoam alone without the need for mechanicalfixings.

PropertiesForm: P.U. foamStorage: Cool place out of sunlightShelf life: 9 monthsDensity: 20 to 25 kg/m³Tensile strength: 9 N/cm²(BS 5241)Compressivestrength at 10%compression: 3 N/cm²(BS 4370)Water absorptionby volume: 0.3% on cured foamFoamstructure: Fine homogeneous cellsColour: Pale greenPhysical orchemical change: Chemical cure by reaction

with moistureThermalconductivity: 0.023 W/m/°K(ASTM C518.76)Applicationtemperature: +5°C to +35°CServicetemperature: –40°C to +90°CTack free time: 6 to 10 minutes at 20°CFlammability: Class B3

DIN 4102Toxicity: Toxic when wet, non toxic

cured


Window frame installation (replacementwindows or re-sealing)

Secofoam is suitable for use with most types of window orsub frames. Ensure the opening is free from dust andloose material before installing the frame. Secofoamreacts with moisture and it is advisable to lightly spray thesurface to be foamed prior to commencement. This isespecially important during warm/hot weather. Secofoamwill adhere to the damp surface.

Position the frame and make the specified number ofmechanical fixings. Because of the strength and adhesivequalities of Secofoam, fewer fixings are required.

The foam is injected into the gap remaining around theframe to fill slightly less than half the gap. The foam willthen expand to fill the remaining depth.

Secofoam is tack free within 10 to 30 minutes and excesscan normally be cut off after 2 hours. The rate of cure isdependent upon prevailing temperature and humidityconditions. Full cure normally takes place within 12 to24 hours.

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Pipe and duct entries

Secofoam does not shrink and is suitable for sealingaround pipes and ductwork where they pass throughwalls. Minor vibrations will not affect the bond. Secofoamwill dampen noise transmission and will prevent theingress of insects. When cured Secofoam may be cut orsanded and then plastered, rendered or finished withemulsion paint.

1 Secofoam2 Brick3 Pipe4 Nitoseal MS50

Insulation

Because of its acoustic and thermal insulation properties,Secofoam is recommended for filling irregular voids andgaps between insulation and cellular slabstock incaravans and refrigerated container construction, etc.

1 Secofoam2 Concrete3 Insulation board

Page 2

Fosroc® Secofoam

1 Secofoam2 Frame3 Glass4 Brick5 Putty6 Window7 Sealant

Door frame installation

Brace or wedge the frame into position as required. Sealand fix by filling the gap between the frame and thesurrounding structure with Secofoam. By tightly coveringthe frame gap opening internally with polythene, it ispossible to direct Secofoam expansion outwards. Fill gapto slightly less than half the known depth and finish off aspreviously described under ‘Window frame installation’.

1 Secofoam2 Frame3 Brick4 Door5 Sealant


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It is recommended that, for any large areas, Secofoamshould be in layers of approximately 25 mm, allowing aninitial cure to take place before the next application,otherwise sufficient pressure may be generated duringexpansion of the foam to cause deformation or damagethe structure insulated.

Others

Secofoam may be used to fill wall chases over pipes andelectrical conduit and should be finished as previouslydescribed. It may also be used as an eaves or ridge filleron industrial roof details providing it is top sealed toprevent UV degradation of the foam.

Operating instructions

1. Shake aerosol canister vigorously. Check that thecontents of the canister are fluid enough to shake, ifnot stand in warm water for a few minutes prior to use.

2. Fix applicator mechanism to canister.

3. When required, insert canister, insert flexible tube andpress applicator sideways allowing the foam to exudeas required.

4. Control of the rate of application may require someinitial practice. It is recommended that trials arecarried out excluding beads onto waste paper orsimilar until a degree of competence is attained.Always press adaptor trigger slowly first. All trialmaterial must be disposed of carefully. Any overheadwork should be done first as the propellant is morepowerful when canister is full.

5. When work is completed, stand canister upright for5 minutes slowly release a small quantity of propellantto blow excess foam out of the tube and valve.Unscrew applicator and replace dust cap.

Application guide

1. Ensure the gap is free from all loose material andlightly dampen or spray with clean water.

2. Inject the foam to fill half the gap depth and allow torise. After each section is injected re-shake thecanister and wipe nozzle regularly. Do not overfill sincethe foam expands many times its original volume andwill continue to expand, whilst curing.

3. When the foam has hardened trim off excess with asharp knife and protect any exposed edges from UVattack by application of suitable Fosroc sealant,plaster or paint.

4. Contents should always be fluid enough to shake, ifnot stand in warm water for a few minutes prior to use.

Cleaning

Once cured Secofoam can only be removed mechanically.

Estimating

Pack size: 750 ml x 12Foam, freeexpansion: 45 times initial volume

Limitations

Secofoam is subject to discoloration and deterioration byUV light. The foam must be cut back and protected bypointing with a suitable sealant, plaster or paint. A rangeof appropriate sealants are available from Fosroc.

Precautions

Health and safety

Secofoam contains isocyanates.

For further information please consult product Safety DataSheet.


Secofoam is a trade mark of Fosroc International Limited

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Flexible sealing compound for PrecastConcrete Units

Uses

Provides a permanent watertight joint for precast concreteunits regardless of their shape or size.

Easily compressible and designed to completely seal andfill the annular space between pre-cast units.

Advantages

Not affected by rainwater, allowing for delaysbetween application and jackingResistant to chemicalsCost-effective installation

Description

The Supercast Butyl-Nek range consists of preformedrubber/bitumen sealing strips of varying sizes designedto form watertight seals between precast concreteelements such as pipes, box culverts and manhole rings.

Standard Compliance

Supercast Butyl-Nek meets the requirements of:

Civil Engineering Specification for the Water Industry, 5th

edition, WRc 1998DOT Specification for Highway Works, HMSO 1998BS EN1917 (supersedes BS8005) sewerageBS 8301 (Building Drainage) 1985Federal Specification SS-S-210(210A0)Federal Specification AASHTO M-198BFederal Specification ASTM C-990-91


Flexible rubber/bitumen sealing compound, whereshown on the drawings, shall be Fosroc Supercast Butyl-Nek obtained from Fosroc Limited, Coleshill Road,Tamworth, Staffs, B78 3TL.

The flexible rubber/bitumen sealing compound, shallcontain 55% by weight of hydrocarbons to ASTM D 4-80,45% inert mineral filler to AASHTO T111 and 1.69%volatile matter to ASTM D 6-80. The compound shallhave a specific gravity of 1.331 at 25 deg. C to ASTM D71-84. It shall be used in accordance with the Fosroc’scurrent application instructions.

Properties

Physical PropertiesASTM

Specific Gravity @ 25oC D 4-801.331

Ductility @ 25oC D 113-85 6.0cm

Softening Point @ 25oC D 36-86 325 min

Penetration @ 25oC D 217-82 75

Flash Point D 92-85 62oC

Application Temp Range 5oC min 50oC max

Service Temp Range -20oC min 50oC max

Chemical PropertiesImmersed for 30 days, FS SS-S-2120A section 4.5/ASTMC 990

5% Solution of Caustic Potash Complies

5% solution of Hydrochloric Acid Complies

5% solution of Sulphuric Acid Complies

Saturated Hydrogen Sulphide Solution Complies

Sag or Flow Resistance

Tested to FS SS-S-210A section 4.5.3/ASTM C990, heldin a vertical position for 5 days @ 57C - no visiblechange.


Preparation

Wire brush all loose dirt and particles from the jointsurface. Joint surfaces should be free from dirt, dust,oils, release agents and curing compounds.

Priming

Brush or spray apply Supercast Butyl-Nek Primer aroundentire joint circumference and allow to dry thoroughly.Supercast Butyl-Nek Primer may be applied at theprecast manufacturing plant or on site. Supercast Butyl-Nek will not adhere to wet primer, the primer will take 1-3hours to dry in good weather conditions. Drying can takeup to 24 hours depending on coating thickness,temperature and condition of substrate. The primer willneed protecting from rain and frost until fully dried.

Vertical Application

Unroll Supercast Butyl-Nek coil whilst pressing firmly tothe dry, clean, primed joint surface. Leave plastic film inplace to protect Supercast Butyl-Nek from contaminantsuntil ready to join units. Form a continuous joint,attaching Supercast Butyl-Nek end to end. Do not stretch

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Fosroc® SupercastButyl-Nek


www.fosroc.com



the product. Remove plastic film from Supercast Butyl-Nek and align next unit. Each unit is homed by its ownweight, compressing Supercast Butyl-Nek to tightly packand immediately seal the joint. After the last section isset and fully homed the installation is complete.Backfilling and compaction can commence immediately.

Horizontal Application

Ensure that unit jointing can be accomplished withoutgetting mud, silt, gravel or other foreign material into thejoint. Generally the trench should be de-watered andhave a firm base. Unroll Supercast Butyl-Nek coil whilstpressing firmly to the dry, clean joint primed surface.Leave plastic film in place to protect Supercast Butyl-Nekfrom contaminants until ready to join units. Form acontinuous joint, attaching Supercast Butyl-Nek end toend. Do not stretch the product. Remove plastic filmfrom Supercast Butyl-Nek and align next unit. The unitshould be partially supported to maintain concentricityuntil the Supercast Butyl-Nek is fully compressed withinthe annular joint space. Backfilling and compaction canbegin immediately after jointing is complete.

Estimating

Pack sizes for Supercast Butyl-NekSupercast Butyl-Nek Box of 4 x 6mm rolls12mm x 60mm

Supercast Butyl-Nek Box of 3 x 6m rolls12mm x 80mm


Supercast Butyl-Nek Box of 8 x 4.5m rolls18mm x 18mm

Supercast Butyl-Nek Box of 8 x 4.5m rolls22mm x 22mm


Supercast Butyl-Nek 5 litre canPrimer:

Storage

Supercast Butyl-Nek has a shelf life of 12 months.

Store in original boxes in cool, dry conditions, away fromsunlight.

Precautions

Health and Safety



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16

20

250mm

200mm

12

24

17

30

250mm

25

22

22

22

20

20

250mm

200mm

150mm

All centrally placed Supercast waterstops incorporate aneyeletted, reinforced edge flange. This enables them to beeasily positioned by wiring to surrounding reinforcement.

Hydrofoil sections

Heavy duty sections

Increased web thickness gives a much stiffer section. Thestiffened profile is used where large volumes of concreteare being placed. They are used where concrete is beingplaced from a great height such as deep wall shutters.

XHD Hydrofoil section

All dimensions are approximate and subject to Fosrocmanufacturing tolerances.

Supercast Rearguard S

Sections incorporate a flat top centre box which allowsmovement to be accommodated in expansion joints. Thecentre box also provides a seating to support joint fillers.

Supercast Rearguard S can also be used in contractionand construction joints.

All Rearguard sections incorporate a nailing flange with areinforced edge to provide a secure fixing that will resisttearing.

Rearguard S sections

All dimensions are approximate and subject to Fosrocmanufacturing tolerances.

Centrally and externally placed PVCwaterstops

Uses

The Supercast range of PVC waterstops is designed toprovide an integral sealing system for movement andconstruction joints in concrete cast in-situ. These jointstypically occur in the following types of structure:

Water retaining

Reservoirs, water towers and sewage tanks

Dams, culverts, canals and spillways

Swimming pools

Bunded areas surrounding liquid retaining tanks

Water excluding

Basements and underground car parks

Tunnels and subways

Abutments and retaining walls

Roof decks and podium areas

Advantages

Range of profiles to suit every need

Fully continuous 4 bulb network

Reinforced eyeletted edge flanges for positive fixing

Simple on-site jointing

Full range of moulded and fabricated intersectionpieces

WRc approval for use in contact with potable water

The range consists of centrally placed profiles; SupercastHydrofoil and Supercast XHD Hydrofoil; and externallyplaced profiles; Supercast Rearguard S.

Description

Supercast waterstops are extruded from a high gradePVC compound which has been formulated to giveexcellent flexibility and longevity characteristics. They areavailable as straight lengths and factory producedintersections or as a factory prefabricated segment of anetwork to minimise site jointing.

Supercast Hydrofoil sections

Centre bulb sections are used in expansion, contractionand construction joints. The centre bulb allows formovements in a structure to be accommodated whilst itshexagonal design provides a flat surface. This allowsshuttering and joint fillers to fit snugly.

Fosroc® SupercastPVC waterstops range constructive solutions

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specification CRD-C 572-74. It shall have a tensilestrength in excess of 14 MN/m² and an elongation atbreak in excess of 300%

Properties

Profiles

Form: Extruded thermoplastic sectionsColour: BlueHydrostatic head: Up to 10 mJoint movement: Up to 10 mm

CompoundTypical figures: To BS 2782 at 25°CTensile strength: Minimum 14 MN/m²Elongation at break: Minimum 300%Hardness: Shore ‘A’ 80-90

Installation instructions

Supercast Hydrofoil

Waterstops must be installed so that they are securelyheld in their correct position while the concrete is beingplaced. Concrete must be fully compacted around thewaterstops to ensure that no voids or porous areasremain. Where reinforcement is present, an adequateclearance must be left to permit proper compaction.

The brass eyelets used in securing the waterstop arelocated outside the edge bulbs so as not to create waterpaths around the profile.

Supercast Rearguard

When used on ground slabs where the waterstop issupported on blinding, Rearguard profiles usually requireno fixing. Lay the waterstop centrally over the line of thejoint to be formed.

Fixing to vertical shuttering is done by nailing through theouter nailing flanges leaving the head of the nail proud sothat it is held in the cured concrete. This prevents thewaterstop being displaced when the shuttering is struck.

Fixing to vertical shutter

Design criteria

The choice of the width and thickness of waterstop islargely governed by concrete thickness, the position of thereinforcement, aggregate size and complexity of the pour.

In general the 250mm width of waterstop is suited to wallthicknesses of 250mm and over. For concrete between200mm and 250mm thick, the use of the 200mmwaterstop will be appropriate and below 200mm, 150mmwaterstop should be used.

Centrally placed waterstop

These waterstops are positioned within the thickness of theconcrete components and as a result are supported byconcrete on both sides. They are therefore able to withstandwater pressure from either side. This makes them suitablefor use in water retaining structures. They will prevent lossof water from within the tank and will prevent ingress ofground water when the tank is drained down.

Externally placed waterstop

These waterstops are designed for use in basement,foundation and floor slab construction in vertical andhorizontal joints in both water retaining and waterexcluding structures.

When used in walls, externally placed waterstops will onlyresist water pressure from the face to which they are fixed.When used below floor slabs, where the waterstop issupported by the blinding concrete or when placed invertical situations against permanent concrete shuttering,externally placed waterstops will resist water pressurefrom either face.


Supercast PVC waterstops are suitable for use in contactwith potable water. Water Regulations Advisory Serviceapproved product.

Drinking Water Inspectorate Regulation 25(1)b of theWater Supply (Water Quality) Regulations 1989.


1. Supplier specification

Where indicated on the drawings, PVC waterstops shallbe Supercast Waterstops obtained from Fosroc. All wall/floor waterstop connections shall be made usingSupercast intersection pieces to ensure continuity of thefour bulb profiles.

2. Performance specification

Where indicated on the drawings, PVC waterstops shallbe made from extruded plasticised PVC compound. Thecompound used shall meet the US Corps of Engineers

Fosroc® SupercastPVC waterstops range


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223

T-piece on edge 90° mitreon edge

(T-PCE) (M-O-E INT)

Factory welded Supercast Rearguard S to Hydrofoil andRearguard S XHD Hydrofoil

Factory welded intersections for Supercast Rearguard S

Site jointing instructions

Jointing of Supercast waterstops is carried out usingFosroc Heat Welding Equipment. The ends to be joinedare cut square and held in alignment in a special jig. Theends are then pressed either side of a special heatedblade, until an even, molten bead of PVC appears aroundthe section. The heated blade is then removed and themolten ends pressed fully together. The PVC cools to forma strong fusion welded joint. Full instructions are availablefrom Fosroc.

Intersection pieces

Standard intersection pieces are available for eachSupercast waterstop profile. The standard on-flatintersection leg length is 230 mm from centre line. On-edge intersections have a standard 75 mm leg length.

Factory welded intersections for Supercast Hydrofoiland Supercast XHD Hydrofoil.



16CI/SfB: Hn6

October 2009

Flat mitre(M-O-F)

3 wayon flat

4 wayon flat

90° mitre on edge(M-O-E INT)

270° mitre on edge(M-O-E EXT)

Flat mitre(M-O-F)

3 wayon flat

4 wayon flat

90° mitre on edge(M-O-E)

T-piece on edge(T-PCE)

224

Estimating

Section Wt/roll Minimum radii Rollwidth in in on flat on edge length

Supercast mm kg m m m

Hydrofoil 250 27.1 15 0.15 12200 27.3 14 0.15 15150 21.3 12 0.075 15

Rearguard S 250 33.4 10 5.0 12200 24.0 9 5.0 12

XHDHydrofoil 250 42.9 15 0.23 10

Storage


Equipment

Jointing jigs200 mm Supercast Rearguard S250 mm Supercast Rearguard S200 mm Supercast Hydrofoil250 mm Supercast Hydrofoil250 mm Supercast XHD Hydrofoil

Heater blades

110 v and 220v, 350w blades are available.

Warning: Ensure that heater blades are earthed by thegreen/yellow wire, and that the wiring operation iscarried out by a competent electrician.

Warning: Hot bladeDo not immerse blade in water/liquids.



www.fosroc.com



Precautions

Health and safety

Hot weld site jointing of PVC waterstops liberateshydrogen chloride mist and vapour. Ensure adequateventilation. If working in still air or confined spaces,provide forced ventilation or suitable respiratory protectiveequipment.



Application at low temperatures

Care in the handling and installation of Supercast PVCwaterstops is necessary at low ambient temperatures.Such temperatures will also require special precautionsto be taken with the placing and curing of concrete.


Supercast is a trade mark of Fosroc International Limited

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225

Swellable waterstops for in-situ concrete

Uses

Integral sealing for construction joints in concrete castin-situ.

Convenient and problem solving in situations where aconventional waterstop would require complex shuttering.

Typical uses include secant piled and diaphragm walledbasements, pile caps and casting against old concrete.The Supercast SW range can provide simple solutions todetailing pipe entries, construction joints in the verticalplane and to kicker joints.

They can be linked to Supercast PVC waterstops to givean appropriate effective combination of waterstops whichmaintain network continuity.

Advantages

Easy to install by adhesive bonding, or casting intojoint facesSupercast SWX enables full integration of SupercastSW and Supercast PVC networksSupercast SW Adhesive can be applied to dampsubstratesSolves detailing problems in conjunction withSupercast PVC waterstopsSwelling properties unaffected by long term wet/drycyclingTolerant of salts in concrete and groundwaterSustains effective seal in wet conditionsHighly adaptable to accommodate complex jointshapes

Description

The Supercast SW range consists of swellablewaterstops; Supercast SW formed sections, SupercastSWX gun-applied paste and Supercast SW adhesive.

Supercast SW sections are made from high performancesynthetic elastomer strips. The swelling action of theSupercast SW range is the result of contact betweenwater and hydrophilic groups which are an intimate part ofthe Supercast SW polymeric structure. These hydrophilicgroups are not subject to extraction and loss of swellingperformance by prolonged or repeated wetting.

Expansion of the waterstop creates a positive pressureagainst the faces of the concrete joint, thus preventingwater passing through the joint.

Supercast SWX is a grey, elastomeric water-swellablegun applied paste. Supercast SWX can be used as aswellable adhesive to adhere Supercast SW waterstop toconcrete. It has the capability to fill undulations andsurface holes in the concrete beneath the waterstop andswell into these when required.

Supercast SWX also enables Supercast SW sections tobe linked into conventional Supercast PVC waterstopnetworks. This allows the use of Supercast PVC forexpansion joints and Supercast SW for construction jointswhilst maintaining an integrated waterproofing network.

Design criteria

Supercast SW should be used to prevent the passage ofwater through non-movement joints in both new in-situconcrete and between new and existing concrete.Supercast SW increases in volume up to 300% and givesresistance to hydraulic pressure.

Swelling of Supercast SW in fresh concrete is minimaltherefore maximising the positive pressure seal providedby the hydrophilic to the protected joint.

Supercast SW20 has a larger section and so offers agreater surface area of contact to the concrete in areas ofhigher risk, such as when waterproofing Grade 3 andGrade 4 basements.

Both Supercast SW10 and SW20 have a delayed swellaction which helps prevent pre-swell during wet siteconditions (see limitations).

The minimum thickness of concrete cover required toaccommodate pressure developed during the swellingprocess is 75 mm for Supercast SW10 and 80mm forSW20.

Standard compliance

Supercast SW10 and Supercast SW20 are suitable foruse in contact with potable water and are WaterRegulations Advisory Service approved products.

Drinking Water Inspectorate Regulation 25(1)b of theWater Supply (Water Quality) Regulations 1989.


Supercast SW

Water swellable polymeric hydrophilic waterstops (andattachments) where shown on the drawings, shall beFosroc Supercast SW10 (or SW20) obtained from FosrocLimited, Drayton Manor Business Park, Coleshill Road,Tamworth, Staffs. B78 3TL. It shall be used in accordancewith the manufacturer’s current application instructions.

Fosroc®

Supercast SW constructive solutions

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Fosroc®

Supercast SW

Water swellable polymeric hydrophilic waterstop, whereshown on the drawings, shall be made from a preformedelastomeric strip which can integrate into existingwaterstop networks. It shall be free from rubber, bentoniteor other inclusions. The waterstop shall have anunrestrained volumetric expansion of up to 300%. It mustnot deteriorate under prolonged wet/dry cycling. It must beable to withstand a hydrostatic head of up to 50 metres(refer SW grade). It shall be used in accordance with themethods given in the manufacturer’s current data sheet.

PropertiesForm: Rectangular section

elastomeric stripsSize:Supercast SW10: 5 mm x 20 mmSupercast SW20: 10 mm x 20 mm

Solids content: 100%Colour:Supercast SW10: BlackSupercast SW20: Red

Unrestrained volumetricexpansion ratio: Up to 300%Application temperaturerange: –5°C to 50°CService temperaturerange: –30°C to 70°CHydrostatic pressure SW10: 30 metresresistance*: SW20: 50 metres

*(In concrete construction joint with no movement)

Graphic showing reproducibility of volume swell withwet/dry cycling

Pile cap detail using Supercast SW waterstop

Supercast SW, Supercast SWX and SupercastRearguard waterstops at secant pile wall and floor slabjunction


Supercast SW may be positioned by bonding withSupercast SWX or Supercast SW Adhesive. The waterstopmay be installed either into a suitable groove cast in theconcrete or directly onto the concrete surface.


16CI/SfB: n5

November 2008

0 20 3010

Unr

estr

aine

d vo

lum

e sw

ell

Number of wet/dry cycles

Swollen

Dry

Supercast SWwaterstop

Secant piledwall

SupercastRearguardwaterstop

Supercast SWwaterstop

Supercast SWXgunned betweenbulbs to formseal

227

Storage

Supercast SW

Shelf life: 12 monthsStore in original unopened cartons or bagsin cool, dry conditions, away from sunlight.

Supercast SWX

Shelf life: 9 monthsStore in original unopened cartridges orcartons in cool, dry conditions, away from

Supercast SW Adhesive

Shelf life: 12 monthsStore in original unopened cartridges orcartons in cool, dry conditions, away fromsunlight

Fosroc®

Supercast SW

Estimating

Pack sizes

Supercast SW10: 5 mm x 20 mm x 15 metrerolls

Supercast SW20 : 10 mm x 20 mm x 5 metrerolls

Supercast SWX: 310 ml cartridge packed incartons of 20, or as a singletube

Supercast SW Adhesive: 380 ml cartridge packed incartons of 20

Coverage

Supercast SW10 /SW20: Usually single run of strip perjoint

Supercast SWX: 6 mm diameter bead(per cartridge) - 11 metres run

12mm diameter bead- 2.7 metres run

Supercast SW Adhesive: 6 mm diameter bead(per cartridge) - 13.5 metres run

12 mm diameter - 3.4 metres run

The above coverages are approximate and make noallowances for wastage.

Limitations

Supercast SW should not be used for expansion joints orthose subject to movements in excess of 2mm.

Supercast SW should not be used in locations whichallow free unrestrained swelling or for free standing walls,such as bund or dwarf walls, where the swell pressure issufficient to lift the wall from its foundations. ContactFosroc for product/method recommendations in this case.

Supercast SW may be fixed with SWX Adhesive onsmooth surfaces, but SWX Adhesive should be usedwhere concrete is rough. In both instances the beaddiameter of the adhesive should be a minimum of 12mm.

Supercast SW must not be immersed in water prior toconcrete placement, however, Supercast SW20 cantolerate upto 3 days exposure to damp conditions on site.

See diagram opposite.


16CI/SfB: n5

November 2008

Minimum wall height abovekicker is 1m

Minimum wall thickness190mm with SW 10

200mm with SW20

Minimum concrete cover to SW75mm with SW1080mm with SW20

Note: assuming 20mm diameter rebar.

SW Details with 1 cage of reinforcement placedcentrally

SW Details with 2 cages of reinforcement

228

Fosroc®

Supercast SW


www.fosroc.com




Ancillary materials

Supercast SWXForm: Elastomeric water

swellable pasteColour: GreyTack-free time: Approximately 1 hour

(20°C / 50% RH)Cure rate: 3mm in 24 hoursVolume swell ratio: 200%Concrete pour: 2 to 8 hours

Supercast SW AdhesiveForm: Grey pasteApplication temperature: 5°C to 30°CMaximum open time: 30 minutesConcrete pour: 2 to 8 hours

Adhesion: Can be used on damp concrete provided it israg dry.

The above data represents typical values and should notbe considered as a purchase specification.


16CI/SfB: n5

November 2008

Precautions

Health and safety

Supercast SW

There are no known health hazards associated withSupercast SW10 and SW20 in normal use.

Supercast SWX

Supercast SWX may cause sensitisation by skin contact.Avoid contact with skin and eyes. Wear suitable glovesand eye/face protection. Use only in well ventilated areas.

Supercast SW Adhesive

No significant hazard. For additional information seerelevant product safety data sheet.

229

General purpose non swelling preformedplastic adhesive waterstops for concretejoints

Uses

Supercast Synkoflex and Supercast Synkoflex FRwaterstops provide watertight integrity for constructionjoints in concrete structures where swellable waterstopsare not best suited i.e. bund walls, thin section walls andwhere concrete placement is delayed to allow steelreinforcement fixing.

Advantages

Can be applied onto freshly poured concreteCan be applied onto existing concrete which isprimed with Supercast Synkoflex Primer or SupastikE10 Adhesive (for Supercast Synkoflex FR)Fuses with fresh concrete, allowing it to be appliedwith a minimum cover of 25mmNot affected by rainwater, allowing prolonged delaysbetween application and concrete pourCan be easily joined to Fosroc Supercast PVCwaterstops at expansion jointsHighly adaptable to accommodate complex jointshapesResistant to chemicalsFuel resistant (Supercast Synkoflex FR only)Cost – effective installation.

Description

Supercast Synkoflex is a non-swelling preformed plasticadhesive waterstop of dimensions 25mm x 25mm. It canbe laid onto fresh concrete, or applied to existing concretewhen used in conjunction with Supercast SynkoflexPrimer.

Supercast Synkoflex FR is a fuel-resistant, non-swellingpreformed plastic adhesive waterstop of dimensions12mm x 30mm. It can be laid onto fresh concrete, orapplied to existing concrete when used in conjunction withSupastik E10 Adhesive.

Specification Clauses

Supercast Synkoflex

Non-swelling plastic adhesive waterstop, where shownon the drawings, shall be Fosroc Supercast Synkoflex (orSupercast Synkoflex FR for fuel-resistant applications)obtained from Fosroc Limited, Coleshill Road, Tamworth,Staffs, B78 3TL.

It shall be capable of being applied to freshly pouredconcrete and be unaffected by rainwater or by infiltrationof groundwater up to a hydrostatic head of 50m. It shall

be applied in accordance with Fosroc’s current datasheet

Supercast Synkoflex FR

Non-swelling plastic adhesive waterstop, where shownon the drawings, shall be Fosroc Supercast SynkoflexFR. It shall be capable of being applied to freshly pouredconcrete and be unaffected by fuels or by infiltration ofgroundwater up to a hydrostatic head of 30m. It shall beapplied in accordance with Fosroc’s current data sheet.

Properties

Supercast SynkoflexForm : Square section flexible

waterstop

Nominal size : 25mm x 25mm x 4m roll

Colour : Black

Specific gravity : 1.20 to 1.35

Resistance to : 50m of waterHydrostatic head

Application Temp. Range : 5oC min 50oC max

Service Temp. Range : -20oC min 50oC max

Supercast Synkoflex FRForm : Rectangular section flexible

waterstop

Nominal size : 30mm x 12mm x 5m strips

Colour : Blue

Specific gravity : 1.60

Resistance to : 30m of waterhydrostatic head

Application Temp. Range : 5oC min 50oC max

Service Temp. Range : -20oC min 50oC max


Supercast Synkoflex

Existing concrete surfacesEnsure all debris is removed and surfaces are clean anddry. Brush on a 50mm wide strip of Supercast SynkoflexPrimer and allow primer to dry (usually 2-3 hours). Handpress the Supercast Synkoflex onto the primed area.Individual strips must be overlapped by 25mm.

Freshly poured concreteLay the Supercast Synkoflex onto the fresh concrete andoverlap strips by 25mm.

Fosroc® SupercastSynkoflex and Synkoflex FR constructive solutions

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Fosroc® SupercastSynkoflex & Synkoflex FR


www.fosroc.com



Supercast Synkoflex FR

Existing concrete surfacesEnsure all debris is removed and surfaces are clean anddry. Trowel on a 75mm wide strip of Supastik E10Adhesive. Hand press the Supercast Synkoflex FR ontothe primed area. Individual strips must be overlapped by25mm.

Freshly poured concreteLay the Supercast Synkoflex FR onto the fresh concreteand overlap strips by 25mm.

Estimating

Supercast Synkoflex : Box of 6 x 4m rolls

25mm x 25mm

Supercast Synkoflex FR : Box of 6 x 5m rolls12mm x 30mm

Supercast Synkoflex Primer: 50 - 60m per can@ 50mm wide

Supastik E10 Adhesive : 10 - 13m per pack@ 75mm wide

Limitations

Cannot be used for expansion joints.

Should not be installed at less than 25mm concrete cover(for Supercast Synkoflex) or less than 50mm concretecover (for Supercast Synkoflex FR).

Supercast Synkoflex should not be used for fuel storageareas - Supercast Synkoflex FR (fuel-resistant) should beused.

Storage

Supercast Synkoflex and Supercast Synkoflex FR have ashelf life of 12. Store in original boxes in cool, dryconditions, away from sunlight.


Health & Safety

There are no known health hazards associated withSupercast Synkoflex or Supercast Synkoflex FR in normaluse. For further information refer to appropriate ProductSafety Data Sheet.

Supastik E10: Contains resins which may causesensitisation by skin contact, avoid contact with skin andeyes. Wear suitable protective clothing, gloves and eye/face protection. Barrier creams provide additional skinprotection. Should accidental skin contact occur, removeimmediately with a resin removing cream, followed bysoap and water. Do not use solvent. In case of contactwith eyes, rinse immediately with plenty of clean waterand seek medical advice. If swallowed seek medicalattention immediately — do not induce vomiting.eyes.Wear suitable protective clothing, gloves and eye/faceprotection. Barrier creams provide additional skin

Supercast is the trade mark of Fosroc International Limited

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231

Composite PVC and hydrophilic waterstopsystem for dual watertight security

Uses

Supercast Twinstop has been specially designed toprovide significant advantages over co-extrudedhydrophilic waterstops. This enables the PVC waterstopto be fixed on site in the usual way and provides theadditional benefit of two hydrophilic elements treated witha retarded swell coating, thus avoiding the commonproblem of hydrophilic pre-swell on site.

AdvantagesHydrophilic elements are treated with a delay swellcoating to avoid problems associatd withhydrophilic pre-swell WRc approval for use in contact with potable waterFully continuous four-bulbed networkComplete integration with existing PVCPatented, reinforced eyelet edge flanges for positivefixingCost-effective alternative to co-extruded waterstopsRange of fabricated intersection piecesHydrophilic elements have been designed into thesystem in the optimum positionCan be used in situations where salt water, sewage,agricultural silage, oil, diesel and petrol are prevalentTolerant of site conditions — if damage does occurto hydrophilic elements, they can simply be removedand replacements slotted in


Supercast Twinstop is suitable for use in contact withpotable water and is a Water Regulations Advisory Serviceapproved product.

Supercast PVC waterstops are made from extrudedplasticised PVC compound which meets the US Corps ofEngineers specification CRD-C 572-74. When tested toBS 2782 at 25°C, it has a tensile strength in excess of14 MN/m² and an elongation at break in excess of 300%.

Description

Supercast Twinstop has been designed to combine thelatest developments in hydrophilic technology with thetraditional benefits of Supercast PVC waterstops.

Supercast Twinstop is available in two forms based on:

a centrally placed profile: Supercast Hydrofoil TS 250mm

an externally placed profile: Supercast Rearguard TS 250m m

Supercast PVC waterstops are extruded from a high-grade PVC compound which has been formulated to give

excellent flexibility and longevity characteristics. Profilesare available as straight lengths and factory producedintersections or as a factory produced prefabricatedsegment of a network to minimise site jointing.

Technical support

Fosroc offers a comprehensive range of highperformance, high quality construction products. Inaddition, Fosroc offers a technical support service tospecifiers, end-users and contractors, as well as on-sitetechnical assistance in locations all over the world.

Design criteria

Supercast Rearguard TS 250 mm

1 Supercast SW TS hydrophilic elements2 Supercast PVC waterstop

Supercast Hydrofoil TS 250 mm

1 Supercast SW TS hydrophilic elements2 Supercast PVC waterstop

PropertiesForm: Composite PVC

hydrophilic waterstopColour: Blue/redTensile strength at 25°C:BS 2782 Minimum 14 MN/m²Elongation at break at 25°C:BS 2782 Minimum 300%

Fosroc®

Supercast Twinstop constructive solutions

12

12

16CI/SfB: Hn6

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232

Example of Supercast Twinstop System

1 Supercast Twinstop waterstop2 Supercast SW TS hydrophilic insert on side facing

water3 *Thioflex 600 joint sealant4 *Hydrocell XL filler board5 Water face

Storage


Precautions

Health and safety

Hot weld site jointing of PVC waterstops liberateshydrogen chloride mist and vapour. If welding is carriedout after the hydrophilic insert has been positioned, somerubber fume may be evolved. Ensure adequate ventilation.If working in still air or confined spaces, provide forcedventilation or suitable respiratory protective equipment.

1

23

4

5

Fosroc®

Supercast Twinstop


www.fosroc.com




Installation

Waterstops must be installed so that they are securelyheld in their correct position while the concrete is beingplaced.Concrete must be fully compacted around thewaterstops to ensure that no voids or porous areasremain. Where reinforcement is present, an adequateclearance must be left to permit proper compaction.

Supercast Rearguard TS 250 mm

When used on ground slabs where the waterstop issupported on blinding, the Rearguard profile usuallyrequires no fixing. Lay the waterstop centrally over the lineof the joint to be formed. Fixing to vertical shuttering isdone by nailing through the outer nailing flanges leavingthe head of the nail proud so that it is held in the curedconcrete. This prevents the waterstop being displacedwhen the shuttering is struck.

Supercast Hydrofoil TS 250 mm

The brass eyelets used for securing the waterstop arelocated outside the edge bulbs so as not to createwaterpaths around the profile. The Hydrofoil profile shouldbe positioned with the hydrophilic inserts on the waterfacing side.

Notes

Care should be taken to ensure that the hydrophilicinserts are not exposed to excessive rain or puddlingbefore the concrete pour. If this does happen and damagedoes occur to the hydrophilic element, the damagedhydrophilic can simply be removed and a replacementtooled in.

Concrete should never be poured onto a pre-activatedhydrophilic strip.

Important notFosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for theSupply of Goods and Services, copies of which may be obtained on request. Whilst Fosroc endeavours to ensure that any advice,recommendation, specification of information it may give is accurate and correct, it cannot, because it has no direct or continuous controlover where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether ornot in accordance with any advice, specification, recommendation of information given by it.

Supercast Twinstop is the trade mark of FosrocInternational Limited


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233

Crystalline capillary waterproofing systemfor concrete substrates

Uses

Integra is an economical cementitious coating system forwaterproofing concrete against positive and negativehydrostatic heads of water.

Its uses include: sewage treatment and water treatmenttanks, pipes, tunnels, manholes and below gradebasements including retaining walls.

Advantages

Penetrates concrete, seals capillary tracts and hairlinecracksCost effectiveEffective waterproofing treatment for hydrostaticconditionsContains no chloridesEasy to applyExterior and interior applicationsCan be applied onto new and old concrete surfacesCan be used above or below ground

Description

Integra is a crystalline capillary concrete waterproofingsystem containing proprietary blends of Portland cement,quartz aggregate and special chemicals. In the presenceof moisture, the active chemical additives in Integrapenetrate concrete and react chemically with free lime toproduce insoluble crystals. This crystalline growthreduces concrete porosity by blocking capillaries andfilling hairline non-structural cracks.


Surface preparation

Surfaces must be clean and sound. Remove all oils, dustand laitance ideally by water blasting.

Note that all surfaces must be damp prior to theapplication of Integra.

Mixing

Slurry consistencyAdd Integra to clean potable water. Mix 1 part water to 2.5to 3 parts powder by volume, or 7.0 to 7.5 litres of waterper 25kg bag. Mix thoroughly with a slow speed drill andpaddle until a creamy consistency is achieved.

Mortar consistencyAdd Integra to clean potable water. Mix 1 part water to 4.5to 5 parts of powder by volume, or 3.7 to 4.2 litres of waterper 25kg bag. Mix thoroughly with a slow speed drill andpaddle until a mortar consistency is achieved.

Do not mix more material than can be applied in 20minutes. If material thickens re-stir to reduce consistency.Do not add extra water.

Application

Dry shake for newly poured concreteUse Integra as is directly from container. Wearing rubbergloves, distribute the powder evenly by hand, over freshlypoured concrete at 1.2 to 1.3 kg/m² before final floatingoperation. It is best to distribute the powder at half therecommended rate in one direction and the other half at aright angle to the first application. Keep hands as closeas possible to the surface to prevent material fromblowing away. For large areas, a rotary type spreader maybe used. Float slab and trowel to final finish.

Slurry coat for existing concreteIntegra slurry coat may be applied with a brush (syntheticbristle), broom, or plaster sprayer. Be sure to work slurrywell into openings, rough surfaces, joints and routed outareas. Apply second coat, when required, when first coathas taken an initial set (usually within one hour). If firstcoat has dried out, moisten surface before applyingsecond coat.

During the application of Integra no water should beallowed to seep through the substrate. Water leakagesshould be presealed by means of the quick set pluggingmortar, Renderoc Plug 1 (see separate data sheet).

Curing and protecting

All Integra applications must be kept moist for a minimumof 48 hours. After initial set, moist curing, using waterspray is recommended. Treated surfaces shall be fogsprayed 3 to 4 times daily for the 48 hour period. Forwarmer climates, more frequent spraying may berequired. It is important to keep Integra moist to allow thecrystal formation to occur. Call your Fosroc representativefor specific recommendations on the use of curingcompounds. Protect surfaces from traffic for 48 hours andheavy traffic for 7 days. Freshly applied Integra must beprotected from extreme weather conditions such as rain,strong winds, high temperatures and freezing for a periodof not less than 48 hours after application.

Cleaning

Prior to curing, Integra may be cleaned from tools andother surfaces with water.

Fosroc® Integra constructive solutions

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237

Fosroc® Integra

Estimating

Supply

25kg bags.

Coverage

Two coat application

By brush: 1-1.5kg/m² per coatBy trowel: 2-2.5kg/m² per coat

Actual coverage rates will depend on the profile andporosity of the substrate.

Limitations

Not recommended for application temperatures below5ºC. Full activation and effectiveness may occur 2-3weeks after application.

Storage


If stored at high temperatures and/or high humidityconditions the shelf life may be reduced to less than6 months.

Precautions

Health and safety


17CI/SfB: Y9

October 2005


www.fosroc.com




Integra is the trade mark of Fosroc International Limited

238

Bitumen / rubber latex waterproofingemulsion

Uses

Mulseal DP is a bitumen rubber / latex compounddesigned for use in waterproofing applications. Mulseal issuitable for uses such as waterproof membrane toretaining walls, as a vapour barrier to panels andrepairing fine cracks in asphalt surfaces.

Advantages

Excellent adhesion to most common buildingmaterialsLow water vapour permeabilityCan be applied to “green” concreteResistant to sulphates and ground saltsDries to a flexible filmSimple to apply by brush

Description

Mulseal DP single part bitumen latex emulsion is appliedby brush or squeegee. The incorporation of rubber lateximparts elasticity to the dried coating. Mulseal DP issuitable for use on most building materials such asconcrete, brickwork, metals and stone. It is easily appliedand may be used on damp surfaces, provided that no freewater is present. It can also be applied to “green” concreteimmediately shuttering has been struck. Where it is usedas a sandwich membrane in floors, Mulseal DP shouldhave continuity with the damp courses.


DTp Specification for Highway Works May 2005 series2000 clause 2004.


Where shown on the drawings, the waterproofing/vapourbarrier membrane shall be Mulseal DP from Fosroc.Surfaces shall be prepared and the product applied inaccordance with the manufacturers current data sheet.

Properties

Form: Thixotropic liquidSolids content: 60%Density: 1.00 kg/litreApplicationtemperature: 5 to 50°CDrying time: 4 to 6 hours. 24 hours should be left

between coatings. Mulseal shouldnot be applied in enclosed spacesunless there is adequate circulationof air to allow for evaporation of water

Coverage: Typically 1.1 - 1.4 m²/litre per coat, butwill depend upon the nature of thesurface being treated


Preparation

Surfaces shall be clean and free from dust, dirt, oil,grease, moss and loose material. Mulseal DP may beused on damp surfaces such as green concrete, brick orblock work but there must be no standing water. Metal andtimber surfaces should be dry and primed with one coat ofFosroc Primer 3. All other surfaces should be primed witha coat of a 1:1 mixture of Mulseal DP and water.

Application

Mulseal DP may be applied by brush or squeegee. Formost purposes two full coats should be considered aminimum requirement. Where required Mulseal DP maybe reinforced by a bedding layer of bitumen saturatedglass fibre into the first full coat prior to application ofsubsequent coats. When used as a sandwich dampcourse to ground slabs, the final coat should be blindedwith clean sharp sand passing through a 3 mm sieve toprovide a key for the second concrete pour.

Limestone should not be used. Mulseal DP is waterbased and remains soluble until thoroughly dry. Do notapply during rain or when rain is expected.

Priming

Porous surfaces such as concrete or block work must betreated with a priming coat made up of a solution ofMulseal DP and clean cold water mixed in equal parts.

Metal and timber surfaces must be primed with a coat ofPrimer 3 before applying. Mulseal DP can be applied bybrush or squeegee. It must be thoroughly stirred beforeuse. For efficient waterproofing, a minimum of two fullcoats must be used.

For horizontal surfaces, a squeegee or a cheap, softbristle broom is satisfactory. For vertical surfaces, use acheap expendable brush. A useful technique that may beemployed to keep brushes clean when using Mulseal DPis as follows:

Mix a strong solution of detergent and water, minimum5 litres. Soak the brush in the solution and shake outbefore use. As work progresses, rinse the brush atintervals to prevent it clogging and shake out surplusdetergent solution before resuming. Mulseal DP shouldbe laid on to the surface using the brush in one directionand not brushed out. During a break in work or when it iscompleted, clean the brush in a strong detergent solutionand then in running water. Clean off any remainingMulseal DP with white spirit, allowing the spirit toevaporate before re-using the brush. Brushes should beof an inexpensive type and considered as expendable.Paint brushes are not suitable. On the larger job, it ispreferable to maintain several brushes in use.

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Mulseal is supplied ready for use. If, however, afterthorough agitation the product appears unduly thick it can,as an exception, be thinned with not more than 0.25 litre ofclean water per 5 litres of Mulseal DP.

Cleaning

Splashes of Mulseal DP on paintwork, etc, should bewiped off at once with a damp cloth.

Ancillary materials

Fosroc Primer 3.

Estimating

Supply

Mulseal DP: 5 litre tins, 25 and 200 litre drums

Fosroc Primer 3: 5 litre tins

Yield

Mulseal DP 1.1 to 1.4 m²/litre per coat

Mulseal in 1.1 priming coat2.0 to 2.5 m²/litre.

Fosroc Primer 312 to 15 m²/litre.

Limitations

Protect from frost during storage. Mulseal is damaged byfreezing. Mulseal DP should not be used if rain or frost isexpected, but frost will not affect the dried film.

Storage


Mulseal DP should be protected from frost.

Precautions

Health and safety


Fire

Fosroc Primer 3 is highly flammable. Keep away fromsources of ignition. No smoking. In the event of a fire,extinguish with CO2 or foam. Do not use water.

Flash points

Fosroc Primer 3 -7oC

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Mulseal is the trade mark of Fosroc International Limited

240

Flexible cementitious waterproof coating

Uses

Nitocote CM210 is a flexible cementitious coating, usedfor waterproofing water retaining structures and waterexcluding structures.

Nitocote CM210 provides a flexible waterproof coatingsuitable for use in potable water tanks, reservoirs, canalsand culverts.

The material can be used on concrete, brick andblockwork substrates.

Advantages

Approved by Drinking Water Inspectorate (DWI)Withstands high positive and negative hydrostaticpressuresExcellent bond to concrete and masonryLong working lifeEasy application by brush, roller, trowel or sprayBonds to green or damp concreteEffective barrier to sulphates and chlorides


BS 6920: 2000 Effect on Water Quality.

Water Regulations Advisory Scheme approved.

DWI Regulation 31 approved.

Fire Tested to BS 476: 1987 Parts 6 and 7.

Description

Nitocote CM210 two-component polymer modifiedcementitious coating is supplied in a pre-packaged form.The product has been designed to be easily mixed on-siteusing a slow speed drill and paddle and then applied tothe substrate using a brush, roller, trowel or by sprayapplication. Nitocote CM210, available in grey and white,cures to form a flexible impermeable membrane.


The waterproofing coating shall be Nitocote CM210, aflexible cementitious coating approved under the DWIRegulation 31 (WRc Listed). The cured coating shall havethe capability to resist a positive water pressure of 7 bar anda negative water pressure of 3 bar when tested to DIN 1048.

Properties

Typical properties of mixed material:

Pot life at 20ºC: 1 hourColour: Grey or whiteMixed density: 1850 kg/m³Minimum applicationtemperature: 5ºC

Properties of cured coating (21 days cure at 23ºC followedby 28 days immersion at 23ºC). The values obtained arefor Nitocote CM210 when applied in two coats each of1mm wet film thickness:Resistance to positivewater pressure (DIN 1048): 7 bar (70m head of water)Resistance to negativewater pressure (DIN 1048): 3 bar (30m head of water)Static crack accommodation: >1.0mmAbrasion resistance: Wear Index 1

(ASTM D 4060) equivalentto 40 N/mm2 concrete

Chloride ion diffusion No penetration afterresistance (Taywood method): 12 months continuous

testingCO2 diffusion resistance(Taywood method)after 5000 hours QUV* : >50m* Note QUV test required coating to be exposed to 4 hourscondensation at 50oC followed by 4 hours ultraviolet lightat 50oC. Total exposure time was 5000 hours.



Surface preparation

All surfaces which are to receive the coating must be freefrom oil, grease, wax, dirt or any other form of foreignmatter that might affect adhesion. Typically, concretesurfaces can be cleaned using a high pressure water jetand detergent. Poor quality, friable, or contaminatedsurfaces require grit-blasting or scabbling

Spalled surfaces or those containing large blow-holesand other such defects should be repaired usingNitocote CM210 or a Fosroc approved repair mortar orrender. Care must be taken when choosing the repairmortar to ensure that it has all necessary approvals forcontact with potable water. Contact local Fosroc office foradvice on suitable materials.

If the surface contains small blow-holes, typically lessthan 1mm wide, the coating can be applied directly on tothe substrate without the need for a treatment.

Cracks which are greater than 0.2mm in width should bechased-out to 4mm in width and approximately 15mm indepth. This should be filled with Nitocote CM210 (appliedusing a Fosroc ‘G’ Gun). When the material in the crackhas hardened the coating should be applied over thecrack and reinforced with polypropylene mesh (see latersection).

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Mixing

The liquid component should be poured into a plastic ormetal drum having a volume of at least 25 litres.

This should be placed onto a plastic sheet to avoidcontamination. The powder component is graduallyadded to the liquid whilst mixing with a Conbextra MixingPaddle or other approved spiral paddle attachment on avariable speed drill. Mixing is continued, constantlymoving the paddle around the drum, until a lump-freeslurry is obtained. This should take a minimum of 3minutes and a maximum of 5 minutes.

Note: The preferred drill speed is between 250 and750 rpm.

Mixing warning

Nitocote CM210 may exhibit satisfactory handlingcharacteristics even though inadequately mixed. This willresult in a significantly lower level of performance orpossible failure. It is therefore essential that mixinginstructions are strictly adhered to with particularemphasis on the time of the mixing operation.

Pre-wetting of substrate

Thoroughly dampen the substrate surface with waterusing a brush, roller or spray. High porosity substrateswill require more dampening that dense substrates. Donot apply the coating when the substrate is wet, but allowthe water to soak in until the substrate is just visibly dampbefore proceeding.

Any excess water should be removed using a sponge.Any running water should be stopped with a suitablyapproved plugging mortar such as Renderoc Plug 20.Contact the local Fosroc office for further advice onsuitable materials.

General

For optimum use of the product, Nitocote CM210 whiteshould be applied as the first coat, with Nitocote CM210grey as the second coat. This gives a visual indication ofcoverage.

The first coat should be applied at a wet film thickness of1mm (coverage per coat is 1.8kg/m2 or 1 litre/m2). Toensure the correct thickness is achieved, measure out anarea (for example 200m2), then calculate how muchmaterial will be needed to cover this area. Monitor thecoating thickness during application at regular intervalsusing a wet film gauge. Care must be taken to fill allimperfections such as blow-holes during application.Blow-holes can be filled while the coating is still fluid byusing a dry sponge. If the coating has dried before theseimperfections are found they can be filled using freshmaterial.

All the mixed material should be used within 1 hour ofmixing.

Allow first coat to cure for a minimum of 4 hours at 20oC/50% RH and longer at lower temperatures or higherhumidities. The exact drying time will depend on surfacetemperature, relative humidity and air movement. Hightemperatures and/or low humidity will reduce the dryingtime. This can vary from 1 to 16 hours. The maximumambient temperature for application is 40oC.

The first coat should be left to dry until firm andunmarkable to the touch. There is no maximum timebetween coats, however the surface may need cleaningwith water prior to application of the second coat toremove potential contamination.

The second coat should also be applied at a wet filmthickness of 1mm. Pre-dampening of the surface is notnecessary when applying the second coat.

No curing membrane is necessary, however the freshlyapplied coating should be protected from rain and strongwind or until firm to the touch to prevent damage to the wetcoating.

Brush application

The most suitable type of brush is a soft bristledwallpaper paste brush (120 to 220mm wide). Wherelarger areas are to be applied it is advisable to use abrush with a handle.

Load the brush up well and spread the material to therequired thickness. If the brush begins to drag duringapplication, do not add water to the material but dampenthe surface again. Finish in one direction for a neatappearance.

For floor application, a soft bristled broom isrecommended. Pour the material on to the substrate andthen spread to the required thickness.

Roller application

Application by roller has the benefit of speed over brushapplication, particularly on smooth substrates. A goodquality medium hair roller is recommended. The rollershould be well loaded for ease of application. A heavyroller pattern will be left, therefore it is important to use afinishing tool to produce a smooth coating, with a uniform1mm wet film thickness.

Trowel application

Application with a steel plastering trowel also has thebenefit of speed over brush application, as well asproducing a superior finish. It is recommended that ascratch coat of Nitcote CM210 be applied prior to the firstcoating to fill blow-holes, which should be allowed to curefor the equivalent of 2 hours at 20oC.


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Finishing tools

A finishing tool may be required to produce a smoothfinish or to repair film defects. Examples of suitable toolsinclude a steel plastering trowel, a caulking tool and ahard sponge. All of these must be used immediately aftercoating application, otherwise the coating may drag ortear. When using a hard sponge it should be dry or veryslightly damp. A wet sponge should not be used as thiswill cause polymer to come to the surface of the coatingwhich causes an unsightly white streaky effect.

Spray application

Spray application should be carried out using a suitablewet spray technique. This is the preferred method forapplications over 150m2. In smaller tanks with restrictedaccess it may be beneficial to spray. This means thematerial will be pumped into the restricted area ratherthan having to be physically carried.

Mixing should be carried out as previously described, andparticular care should be taken to ensure that no lumpsremain in the mix. The mixing container should be placedon plastic sheeting to stop gravel and stones fromcontaminating the mix. Material should be scraped off themixing bucket above the wet line after every mix. Thepaddle should also be cleaned at this stage. All of theseprecautions are important to stop dried material or gravelfrom causing blockages in the pump.

Pour the material into the hopper. Scrape the sides of thehopper down regularly to stop material from hardeningand then dropping into the mix. Place a cover over thehopper to prevent product skinning caused by water loss.

The mixed material is pumped through the hose to thespray gun. Substrate preparation and coverage ratesdescribed above should be adhered to. Wet filmthickness should be measured using a wet film thicknessgauge every 2 to 3 metres initially until the sprayer hasjudged the ideal application speed and distance from thewall. Any areas less than 1mm thick should be sprayedover again. For the rest of the application, thicknessmeasurements should be carried out every 10m2.

Reinforcement with polypropylene mesh

Proofex LM mesh may be used to reinforce NitocoteCM210 at joints and cracks. The mesh should be beddedinto the first coat while still wet. Immediately after placingapply a further thin coat of Nitocote CM210 to ‘wet’ out themesh. Allow to set before applying the second coat.

Sealed joints

Sealant joints should be filled with a suitable joint sealantbefore application of Nitocote CM210. If potable watercontact is expected, the sealant should be approved.Contact your local Fosroc office for recommendations.

Apply debonding tape over the sealant. After application ofthe Nitocote CM210 remove the tape and overlaying coating.

Curing

For contracts not requiring UK potable water approvals,allow a minimum cure time of equivalent to 7 days at 7oC(3 days at 20oC and above). Nitocote CM210 should bedry cured. This is to ensure the full physical properties aredeveloped.

UK potable water approvals

In the case of contracts requiring DWI and Water ByelawsScheme certification, Nitocote CM210 white should beapplied as the first coat followed by a second coat ofNitocote CM210 grey. The product must be allowed tocure for a minimum of 7 days at 7oC or greater.

Tanks with a surface area less than 250m2 should beflushed with water prior to filling.

The tank should be disinfected in accordance with localregulations before re-connection to the public water supply.

Cleaning and disposal

Immediately after application is completed, clean all toolsand equipment with clean water. Hardened material canbe removed by mechanical means and by use of FosrocSolvent 102.

Waste material should be allowed to harden overnightthen disposed of as non-hazardous waste.

Estimating

Supply

Powder component(grey or white): 18.2kg bagLiquid polymer component: 5.0kg plastic containerProofex LM mesh: 100mm x 50m

CoverageCoverage rate at 1mm 12.5m2 per packwet film thickness: 0.54m2 /kg

The coverage figure given is theoretical - due to wastagefactors and the variety and nature of possible substrates,practical coverage figures will be reduced. A minimumcoverage of 3.6kg/m2 applied in not less than two coats isrecommended.

Limitations

Nitocote CM210 should not be used when the temperatureis below 5oC. The product should not be exposed to rainfallor moving water during application or within 4 hours at20oC. The maximum ambient temperature for applicationis 40oC.


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Nitocote CM210 should not be used on external surfaceswhere an aesthetic appearance is critical becausedifferences in environmental conditions during cure maycause colour differences in the final surface. If any doubtsarise concerning temperature or substrate conditions,consult the local Fosroc office.

Nitocote CM210 should not be used on structures subjectto high movement, i.e. elevated water retaining tanks. Ifany doubts arise consult the local Fosroc office.

Storage

Store in unopened bags in cool dry internal conditions.The product has a shelf life of 12 months from the date ofmanufacture if kept in a dry storage in the original,unopened bags. Material from different batches shall bestored separately.

If stored at high temperatures and/or high humidityconditions the shelf life may be reduced to less than 6months.

Precautions

Health and safety



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244

Fast setting, pure polyurea elastomericwaterproof coating

General Information

Fosroc Polyurea WPE is a spray-applied, 100% solids,flexible, two-component, rapid curing pure Polyureasystem, designed as a waterproofing and protectivecoating. It combines the advantages of seamlesscoating with very long life cycles and high durability.

Fosroc Polyurea WPE consists of Fosroc Polyurea WPEPart A ISO, Fosroc Polyurea WPE Part B AMINE and apigmented colour pot. The system offers excellentsurface properties and overall physical properties.

Uses

Anti-corrosion, waterproof and protective coating forconcrete and steel in a wide range of environmentalconditions. Typical applications include:

Below ground waterproofingPipe/ Pipeline coatingTank coatingWaste water tank liningRoof waterproofingAquarium liningStadiaLandscape & water containment

Advantages

Environment friendly - zero VOCExcellent chemical resistance, thermal stability andUV Resistance *Very fast turn-around time. The coated substrate canbe put into service within an hourExcellent impact, abrasion and puncture resistanceSeamless and monolithic, including day jointsSignificantly enhances the durability of reinforcedconcreteLow permeability valuesDesigned for service temperatures from -30oC to+135oCNon slip finish easily achievable

* See Limitations

Specification

The protective and / or waterproofing coating shall beFosroc Polyurea WPE, a 100% solid, flexible, twocomponent, rapid curing pure Polyurea coating systemproviding high corrosion, abrasion and thermal shockresistance. It shall meet the values under the section“Properties”.

Properties

Typical Physical properties at 23oCSolids by Volume : 100%Volatile organic compounds : 0 g/litreViscosity : A ISO =1000 mPas

: B AMINE <1500 mPasDensity at 23oC : 1.01 g/mlGel time : 5 - 10 secondsTensile strength ASTM D412 : >19 N mm-2

Modulus 100%/ 200%/ 300%ASTM D412 : > 9/ 13/ 16 N mm-2

Tear Resistance ASTM D624C : 85 N/mmElongation ASTM D412 : >300%Shore D ASTM D2240 : 46Abrasion (1kg,H22 wheels)ASTM D4060 : 36 mg /1000 cyclesService temperature : -30oC to +135oCColour : RAL 7005 Grey(Others colours available : Unpigmentedto order)

Chemical Resistance(ASTM D3912, 72 hours immersion)

Chemical Result Max service temp.Hydraulic Oil R 50oCMotor Oil R-DIS 50oCDiesel Fuel R 25oCPetrol R-DIS 25oCSkydrol NRSodium hydroxide (50%) R 50oCAmmonia (0.880) 33% R 25oCSugar solution conc. R 50oCBleach (5%) R-DIS 50oCButanol R-C 25oCLactic Acid (20%) R 50oCPhosphoric Acid (10%) R 50oCHydrochloric acid (20%) R-C 50oCNitric acid (30%) R-C 25oCSulphuric Acid (10%) R 50oC

R : RecommendedR-DIS : Recommended – Discolouration onlyR-C : Recommended – Conditional; discolouration

and/or slight softening or swelling – washdown within one hour to avoid effects

NR : Not Recommended

Note: The chemical resistance recommendations givenabove apply to spillage and secondary containmentapplications up to 72 hours contact duration; for any

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other requirements/chemicals contact Fosroc for furtheradvice.

Clarification of property values

The typical physical properties given above are derivedfrom independent testing of Fosroc Polyurea WPE sprayapplied in accordance with the Fosroc Polyurea MethodStatement, in controlled laboratory environment. Resultsderived from testing field-applied samples may vary.

Spray application parameters

Block Temperature : +70oC to +80oCHose Temperature : +70oC to +80oCVolume ratio : 1:1Pressure : 120 - 150 barGel Time : 5 - 10 secWalkable : 2 minutesTrafficable (light duty) : 15 - 20 minutesFully Serviceable : 24 hours


Refer to Application section below and Fosroc PolyureaMethod Statement for further detail.

Surface preparation

All surfaces must be clean, dry and free fromcontamination.

ConcreteDry abrasive blasting, wet abrasive blasting, vacuum-assisted abrasive blasting, and centrifugal shot blasting,as described in ASTM D4259, may be used to removecontaminants, laitance, and weak concrete, to exposeblow holes, and to produce a sound concrete surfacewith adequate profile and surface porosity.

Blow holesAll blow holes and minor surface imperfections shall befilled with Nitomortar FC prior to application of Primer.See separate product data sheet. Nitomortar FC shouldbe allowed to cure for 12 –18 hours at 20oC. Lightlyabrade the surface and wipe with a cloth lightly wettedwith Fosroc Equipment Cleaner and allow to dry prior topriming.

SteelThe steel must be of first class quality and must not havebeen allowed to rust more than corresponding to grade Bof BS EN ISO 8501-1:2007. Any laminations must beremoved.

Blast clean to Sa 2½. (BS EN ISO 8501-1:2007).Roughness: using abrasives suitable to achieve acoarse surface of Grade Medium G (50-85μm, Ry5) (BSEN ISO 8503-2:2001).

All welding seams must have a surface finish whichensures that the quality of the paint system will bemaintained. All sharp edges must be removed orrounded off to ensure that the specified film thicknesscan be built-up on all surfaces. The radius of therounding must be minimum 2 mm.

Priming

Following correct preparation, the substrate must beprimed. Fosroc Primer 195 should be used.

For concrete, suggested application rate is 2.5 - 4 m2 perlitre dependant on concrete porosity. On very porousconcrete higher application rates may be required.Consult Fosroc for further recommendations.

For steel substrates, a rate of 6.5 m2 per litre isrecommended.

Add the entire content of Part B into Part A and mix with aslow speed drill and paddle for 3 minutes untilhomogeneous.

Apply by brush, roller or squeegee to a uniform thickness.Initial spreading may be carried out by spray but a finalrolling should be carried out to ensure full wetting and evendistribution of the primer.

A broadcast of 0.2 – 0.5 mm kiln-dried sand onto theuncured primer is recommended for optimum adhesionproperties. Excess sand should be removed prior toapplication of the Fosroc Polyurea WPE.

The primer shall be allowed to become touch-dry prior toapplication of Fosroc Polyurea WPE. Typically 1.5 hoursat 20oC 2 hours at 10oC. Pot life Primer 195 : 30 minutesat 25oC, 60 minutes at 15oC.

If primer is unsanded the Fosroc Polyurea WPE should beapplied within 24 hours. After this time the primer should beremoved by shot blasting and the area reprimed.

Application

Spray Equipment

A high pressure spray proportioning machine/ spray gunfor plural heated polyurea components such as thosemanufactured by GlasCraft or Graco should be used forthis product.

A list of appropriate equipment is provided in the FosrocPolyurea Method Statement.


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Application Method

Add the pigment paste, to the Part B AMINE drum andmix with a slow speed 300-400rpm bunghole mixer for20 minutes until homogeneous.

If pigmented material is stored it should be mixed with abunghole mixer for 20 minutes prior to use.

Avoid moisture contamination of bulk material, sealdrums for storage. Do not add solvent.

Heat the spray lines to 70 – 80oC.

Apply the Fosroc Polyurea WPE at the specified thickness(1.5 – 3.0 mm ) to the primed substrate in a cross hatchpattern with a minimum of two alternate directional passes.

If non slip surfaces are required consult Fosroc PolyureaMethod Statement.

Day joints : when overcoating material applied more than12 hours previously. Remove any dirt / dustcontamination. Wipe surface of cured coating with NEP(N-ethyl pyrrolidone). Apply Polyurea when surface is dry,typically 30 minutes with a 100 mm overlap.

Due to the fast cure rate of Fosroc Polyurea WPEoverspray can only be removed mechanically.

Estimating

Supply:

Fosroc Polyurea WPEPart A ISO component : 200 ltr drumsFosroc Polyurea WPEPart B AMINE component : 200 ltr drums

or: 195 ltr drums (Note :separate 5 litre ColourPack required)

Fosroc Primer 195Part A Base : 12.5kg in 25 litre pailFosroc Primer 195Part B Hardener : 7.5kg in 10 litre pailFosroc Equipment Cleaner : 5litre

Coverage:

Fosroc Polyurea WPE : 1.5 – 3.0 ltrs per m2

(1.5 - 3.0 mm) depending onspecification

Fosroc Primer 195 : Concrete : 2.5 - 4 m2 /litre: Steel : 6.5 m2 /litre

Storage

Fosroc Polyurea WPE and Primer 195 have a shelf life of12 months if kept in a dry, air conditioned store between+5oC and +30oC in the original unopened containers.

Limitations

Fosroc Polyurea WPE should not be applied over existingcoatings.

Fosroc Polyurea WPE is not colour stable when exposedto sunlight and UV. This will not affect the cured physicalproperties of the product.

Application should not be undertaken by the methodsdescribed if the temperature is below 5oC or is 5oC andfalling or where the prevailing relative humidity exceeds90% or the dew point is less than 3oC above the surfacetemperature. Consult Fosroc if these conditions are notmet for specific advice.

Precautions

Health and Safety


Flash Point

Fosroc Polyurea WPE and Primer 195 are non-flammable.

Flash Point Fosroc Equipment Cleaner: 44oC


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High performance waterproofing membranefor basements and structures

UsesA high performance self adhesive membrane for a rangeof waterproofing applications including basements andsubstructures. Proofex 3000 provides a vapour andwaterproof membrane to water excluding structures andprotects concrete from attack by aggressive ground salts.

AdvantagesCross-laminated HDPE film for protection against damageDimensionally stableCombines toughness with flexibility for detailingaround cornersSelf adhesive layer system makes installation quick,simple and reliableResistant to ground water, soluble sulphates andchloridesSuitable for waterproofing basements grades 2, 3 and4 as defined in BS 8102 :1990, ‘Protection OfStructures Against Water From The Ground’

DescriptionProofex 3000 is a cold applied, flexible, waterproof, highperformance membrane incorporating a cross laminatedHDPE carrier film with a polymer modified bitumen compound.

Proofex 3000 should be laid in accordance with theprovisions of BS 8102 :1990.

Where Proofex 3000 is being used as a floor DPM there,should be continuity with wall DPCs and other DPMs usedin the structure. If methane presence is suspected, acomprehensive site survey needs to be carried out. Refer toProofex 3000MR datasheet for further information.

Typical propertiesMembrane thickness: 1.5 mmAdhesion to primed concrete(ASTM D1000): 4.9 N/mmTensile strength (BS EN 12311-1)

Longitudinal: 215 N/50mmTransverse: 220 N/50mm

Elongation (BS EN 12311-1)Longitudinal: 324%Transverse 238%

Water vapour permeability(BS EN 1931): Impermeable to ISO 12572

Hydrostatic test (BS EN 1928): >60 kPa

Application instructionsSurface preparation

All concrete surfaces must be a wood float or shutterfinish and free from cavities or projections.

Masonry surfaces must be flush pointed.

All surfaces must be clean, dry and free fromcontamination, ice and frost.

Priming

Vertical and suspended slab surfaces shall be primedwith Proofex Primer. Ensure complete coverage and allowto dry. Only prime an area to which the Proofex 3000 canbe applied the same day. Very porous surfaces mayrequire more than one coat of primer.

Angle and corner details

Where possible, a 25mm chamfer should be provided toall external angles prior to application of the reinforcingstrip.

Use Proofex Angle Fillet strips fixed using 6 mm beads ofPlastiseal at all wall to floor junctions.

All internal and external angles should be reinforced withProofex Engage Detail Strip or a 300 mm wide strip ofProofex 3000.

Application

Application temperature range 5°C to 35°C.

Vertical application: Cut the Proofex 3000 to lengthallowing 150 mm for the end laps and position by peelingback the release paper and applying the self adhesiveface to the prepared surface.

Start at the top of the wall and work down by progressivelyremoving the release paper in stages. Proofex 3000should be applied to ensure that all end laps areweathered.

In cold weather temporary batten support of the Proofex3000 membrane is recommended.

Horizontal application: Completely unroll the Proofex3000 membrane and place against a chalk line. One halfof the roll should then be rolled up to the mid point, therelease paper carefully cut, without damaging the Proofex3000 membrane and progressively removed from the midpoint out to the end of the roll.

This process should be repeated on the other half of theroll. The Proofex 3000 membrane should be brushed ontothe surface to ensure good bonding.

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The next roll or length is aligned against the previouslyapplied piece allowing for the 50 mm minimum (or asspecified) edge laps and 150 mm end laps and appliedas stated previously. The edge and end laps should berolled to ensure complete adhesion and continuitybetween the layers.

Penetrations

Penetrations e.g. pipe entries through the Proofex 3000membrane require special attention to detail. Use ofProofex Top Hats is recommended and should be stuck tomembrane using Proofex Total Tape and sealed to pipewith Nitoseal MS50

Protection

Proofex 3000 membrane should be protected fromphysical damage and weathering as soon as possibleafter application. Surfaces should be protected fromdamage by Proofex Protection Board.

Proofex 3000 can also be covered with Proofex Sheetdrainto give both protection and a drainage layer.

Ancillary Products

Proofex Protection BoardBitumen impregnated board, designed to protect membranesfrom damage through backfilling and trafficking.

Proofex Engage Detail StripA reinforced, double sided waterproof adhesive tape foruse as reinforcing at all floor and wall junctions. It consistsof a strong synthetic fibre fabric impregnated and coatedboth sides with a butyl adhesive, which is protected by aremovable siliconised paper.

Proofex Top HatMDPE sheathing, which encapsulates an aluminium foillayer. For use at service penetrations through Proofex 3000.

Proofex Angle FilletStrips fixed at all floor and wall junctions with a 6mm beadof Plastiseal.

EstimatingProofex 3000

Roll size: 1 m x 20 m

Roll area: 20 m²Edge laps: 50 mm minimumEnd laps: 150 mm minimumWeight: 32kg

Proofex PrimerCoverage: 6 to 8 m²/litreMinimum installationtemperature: +5°C risingDrying time @ 20oC: 1 to 2 hoursPack size: 5 ltr and 25 ltr drums

Proofex Engage Detail Strip

Thickness: 1.5 mmRoll size: 200 mm x 10 m

Proofex Protection Board

3 mm Thickness: 1000 mm x 2000 mmCoverage: 2.0 m2

StorageProofex 3000 has a shelf life of 12 months and must bestored in an upright position at a temperature between5°C and 40°C.

Proofex Primer has a shelf life of 2 years.


Each Proofex 3000 roll should be lifted by a minimum oftwo site operatives.

For information on Proofex Primer refer to Product SafetyData Sheet.

Proofex Primer is flammable. Keep away from soruces ofignition. No smoking. In the event of fire, extinguish withCO2 or foam. Do not use a water jet.

Flash Point Proofex Primer: >39oC



Proofex is the trade mark of Fosroc International Limited

249

High density polyethylene drained cavity formerfor waterpoofing of sub-structures

Uses

Proofex Cavitydrain is used where sub-structures areconstructed in concrete designed to minimise water entryin accordance with BS 8102, 1990 ‘Protection ofstructures against water from the ground’, Type C.

Any water ingress through the structural concrete will notenter the internal environment because ProofexCavitydrain provides a continuous water and damp proofdrainage former to connect with drainage channels oroutlets cast into floor slabs.

Water leakage problems which show up in theconstruction stage can be remedied before the drainagelayer is put in place, adding to the security of thewaterproofing system.

Advantages

Internal application in a controlled environmentincreases security against waterproofing failureProvides a continuous drainage former and dampproof barrierHigh compressive strengthConical voids enable high load transfer to structuralelementsChemically resistantEasily fixed and installed using mechanical fixings

Description

Proofex Cavitydrain is a profiled HDPE with ribbed conicalvoids spaced to permit high water flow through apermanent void against the sub-structure face.

Mortar is poured into the conical voids on the internal faceof the drainage former allowing high load transfer tostructural elements.

PropertiesVoid height: 20 mmVertical drainagecapacity (H.G. = 1.0): * 12 l/s/mHorizontal drainagecapacity (H.G. = 0.01): * 0.34 l/s/mCompressive load at10% compression: † 90 kN/m²Mass/unit area: 1.0 kg/m²Chemical resistance: Resistant to most acids, alkalis,

oils and fuels

* BS 6906, Part 7. † ASTM D1621.


Ensure drainage system is free from obstructions.

Check floor slab is laid to adequate falls and all channeland outlet grills are fixed. Make good any defects toconcrete surfaces that would prevent adequate fixing ofProofex Cavitydrain.

Cut Proofex Cavitydrain to length allowing for theconnection detail at the drained wall cavity. Ensure thebases of the conical voids always face the substrate.

Fix along the opening jointed edge by mechanical fixing withSteel Hammer-in Anchors (6mm diameter x 30mmoverall length) at 1000 mm centres. If shot fired fixing ispreferred use Hilti XSW 30 fasteners or similar. In bothcases apply a small quantity of Plastiseal into the conicalvoid before mechanical fixing to ensure continuity of thedamp proof barrier.

Edge laps between adjacent sheets of ProofexCavitydrain should be formed by bonding with self-adhesive foam strip or a bead of Plastiseal. Theminimum overlap should be 25 mm and fixed firmlytogether using 10 mm long self tapping screws at300 mm centres.

Use fixings at 1000 mm centres in the conical voidsadjacent to the formed edge lap.

Where projections through the floorslab occur trimProofex Cavitydrain to butt against the projection. Fillthree rows of conical voids around the perimeter of theprojection with mortar or concrete and allow to dry. Primethe face of the projection and the area of filled conicalvoids with Proofex Primer and allow to dry.

Flash around pipes and column bases using Proofex3000 membrane to provide continuity of water proofing(see detail).

Example of Proofex Cavitydrain at floor slab /columnbase joint

1 Proofex Cavitydrain 4 Floor screed2 *Proofex Angle Fillet 5 *Proofex 3000 membrane3 Insulation if required* Also available from Fosroc

Where a joint occurs between horizontally and verticallyapplied Proofex Cavitydrain it may be formed by first fixingthe wall cavity former terminated 20 to 30 mm above floorslab level.

The floor cavity former is then bent through 90 degreesup the wall, interlocking the first two rows of conical voidsinto the wall cavity former (see detail).

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Example of Proofex Cavitydrain at joint between wall andfloor

1 Proofex Cavitydrain2 Floor screed3 Supercast Rearguard S Waterstop*4 Channel connected to site drainage system


Where this detail is not possible butt the horizontal sheetagainst the vertical sheet ensuring both drainage planesdrain freely into the drainage channel (see alternativedetail).

Example of Proofex Cavitydrain at joint between wall andfloor (alternative detail)

1 Proofex Cavitydrain2 Proofex 3000 membrane flashing*3 Proofex Angle Fillet*

4 Floor screed5 Butt joint6 Supercast Rearguard S Waterstop*


Fill the first three rows of conical voids in the horizontalProofex Cavitydrain with mortar or concrete and allow todry. Prime surface with Proofex Primer. Apply ProofexAngle Fillet and a 300 mm strip of Proofex 3000membrane as a closure strip between the horizontal andvertical Proofex Cavitydrain.

Estimating

Proofex Cavitydrain HC comes in rolls: 0.97 m x 50 m.Approximately 60 fixings are required per roll of ProofexCavitydrain.

Limitations

If it is not possible to cast floor screeds immediatelyfollowing the application of Proofex Cavitydrain,temporary protection must be provided to preventphysical damage from site operations.

Avoid point loads of Proofex Cavitydrain from floor screedreinforcement by using spreaders or pre-filling theconical voids with concrete or mortar.

Storage


Precautions

Health and safety

Each Proofex Cavitydrain roll should be lifted by aminimum of two site operatives.

For Proofex Primer refer to Product Safety Data Sheet.


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251

Pre-applied waterproofing membrane whichmechanically bonds to poured concrete,remaining in place if settlement ofsubstrate occurs

UsesA unique patented waterproofing membrane for a range ofwaterproofing applications including basements andsubstructures. Proofex Engage provides a water, watervapour and gas protection to water excluding structuresand protects concrete from aggressive ground salts andchemicals.

AdvantagesUnique mesh system bonds permanently to concrete,remaining in place even if settlement takes placeBasement waterproofing protection to grades 2, 3 and4 as defined in BS8102:1990Methane, radon and CO2 protection as defined in BREReport 212BBA certificationProtects concrete from attack from chemicals andaggressive ground saltsSimple application - requires no primer or protectionInert product - no risk of a reaction with ponded waterprior to concrete being poured

Standard compliance

Independently certified performance, BBA certificate(No. 03/4042).

British Standard 8102:1990 - Code of Practice for'Protection Of Structures Against Water From the Ground'.


The waterproof tanking membrane shall consist of apolyethylene membrane incorporating a complex cellmesh, enabling the membrane to mechanically bond withthe concrete. The membrane shall be supplied with oneselvedge to provide sealed laps and comply with BritishStandard 8102 1990 - code of practice for “Protection ofStructures Against Water from the Ground” to providebasement waterproofing protection to grades 2, 3 and 4.The product shall have a current British Board ofAgrément Certificate.

DescriptionProofex Engage is a unique patented system comprisinga complex cell mesh bonded to a poyethylene membranewhich allows poured concrete to interlock with themembrane forming a tenacious mechanical bond.

Proofex Engage is supplied with a selvedge on one sideto provide sealaed laps.

Typical properties

Membrane properties Typical valuePeel adhesion to concrete:BS4254 mod* 74N per 50mmShear strength of joints:MOAT 27:5.2.2Selvedge: 377NProofex Engage Detail Strip: 506NPuncture resistance:ASTM E154 600NMethane permeability:BS903 Part A30:1996 1.33E-17m2/sec/PaCO2 permeability:Rilem Report 12 <5.12E-13m2/sec/Pa

* Concrete cast against grid and cured for 7 days.Peel adhesion tested at 50mm/minute at 20ºC.

Application instructionsSubstrate preparation

Horizontal application - the membrane must be applied tosmooth prepared substrate. Concrete blinding ispreferred but a well rolled granular fill with a compactedsand blinding is acceptable. The substrate shall be freefrom loose aggregate or other sharp protrusions.Standing water must be removed to preventcontamination of overlaps and subsequent compromiseof waterproof properties.

Vertical application - the membrane is applied toformwork or adjoining structures.

Membrane installation

Cut the membrane to a convenient length for installation.Carefully align the membrane and roll it out with theribbed surface uppermost. Lay adjacent sheetsaccurately so they overlap the previous sheet 75mm alongthe adhesive selvedge. When laying adjacent full rollsthere should be a stagger of half a roll length to avoid abuild up of end joints in one area.

End joints and cut edges - butt join the Proofex Engagesheets onto Proofex Engage L Section. The top surface ofthe join can be further sealed with Proofex LM reinforcedwith Proofex LM Mesh. This overseal should extend 75mmeither side of the formed joint.

All overlaps and joints should be firmly rolled to ensurecomplete adhesion between layers.

If cold or damp conditions prevail the selvedge adhesivemay be tackified by wiping with Fosroc Solvent 102.

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Removal of formwork

Where the membrane has been applied to removableshuttering it is recommended that a minimum concretecompressive strength of 10N/mm² is reached before theformwork is stripped.

Penetrations

Penetrations e.g., pipe entries through Proofex Engage,require special attention to detail. Proofex Top Hat unitsused in conjunction with Proofex Total Tape and NitosealMS50 is recommended.Refer to Fosroc for moreinformation on details.

Ancillary productsProofex LMA two component trowelable membrane for sealing aroundintricate details such as pipe entries, penetrations, pilecaps, etc.

Proofex corner pieces125mm Internal and external corner pieces made frompolyethylene membrane with a 100mm butyl selvedge.

Proofex “L” sectionThis 5m long x 250mm wide section of polyethylene has 2butyl selvedge strips. It is used by bending at 90o along itslength for application between horizontal and verticalmembrane to provide waterproofing continuity it alsoconnects with internal and external corner pieces.

Proofex "L" section is suppied with a butyl "closure" strip ateach end, if the "L" section is cut this strip must be replacedwith Proofex Engage Detail Strip.

Proofex Engage Detail StripA reinforced, double sided waterproof adhesive tape forsealing and jointing roll ends, cut edges and cornerpieces. It consists of a strong synthetic fibre fabricimpregnated and coated both sides with a butyl adhesive,which is protected by a removable siliconised paper.

Proofex LM MeshA reinforced mesh used in conjunction with Proofex LM forareas of extreme loading (covings, edges and pipepenetrations).

Proofex Top HatWaterproof pipe entry consisting of MDPE sheathing,which encapsulates an aluminium foil layer.

EstimatingProofex EngageRoll size: 1.27 m x 30 m x 5mm,Coverage: 38.10 m2

Proofex Engage Detail StripRoll size: 200 mm x 10 m x 1.5 mm

Proofex LMPack size: 28 kgCoverage: 7 m2 (at 4 mm thick)

Proofex LM Mesh

Dimensions: 100 mm x 50 m (nominal )

Proofex Top HatDiameter: 110 mm 160 mm

330 mm x 330mm 380 mm x 380mm

Proofex Total TapeDimensions: 50 mm x 30 m

Nitoseal MS 50Supply: 380 ml cartridge in boxes of 20

StorageStore in original unopened packaging, in cool dryconditions, away from sunlight, in a flat position.

Proofex “L“ section should be stored vertically as supplied,in cool dry conditions. Do not distort or crush the coil.


Proofex Engage weighs approximately 60kg and shouldbe lifted by a minimum of three site operatives.



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Pre or post- applied bentonite water-proofing membrane with unique surfacebentonite impregnation for impermeablelap joints

Uses

Basement waterproofing protection to grades 2, 3 and 4as defined in BS8102:1990. Provides a vapour andwaterproof membrane in building and civil engineeringstructures and protection to the structure from attack byaggressive chemical substances in the ground.

Advantages

Unique impermeable lap joints derived from surfacebentonite impregnation of the non-woven geotextilelayer during manufactureFull surface contact between the bentonite-impregnated cover layer and the concrete ensuresthat small cracks and surface imperfections aresealedQuick and easy installation in almost all weatherconditionsForms a tenacious mechanical bond to pouredconcrete when cast in situ, remaining in place ifsettlement of the substrate occursNo requirement for priming systems, joint taping orprotection systemsOne product can be used in both pre-applied andpost-applied construction situationsBBA accredited, certificate no. 06/4310

Description

Proofex Hydromat consists of two elements –Natural sodium bentonite as the sealing material.Two layers of geotextile to encapsulate and containthe bentonite.

A continuous layer of natural sodium bentonite issandwiched between a needle-punched polypropylenegeotextile (the cover layer) and a slit film woven geotextile(the carrier layer). The components are needle-punchedtogether uniformly across the membrane to hold thebentonite sealing material in a stable position.

The surface of the cover layer is filled during manufacturewith the same bentonite as in the centre of the membraneto facilitate continuity of bentonite across the membraneand the creation of impermeable overlap joints.


British Standard 8102:1990 – code of practice for‘Protection of Structures Against Water From the Ground’.

Properties

Membrane properties Typical valueTensile strength MD/CD 20kN/m / 11kN/mDIN EN ISO 10319Puncture force 2500NDIN EN ISO 12236Peel strength >360N/mASTM D6496Montmorillonite Content Approx. 90%(Sodium Bentonite) XRD


Substrate preparation

Horizontal application – the membrane must be appliedto a smooth prepared substrate. Standing water shouldbe removed before the membrane is unrolled. Concreteblinding is preferred but a well-rolled granular fill with acompacted sand blinding is acceptable. The substrateshall be free from loose aggregate or other sharpprotrusions.

Vertical application – the membrane is applied to as-castconcrete, formwork or adjoining retaining structures. Thesurface of the concrete or retaining structure should be assmooth a prepared finish as possible.

Installation below floor slabs

Roll out the product and trim to fit. A watertight seal isachieved by overlapping adjacent panels by minimum100mm for 1.2 x 2.42m and 150mm for 2.42 x 15m at sideand end laps, ensuring that the lap area is free of debris.Care must be taken to ensure that the product is installedwithout wrinkles or folds, and that the non-wovengeotextile is facing upwards such that it will be in contactwith the concrete when it is poured.

The overlaps should run in a uniform direction, andconcrete must be placed on top of the membrane,following the direction of the overlaps to remove thepossibility of concrete folding back the panel andinterrupting the waterproofing continuity. A minimum150mm concrete floor slab can then be cast.

At day joints, the remaining exposed sections of ProofexHydromat should be covered with a suitable weatherresistant cover to protect it from rain, and accidentaldamage and trafficking of this area should be minimised.In the event that equipment and materials must be storedon the applied membrane, a 50mm concrete screed

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should be cast over the membrane as protection. Uponcontinuation, care should be taken to conform with thelapping requirements detailed above.

Installation against shuttering

At the transition between the horizontal and the vertical,Proofex Hydromat is simply turned up through 90 degreesand stapled or nailed to the shuttering. Remove nailheads before casting concrete if flat head nails are used,such that the nails can be removed with the shutteringwithout damaging the membrane. Staples or nails shouldonly be located in the lap area between adjacent panels,at c. 300mm centres along the line of the lap.

Installation on cast vertical walls

Following completion of the wall, Proofex Hydromat shouldbe fixed to the wall face by nailing with soft washer fixings,such as Hilti X-SW 30-ZF. The nail length is determined bysubstrate type and condition: if in doubt, contact FosrocTechnical Department. Care must be taken to ensure thatthe product is installed without wrinkles or folds, and thatthe bentonite-impregnated non-woven geotextile is placedfacing the concrete and on the backfill side of the wall.

Overlaps must be a minimum of 100mm for 1.2 x 2.42mand 150mm for 2.42 x 15m and be nailed every 300mmalong the top edge and within the lap area. The remain-ing area of the membrane within the laps should not benailed. The overlap of the membrane between the kickerand the wall must be a minimum of 350mm, lapped toensure that the panel coming down the wall laps over thepanel coming up from the slab. This area must be nailedtightly. An additional membrane sealing strip with a widthof 400mm may be placed directly over the kicker joint andrunning parallel to it and directly over the overlap areabetween the vertical and returning horizontal panels.

Backfill must be free from any angular material or debriswhich could damage the membrane and should notcontain rocks larger than 50mm.

To prevent intrusion of backfill materials between theProofex Hydromat and the concrete wall, a protectivetermination bar may be installed. Thus is commonlymade of non-degradable boards, fixed to the structurethrough the membrane at 100-150mm below the top ofthe tanking line around the whole structure.

Installation for sealing vertical walls againstretaining structures

Before constructing the structural wall, fix the ProofexHydromat directly onto the retaining wall. The bentoniteimpregnated non-woven geotextile side of the membranemust be installed facing the structural wall which is yet tobe cast.

Nail or staple the product in place within the lap areabetween adjacent panels, nailing at 300mm centresalong the line of the lap. It is important that the membranepanels are installed evenly, without folds or wrinkles, andensuring that any vertical laps involve the uppermostpanel coming down over the lower panel.

Care and Detailing

Double layers should be used at all corners.

Outside edges of installed membrane should beprotected by plastic sheeting at the end of work to ensurethey remain clean and dry to form the overlap the followingday. Plant or equipment should not be permitted to travelon the unprotected surface of the membrane.

Any repair patches should overlap the repair area andextend beyond the extremity of the damage by a minimumof 200mm. The area to be patched should be free ofdebris and swept clean. If this causes loss of thebentonite in the cover geotextile then extra ProofexHydromat Powder (either in dry form or as a paste forsloping or vertical surfaces) at a minimum of 0.5kg/sq.mshould be placed around the perimeter of the area andthen the patch placed in position.

Sealing around penetrations must be carried out inaccordance with Fosroc’s instructions and technicalguidance.

Tie bolt holes should be filled with Renderoc Plug 20 andthen covered with a ‘mushroom’ of Proofex HydromatPowder in paste form. This should be done before fixingof the Proofex Hydromat for post-fixed membraneinstallations, or prior to backfilling for pre-fix applications.In applications where the membrane is shutter-fixed,patches of Proofex Hydromat extending a minimum150mm beyond the bolt locations are also required,lapping with the surrounding membrane.

Normally Proofex Hydromat does not need to be artificiallyhydrated. However, if the membrane could come intocontact with liquids such as salt water, before it hydratesthe membrane must be artificially hydrated. ConsultFosroc for technical guidance.

Ancillary products

Proofex Hydromat Powder

To ensure watertight continuity during detailing work andfor sealing around awkward geometrical shapes, it maybe necessary to cover an area with loose natural sodiumbentonite powder. This can be done using Proofex


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Hydromat Powder, either in dry condition or mixed 1 partpowder:4 parts water in the form of a paste.

A typical area of use is around piles. See Fosroc standarddetails.

Estimating

Proofex Hydromat

Thickness: 7mm (dry)Roll sizes: 1.2 m x 2.42 m

2.42 m x 15 mWeights: 18 kg, 210 kg

Proofex Hydromat Powder

Bag size: 25kg

Limitations

Proofex Hydromat should only be hydrated with normalgroundwater.

The hydration of Proofex Hydromat is adverselyaffected by the presence of salts e.g sea waterand may also be affected by the presence of solublematerials such as those found in chalk or lime soils.

Consult Fosroc Technical for advice in these circumstances

Precautions

Health & Safety

Proofex Hydromat 2.42m x 15m weighs approximately210kg in the dry state and should be lifted by mechanicalequipment.

Proofex Hydromat Powder weighs 25kg and should belifted by two operatives.


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256

Two component bituminous liquidmembrane for waterproofing ofunderground structures and intricatedetails in conjunction with Proofexwaterproofing systems

Uses and advantages

For the waterproofing of intricate details e.g. pipeentries, covings etcFor external waterproofing of underground structuresCan be applied to damp surfacesResists hydrostatic head of up to 70 metresSeamless - flexible with crack-bridging capabilitiesSimple trowel applicationSolvent-free - environmentally friendly and harmless toground waterResistant to aggressive ground waterCompatible with Proofex waterproofing systems

Standard compliance

Materialprüfanstalt Nordrhein-Westfalen; tested inaccordance with DIN 18195, parts 4 to 6.General test certificate No. P-22 1356 8 96-1, MPADortmund

Description

Two component bituminous rubber emulsion with specialhydraulically hardening fillers.

PropertiesConsistency: Paste-like (mixture)Density: Approximately 1.2 g/cm³ (mixture)

while freshPot life: Approximately 90 minutes at +20ºCApplication Approximately: minimum +5ºC up totemperature: +35ºC ambient temperaturePrimer: Mixed material diluted with water 1:10Curing: 1 to 3 days depending on

temperature, relative humidity,substrate and layer thickness.Typical cure time at 20ºC, 60%relative humidity, 3.3 mm coating, isapproximately 24 hours. Resistant torain after 3 hours at +20ºC/65%relative humidity

Resistance: To numerous salt solutions, weakacids and aggressive substancesnormally existing in soil


Substrate preparation

All surfaces to be sealed must be clean and free from allloose particles and all other adhesion inhibitingsubstances. Mortar residues, laitance, etc., should beremoved.

The substrate to be waterproofed may be dry or damp (notshining wet). There should be no standing water onhorizontal areas. If the surface is dry, it is recommendedthat the substrate is dampened by spraying waterbeforehand. All substrates to be waterproofed withProofex LM must be primed prior to applying thewaterproofing layer. The primer is prepared by dilutingone part Proofex LM (premixed product) with ten parts ofclean water and applied by brush. Once priming iscomplete, the first coat of Proofex LM can be appliedstraight away.

Macro-porous substrates with cavities require a scratch-coat of Proofex LM to avoid bubble formation or risk ofblistering. The scratch-coat should be left to dry for 1 to 2hours before applying the next layer.

It is recommended that, where required, each full first coatof Proofex LM is left to dry overnight before applying asecond coat.

Mixing

Proofex LM kits consist of exact quantities of twocomponents contained within the same pack. Thepowder component is carefully mixed into the liquidcomponent by means of a slow speed drill with paddleuntil it forms a homogeneous, paste-like compound ofuniform colour.

Application by trowel

Proofex LM is applied by steel float in one or two evenlayers depending on the maximum loading. To avoidcrack formation the applied material must not be workedon, once the coating starts to dry.

In areas with extreme loadings (covings, edges and pipepenetrations) the material has to be applied twice. Fosrocrecommend the use of a Proofex LM mesh allowing10mm overlaps between the first and the second coat.

Application temperatures

The pot life of Proofex LM is at least 90 minutes at +20ºCand normal humidity. Higher temperatures shorten whilelower temperatures lengthen the pot life.

Protection of the waterproofing

The structure may only be backfilled after complete curingof the waterproofing layers has taken place. Sharpobjects should not come in contact with the membrane.

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Fire

The completed installation may be protected as requiredwith Proofex Protection Board.

Proofex LM should not be exposed for prolonged periods.The cured membrane should therefore be protected fromthe elements (including sunlight) if the product will be leftexposed for several weeks.

Suitable noise, heat and mechanical insulation materialssuch as styrene and mineral foam may be glued toProofex LM.

Normal application

Proofex LM primer: Dilute Proofex LM with water in amixing ratio of 1:10.

Damp conditions with no water pressure presentWaterproofing (one layer)Layer thickness (wet): Approximately 3.3 mmCoverage: Approximately 4 kg/m²

Positive water pressure:Up to 1 bar(10 metre head of water)Waterproofing (one or two layers)

Layer thickness (wet): Approximately 4.0 mmCoverage: Approximately 5 kg/m².

Incorporate reinforcementmesh at all sharp corners

Up to 7 bar(70 metre head of water)Waterproofing (two layers)

Layer thickness (wet): Approximately 6.7 mmCoverage: Approximately 8 kg/m².

With or without incorporatingreinforcement mesh

Estimating

Supply

28 kg pack.

Coverage and yield

Proofex LM: Approximately 4 to 6 kg/m² at normalloadings. Approximately 8 kg/m² where standing waterand pressurised water occur.

Coverage per m²/mm dry film thickness equalsapproximately 1.65 kg Proofex LM.

Proofex LM primer: Approximately 50 to 80 g/m²unthinned material, depending on the porosity of thesubstrate.

Storage

The product has a shelf life of 12 months from the date ofmanufacture if kept in a dry storage in the original,unopened bags.

Store in unopened bags in cool dry internal conditions. Ifstored at high temperatures and/or high humidityconditions the shelf life may be reduced to less than 6months.

Precautions

Health and Safety

For further information, refer to appropriate Product SafetyData Sheet.


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Geocomposite HDPE drainage sheet withthermobonded polypropylene filter

Uses

Proofex Sheetdrain is a double cuspated drainage sheet,available in 2 sizes: 8mm for depths up to 6m and 16mmfor depths up to 20m. It is fixed to walls and roofs ofstructures to provide a filtered, drainage plane that willroute ground water and gases away from the structure,utilising subsoil drains to link with the site drainagesystem. Proofex Sheetdrain reduces water pressure onstructures and the possibility of water ingress and can beeffectively used in conjunction with other waterproofingsystems.

Proofex Sheetdrain can also be used as protection to asheet membrane against physical damage from backfilloperations.

It is an effective alternative to traditional stone ‘French’drains providing improved drainage performance.

Where directly cast concrete sub-structure walls need tobe drained, Proofex Sheetdrain may be used as a lostshuttering liner.

Proofex Sheetdrain is effective in constructing basements,retaining walls, service ducts, lift pits and subways withand without Proofex sheet membrane, allowingconstruction to BS 8102 :1990.

Proofex Sheetdrain provides filtered drainage andenhanced protection when used with Proofex waterproofmembranes on reservoirs, podia and elevated slabs.

AdvantagesMaintains high rate of flow (water and gas) while understress thanks to its symmetrical, impervious structureMaintains an air layer along wallsHigh impact resistant, high density polyethylene corewith a crush strength of up to 450 kPa/m² providesdrainage void around structures under backfill andlong term loadingsCost effective alternative to ‘French’ drainsEasily fixed on site

Example of external tanking with drained protection isshown below

1 *Proofex 3000/3000MR/4000R2 *Proofex Engage Detail Strip3 *Proofex Angle Fillet4 *Proofex Sheetdrain5 *Supercast Rearguard Waterstop6 Sub-soil drainage pipe7 Drainage stone* Also available from Fosroc.

Description

The Proofex Sheetdrain range are geocompositedrainage sheets with either 8mm or 16mm thick highdensity polyethylene cores and polypropylene geotextiles,recommended for most building and civil engineeringdrainage applications. Supplied in 1.1m x 25m rolls.

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Properties

8mm 16mmGeospacer:Raw material 100% virgin HDPE 100% virgin HDPEProfile Double cuspated symmetrical and watertightCrush resistance (NF EN 964-1) >150 kPa >450 kPa

Filter:Raw material Polypropylene non woven heat bonded

Flow rate at 10cm head (BS6906-3) 80 litres/m2/s

Proofex Sheetdrain:Width 1.1m 1.1mLength per roll 25m 25mFlow capacity (EN ISO 12958) 0.85 l/m/s (under 20 kPa) 2.3 l/m/s (under 20 kPa)I = 1 / between two foams 0.7 l/m/s (under 50 kPa) 1.6 l/m/s (under 100 kPa)Tensile strength/elongation at break(ISO EN 10319) 15 KN / m / 40% 21 KN / m / 70%Durability predicted to be durable for a minimum of 25 years in all natural soilsMaximum long term load 60 kPa 150 kPa

Compression strength: 150 KN/m2 450 KN/m2

Mechanical Resistance:For an anticipated duration of 100,000 hours (11 years) Proofex Sheetdrain 8 distortion is in the order of 0.72mmunder a 60 kPa load, corresponding to a burial depth of 6m (water-saturated clay soil, laid vertically)

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Example of Proofex Sheetdrain at joint between service reservoir roof and wall

1 *Proofex Sheetdrain2 *Proofex 3000/3000MR/4000R/SM

waterproof membrane3 Geotextile reinforcing strip4 *Supercast Rearguard waterstop5 *Fosroc Slip Membrane6 Water flow to subsoil drain at base of wall



Specification – depth up to 6m

The geocomposite sheet drain shall be Fosroc, 8mmProofex Sheet drain. It shall be a double cuspated HDPEcore, with a polypropylene non-woven geotextile bonded toone side. It shall have a thickness of 8mm under apressure of 50kPA and a crush resistance 150 kPa.Thegeocomposite drainage sheet shall be installed strictly inaccordance with the manufacturer’s technical data sheet.

Specification – depth up to 20m

The geocomposite sheet drain shall be Fosroc, 16mmProofex Sheet drain. It shall be a double cuspated HDPEcore, with a polypropylene non-woven geotextile bonded toone side. It shall have a thickness of 16mm under apressure of 100kPA and a crush resistance 450 kPa. Thegeocomposite drainage sheet shall be installed strictlyin accordance with the manufacturer’s technical datasheet.

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Fixing

Proofex Sheetdrain should be fixed using Hilti IZ 8x70fixings at a rate of 1 per metre 2 or when applied to amembrane with Proofex Engage Detail Strip.

Joints

Pull back the geotextile fabric 100mm from one side ofjoint, and overlap the HDPE cores. Over lap the geotextilefabric. Geotextile should be laid in direction of flow toprevent ingress of fine material.

Drainage connection

Pull back sufficient geotextile fabric to wrap around thedrain. Cut back the HDPE core to an appropriate lengthand wrap geotextile fabric around drain.

Top closure

Pull back the geotextile fabric 100mm. Cut back the HDPEcore by 50mm and wrap the geotextile fabric over theexposed end to prevent ingress of backfill.

Backfilling

Backfilling must be free from any sharp objects or debris,which could damage the Sheetdrain. It should not containrocks or boulder larger than 50mm. This must be placedagainst the Sheetdrain in 300mm layers compacting to85% modified Proctor. Backfilling should be in direction oflaying of strips.

Ancillary materials

*Proofex Detail StripHilti IZ 8x70 fixings* Available from Fosroc.

Limitations

Proofex Sheetdrain should not normally be used insaturated clays at depths greater than 20m for 16mm sizeand 6m for 8mm size to allow for the effects of long termloadings.

Proofex Sheetdrain should not be used in soil containinghigh concentrations of iron oxides or hydroxides or inextremely fine uniformly graded silts or peat. Pleasecontact Fosroc Technical Department for advice when indoubt.

Proofex Sheetdrain is resistant to chemicals found innormal soil conditions, some chemicals in certainconcentrations could have an adverse effect on the drainsperformance. Please contact Fosroc TechnicalDepartment for advice when in doubt.

Estimating

Product Packaging QuantityProofex Sheetdrain: 1.1 m x 25 m roll 1

Storage

The product is supplied in a roll and must not be exposeddirectly to UV radiation for over two months.

Precautions

There are no known health hazards associated withProofex Sheetdrain in normal use.

Health and safety

Proofex Sheetdrain 8 weighs approximately 17kg.

Proofex Sheetdrain 16 weighs approximately 38kg. Eachroll should be lifted by a minimum of two site operatives.


Proofex is the trademark of Fosroc International Limited

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261

High performance Epoxy resin waterproofgrout

Uses

Free-flow epoxy grout for use in waterproofing pile-caps toensure complete integrity of the waterproofing system.Also for applications where the building is beingconstructed on gas – contaminated land.

Advantages

Non-shrink and hence ensures complete surfacecontact and bondFully waterproof and compatible with ProofexmembranesHigh compressive, tensile and flexural strengthsFast, convenient installation with rapid strength gain

Description

Proofex WG is a three-component system consisting ofbase resin, liquid hardener and specially graded inertfillers. It is suitable for thicknesses from 20-100 mm.

Design criteria

Example of Proofex WG applied to circular pile-caps

1

2

3

1 Proofex WG2 *Proofex Engage3 *Proofex LM

*Also available from Fosroc.

Where methane is present, the building needs to beconstructed in accordance with Building ResearchEstablishment Report 212.

Fosroc offers a comprehensive range of highperformance, high quality construction products.

Technical support

Fosroc offers a technical support package to specifiersand contractors as well as technical advice from staff withunrivalled experience in the industry.

Properties

The following results are typical for the hardened grout at20°C.

Test method for Typical resultsDensity: 2025 kg/m³

Compressive strength(B 6319, Part 2: 1983) -

6 hours (24°C): 36 N/mm²1 day: 89 N/mm²3 days: 93 N/mm²7 days: 100 N/mm²

Tensile strength(BS 6319, Part 7: 1985)7 days: 14 N/mm²

Flexural strength(BS 6319, Part 3: 1990)7 days: 32 N/mm

Secant modulus(BS 6319, Part 6: 1984) 13 kN/mm²

Chemical resistance

Proofex WG is resistant to oil, grease, fats, mostchemicals, mild acids and alkalis, fresh and sea water.Consult Fosroc’s Customer Service Department whenexposure to solvents or concentrated chemicals isanticipated.

Pot life

Ambient temperature affects the time for which bulkmaterial will remain fluid.

Typical values in minutes are:

10°C 20°C 30°CProofex WG: 60 30 15

Exotherm

All epoxy systems will develop a temperature rise onmixing. Its extent will be a function of the volume to surfaceratio, the ambient temperature as well as the mass andthermal conductivity of the surrounding materials. ContactFosroc for specific data on each product.


Supplier specification

All epoxy resin grouting where shown on the drawings,must be carried out using Proofex WG as manufacturedby Fosroc and used in accordance with themanufacturer’s data sheet.

Performance specification

All epoxy resin grouting where shown on the drawings,must be carried out with a factory packed productmanufactured by a registered firm. The grout must becompatible with the chosen waterproof membrane. The

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hardened grout must have a compressive strength whichexceeds

99 N/mm² at 7 days, a tensile strength which exceeds13 N/mm² at 7 days and a flexural strength which exceeds31 N/mm² at 7 days.

The storage, handling and placement of the grout must bein strict accordance with the manufacturer’s instructions.


Preparation

Concrete surfacesAll surfaces must be free from oil, grease, free-standingwater or any loosely adherent material. Concrete surfacesshould be cut back to a sound base. All dust must beremoved and bolt holes or fixing pockets blown clean ofany dirt or debris.

Steel surfacesAll steel surfaces should be shot blasted free of rust andflaky mill scale. Cleaned surfaces may be protected by theapplication of Nitoprime 28.

FormworkThe formwork should be constructed to be leakproof asProofex WG is a free-flowing grout.

Mixing

Pour all the contents of the hardener pack into the basecontainer. Mix using a slow speed power drill and paddleuntil homogeneous.

Pour all the resultant liquid into a container with a capacityof 15 to 25 litres. Add all the filler provided for eachproduct. Mix using a slow speed power drill and paddle for2 minutes or until a uniform colour is achieved in thegrout.

Placing

The mixed grout should be poured steadily from one sideonly to eliminate the entrapment of air.

Continuous grout flow is essential.

Sufficient grout must be available prior to starting.

The time taken to pour a batch should be regulated to thetime taken to prepare the next batch.

Cleaning

All tools and equipment should be cleaned immediatelyafter use with Fosroc Solvent 102. Spillages should beabsorbed with sand or sawdust and disposed inaccordance with local regulations.

Limitations

Temperature

During application

The cure rate will be slower near 5°C, and applicationshould not be attempted when the temperature is 5°C andfalling. Where application temperature exceeds 20°C notethe pot life given previously.

In service

The cured grout, which is completely resistant to frost andsub-zero temperatures, is suitable for use up to 45°C.

Estimating

Supply

Proofex WG: 16 litre packs containing liquid base andhardener

Storage

Proofex WG has a shelf life of 12 months if kept in dryconditions at 20°C.

Precautions

Health and safety

Fire

Fosroc Solvent 102 is flammable. In the event of fireextinguish with CO2 or foam.

Flash point


For additional information see relevant Product SafetyData Sheet.


Proofex is the trademark of Fosroc International

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263

Flexible expansion joint membrane

Uses

Expoband H45 is a Hypalon membrane system which isdesigned to be bonded over movement joints or cracks instructures to prevent the passage of water. It is bonded inposition using Supastik E10 two-part epoxy adhesive.Expoband H45 is suitable in construction use and repair/remedial applications.

Advantages

Accomodates continuous and pronounced cyclicmovementExcellent resistance to weatheringWaterproof and chemical resistant for joints aboveand below groundHeat weldable connection

Description

Expoband H45 is an un-reinforced Hypalon membraneincorporating a central release tape.

Expoband H45 is available in 1mm thickness and widthsof 100mm and 200mm, supplied in a 25 metre roll. Whenlonger lengths are required Expoband H45 can be joinedby hot welding. It is bonded to the structure on both sidesof the joint using Supastik E10 two-part epoxy adhesive.

Example of a reservoir roof joint

(sealed internally with Expoband H45)

1 Expoband H45 5. Supastik E10 adhesive*2 Proofex Sheetdrain* 6. Earth Overlay3 Proofex or Famguard 7. Nitoseal MS600* GS100* 8. Supercast waterstop*4 Famguard GS100* 9. Hydrocell* strap laid loose but spot bonded along each edge


Example of Reservoir Wall

(sealed internally with Expoband H45)

1. Expoband H45 4. *Hydrocell2. *Supastik E10 Adhesive 5. *Nitoseal MS6003. *Supercast Waterstop



Where indicated on the drawings, joints shall be sealedwith Expoband H45 flexible expansion joint membranesystem supplied by Fosroc. Expoband H45 shall beinstalled strictly in accordance with the manufacturer’sprinted instructions.

Properties

Expoband H45 Hypalon membrane

Form: Elastomeric StripsColour: Dark GreyDensity: 1.7 approximateTensile Strength: 7.0 N/mm2

Elongation at break: 400%Adhesion to concrete(with Supastik E10): >tensile strength of substrate

Fosroc®

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Joint preparation

Expansion joints must be packed with a firm,consolidated joint filler prior to laying the Expoband H45. Ifnecessary joints may be pre-sealed using a bituminousor elastomeric sealant. Ensure that any sealant used iscapable of accommodating the anticipated jointmovement. Where Expoband H45 has to be turned upparapets and the like, a splay should be provided so thatthe change in direction is smooth and progressive.

Surface preparation

Concrete surfaces onto which the Expoband H45 is to belaid must be sound, frost and dust free. New concretemust be fully cured and free from curing compound. Theconcrete surface ideally should be wood float finished forthe width of Expoband H45 and free from irregularities,with well deigned arrises and no vertical misalignmentbetween each side of the joint.

Prepare a suitable width of substrate slightly wider thanthe membrane width selected. Sharp arrises should beground down pencil round.

Remove all dirt, dust and laitance by rigorous wirebrushing needle gun, abrasive blasting or grinding. Anyspalling or honeycombing must be repaired prior to theapplication of the Expoband H45 system. Should thesubstrate be wet, dry gently with a gas torch or hot airblower. Dampness should not re-appear within 15minutes for the substrate to be considered as being dryenough for the application of the Supastik E10. Maskingtape should be applied over the sealant in the joint and, ifrequired, on both arrises to provide an increasedunbonded width and greater movement potential ifrequired.

Priming of concrete

Priming of concrete is not normally required with theSupastik E10 / Expoband H45 system. The use of FosrocPrimer 13X should be considered where there could bedoubt about porosity or condition of the concrete.

Apply Fosroc Primer 13X by brush, working well in, to awidth of 25 mm either side of the membrane. FosrocPrimer 13X should be left for about 40 to 60 minutes(depending upon temperature) to allow evaporation of theprimer solvent prior to the application of the Supastik E10adhesive.

If the primer has been left longer than 8 hours or hasbecome contaminated with dust, the surface must bereprimed.

The rate of cure of Fosroc Primer 13X is temperaturedependent. Ideally the substrate should be above 10°C toensure a reasonable cure rate, however this primer canbe applied when substrate temperatures are 5°C andrising.

Preparation of the membrane

This operation is vital to the adhesion and performance ofthe Expoband H45 system. Measure and cut the length ofExpoband H45 to suit the joint.

The Expoband H45 Hypalon membrane must beprepared by thoroughly wiping both faces with FosrocSolvent 105 and a clean cloth. DO NOT use excessivequantities of solvent. Allow 1 hour to dry before placing.

Mixing and application of the adhesive

Transfer the entire contents of Part B of Supastik E10adhesive into the Part A container and mix thoroughlyusing a slow speed drill and Fosroc sealant mixingpaddle for 4 minutes, stopping to scrape down the sidesof the container. When mixed, the adhesive should be auniform grey colour. Use masking tape at extremities andalong centre line of joint. Apply mixed Supastik E10 usinga serrated spreader.

Following application, remove central masking tape,together with any additional tape applied to arrises (asdescribed in Surface Preparation). Immediately positionmembrane into the Supastik E10 with central release filmuppermost.

Roll firmly to displace trapped air and to ensure extrusionof Supastik E10 through the edge perforations.

Apply a second layer of Supastik E10 to the full width ofthe top surface of membrane. Remove central releasefilm from membrane. Finally remove outer edge maskingtapes and feather-edge the Supastik E10.

Jointing the Expoband H45 membrane

The surfaces to be jointed must be clean and wiped withFosroc Solvent 105 prior to jointing.

For heat welded joints, a 50 mm overlap should be used.Welding is carried out using a proprietary hot air weldingtool. The tool should be set to the correct heat output bytrial to achieve a satisfactory weld.

The faces of the overlap are heated by moving the weldingtool along the joint and, simultaneously, pressure shouldbe applied by roller to the heated overlap to ensure thatthe faces are fused together.



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Water applications

After application the Expoband H45 system should beallowed to cure for 28 days at 7°C before permanentcontact with water.

Ancillary materials and equipment

Supastik E10 adhesive.Fosroc Solvent 105.Fosroc Primer 13X.Slow speed drill and Fosroc sealant mixing paddle.Adhesive spreader with 2 to 3 mm serrations.Hot air welding gun and roller.

Estimating

SupplyExpoband H45: 1mm thick x 100mm wide,

25metre roll1mm thick x 200mm wide,25metre roll

CoverageSupastik E10: (based on a 2mm spread of

adhesive above and below themembrane)

For 100mm wide Expoband H45:5 to 6 linear metres per 2 litresSupastik E10For 200mm wide Expoband H45:2.5 to 3.5 linear metres per 2litresSupastik E10Dependent upon surfaceroughness and film thickness

Fosroc Primer 13X 10m2/litre

The coverage figures are theoretical — due to wastagefactors and the variety and nature of substrates, practicalcoverage figures may be substantially reduced.

Limitations

Joint layouts incorporating Expoband H45 should be keptas simple as possible to allow for site joints to berestricted to straight butt joints. Avoid complex changes ofangle or skew giving rise to difficulty in jointing andinstallation.

Storage

Expoband H45 should be stored in original unopenedpackaging, in cool dry conditions, away from sunlight.

Fosroc Primer 13X should be stored in accordance withthe Highly Flammable Liquids and Liquefied PetroleumGases Regulations 1972.

Precautions

Health and safety

Expoband H45

There are no known hazards associated with this productin normal use.

Supastik E10, Fosroc Primer 13X, Fosroc Solvent 105


Fire

Fosroc Primer 13X, Fosroc Joint Cleaner and FosrocSolvent 105 are flammable. Do not expose to nakedflames or other sources of ignition. No Smoking.Containers should be tightly sealed when not in use. Inthe event of fire, extinguish with CO2 or foam.


Technical data — ancillary materials

Fosroc Solvent 105

Flash Point: 43°CStorage Life: IndefinitePack Size: 5 litre

Supastik E10

Form: Base: Off-white viscous pasteCuring agent: Grey viscous paste

Storage Life: 12 months in originally sealedcontainers sotred below 25°C incool dry conditions

Flash Point: Above 65°CMixed density: 1.2 kg/litrePot Life:5°C: 3 to 4 hours10°C: 1 to 2 hours20°C: 50 to 60 minutes40°C: 20 to 30 minutesSolids content: 100%



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Expoband H45

Cure duration: Over 15°C: 48 hoursBefore trafficking: 5°C to 15°C: 96 hoursBefore immersion: >7°C: 7 daysApplicationtemperature: 5°C to 50°CMixed Colour: Grey

Fosroc Primer 13XFlash Point: Base: -7°C

Curing Agent: -7°CDensity: 1.0 kg/litreStorage Life: 12months in originally sealed

containersPot Life: 30 minutesApplicationtemperature: 5°C to 35°CTack-free timeat 20°C: 10 to 60 minutesPack size: 200ml


Expoband is the trade mark of Fosroc International Limited


www.fosroc.com




267

High performance methane, radon and CO2resisting waterproof membrane forbasements and structures

Uses

A high performance self adhesive membrane for resistingmethane, radon and CO2, and preventing water enteringbuildings. Proofex 3000MR also provides a vapour andwaterproof membrane to water excluding structures andprotects concrete from attack by aggressive ground salts.

Advantages

Aluminium film provides methane, radon and CO2resistance, protection against damage and givesdimensional stabilityCombines toughness with flexibility for detailingaround corners, pipes, etc.Self adhesive layer system makes installation quick,simple and reliableResistant to ground water, soluble sulphates andchloridesSuitable for waterproofing basements grades 2, 3 and4 as defined in BS 8102 :1990, ‘Protection OfStructures Against Water From The Ground’

Description

Proofex 3000MR is a cold applied, flexible, methaneresisting and waterproof high performance membraneincorporating an aluminium layer and a polymer modifiedbitumen compound on a high strength polymer backing film.

Where methane, radon or CO2 is present, acomprehensive site survey must be carried out and thebuilding constructed accordingly. Refer to BuildingResearch Establishment Report 212 and CIRIA Guide149 for further information.

Proofex 3000MR should be laid in accordance with theprovisions of BS 8102 :1990.

Typical properties

Membrane thickness: 1.2 mmMethane gas resistance: <5cm3/m2 24h bar

Radon permeability (SP Sweden): 0.56 10-12m2/sAdhesion to primed concrete 4.9 N/mm(ASTM D1000):Tensile strength (BS EN 12311-1):

Longitudinal: 230 N/50mmTransverse: 235 N/50mm

Elongation (BS EN 12311-1)Longitudinal: 33 %Transverse: 37 %

Hydrostatic test (BS EN 1928): >60 kPa

Water vapour permeability (BS EN 1931): Impermeable to ISO 12572

Application instructionsSurface preparationAll concrete surfaces must be a wood float or shutterfinish and free from cavities or projections.

Masonry surfaces must be flush pointed.

All surfaces must be clean, dry and free fromcontamination, ice and frost.

Priming

Vertical and suspended slab surfaces shall be primedwith Proofex Primer. Ensure complete coverage and allowto dry. Only prime an area to which the Proofex 3000MRcan be applied the same day. Very porous surfaces mayrequire more than one coat of primer.

Angle and corner details

Use Proofex Angle Fillet strips fixed using 6 mm beads ofPlastiseal at all wall to floor junctions.

All internal and external angles should be reinforced withProofex Engage Detail Strip or a 300 mm wide strip ofProofex 3000MR. Where possible, a 25 mm chamfershould be provided to external angles.

Application

Application temperature range 5°C to 35°C.

Vertical application:Cut the Proofex 3000MR to length allowing 150 mm for theend laps and position by peeling back the release paperand applying the self adhesive face to the preparedsurface.

Start at the top of the wall and work down by progressivelyremoving the release paper in stages. Proofex 3000MRshould be applied to ensure that all end laps areweathered.

In cold weather temporary batten support of the Proofex3000MR membrane is recommended.

Horizontal application:Completely unroll the Proofex 3000MR membrane andplace against a chalk line. One half of the roll should thenbe rolled up to the mid point, the release paper carefullycut without damaging the Proofex 3000MR membraneand progressively removed from the mid point out to theend of the roll.

This process should be repeated on the other half of theroll. The Proofex 3000MR membrane should be brushedonto the surface to ensure good bonding.

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The next roll or length is aligned against the previouslyapplied piece allowing for the 50 mm minimum (or asspecified) edge laps and 150 mm end laps and appliedas stated previously. The edge and end laps should berolled to ensure complete adhesion and continuitybetween the layers.

Penetrations

Penetrations e.g. pipe entries through the Proofex3000MR membrane require special attention to detail.Proofex Top Hats are recommended and should be stuckto membrane using Proofex Total Tape and sealed topipe with Nitoseal MS50

Protection

Proofex 3000MR membrane should be protected from physicaldamage and weathering as soon as possible after application.Surfaces should be protected from damage by ProofexProtection Board.

Proofex 3000MR can also be covered with ProofexSheetdrain to give both protection and a drainage layer.

Ancillary products

Proofex Protection BoardBitumen impregnated board, designed to protectmembranes from damage through backfilling andtrafficking.

Proofex Engage Detail StripA reinforced, double sided waterproof adhesive tape foruse as reinforcing at all floor and wall junctions. It consistsof a strong synthetic fibre fabric impregnated and coatedboth sides with a butyl adhesive, which is protected by aremovable siliconised paper..

Proofex Top HatMDPE sheathing, which encapsulates an aluminium foillayer.

Proofex Angle FilletStrips fixed at all floor and wall junctions with a 6mm beadof Plastiseal.

EstimatingProofex 3000MR

Roll size: 1 m x 20 mRoll area: 20 m²Edge laps: 50 mm minimumEnd laps: 150 mm minimumRoll weight: 25 kg

Proofex PrimerStorage life: 2 yearsCoverage: 6 to 8 m²/litreMinimum installation +4°C risingtemperature:Drying time @ 20oC: 1 to 2 hoursPack size: 5 ltr and 25 ltr drums

Proofex Engage Detail StripThickness: 1.5 mmRoll size: 200 mm x 10 m

Proofex Protection Board

3 mm Thickness: 1000 mm x 2000 mmCoverage: 2.0 m2

Storage

Proofex 3000MR must be stored in dry conditions, awayfrom sunlight, in an upright position at a temperaturebetween 5°C and 40°C.

Precautions

Health and safety

For information on Proofex Primer refer to Product SafetyData Sheet.

Proofex Primer is flammable. Keep away from soruces ofignition. No smoking. In the event of fire, extinguish withCO2 or foam. Do not use a water jet.

Flash Point Proofex Primer: >39oC




269

High performance, gas-impervious,reinforced membrane

UsesGas membrane designed to protect buildings and theiroccupants from the effects of radon, carbon dioxide andother harmful gases. Like conventional groundmembranes, Proofex Radon Barrier also acts as adamp-proof membrane to help protect the buildingagainst the ingress of moisture from the ground.

AdvantagesVirgin co-polymer product design for maximum gasprotection.Loose-laid system for ease of application.Can be used on ground-bearing concrete floors or onsuspended concrete or beam and block floors.

DescriptionProofex Radon Barrier is a radon and carbon dioxideimpermeable membrane comprising a co-polymer virgingrade LDPE/MDPE blown film.

Building Regulations and Technical Standards requiremeasures to be taken to prevent the build up of harmfulgases inside buildings.

Approved Document C to the Building Regulations shouldbe consulted. This document refers to BRE Reports 211(Radon) and 414 (Housing on gas contaminated sites).

Proofex Radon Barrier offers protection from radon andcarbon dioxide when included in schemes designed andinstalled with reference to the guidance offered by the abovedocuments.

Typical propertiesMembrane thickness: 370μmWeight (DIN53104): 356g/m2

Roll weights (4m x 20m): 28.48kgRadon gas transmission rate : 4 x 10-12m2/sMoisture vapour transmission: 0.16g/m2/dayTear resistance MD: 248N/mm

CD: 303N/mmTensile strength MD: 21.5Mpa

CD: 29.4 MpaElongation@ Max Load MD & CD: >800%Colour Yellow

Standard compliancesIndependently certified performance, IAB Certificate (No.03/0177).

Application InstructionsPreparation

Underslab ground membranesThe hard-core bed should be blinded with soft sand andconsolidated to provide a smooth bed free of sharpprojections.

Overslab ground membranesThe top surface of the concrete slab should be free fromridges, undulations and sharp projections. If this is notthe case a sand bed may be necessary to reduce the riskof puncturing the membrane.

Laying

The membrane should be laid neatly and tucked well intoangles to prevent bridging. At corners in upstands foldedwelts should be formed.

Lapping and jointing

Rolls of Proofex Radon Barrier should be lapped by aminimum of 150mm and sealed with a continuous stripof Proofex TOTAL Tape. Ensure that the membrane isclean and dry at the time of jointing. For increasedperformance, seal the edge of the upper sheet withProofex Detail Strip or strips of Proofex 3000MR.

Proofex Radon Barrier can also be heat welded by aspecialist installer.

Protection

Protect the completed membrane adequately to preventpuncturing using Typar SF56 80g/m2 geotextile or ProofexProtection Board. Alternatively, the overlying construction,such as insulation, can be installed prior to pouring ofconcrete. If used in an overslab situation, unbondedscreeds should be at least 50mm thick and laid as soonas possible after completing the membrane to reducethe risk of puncture.

Penetrations

Where possible services should be routed such that theydo not pass through the membrane, thus reducing thenumber of penetrations.

Where penetrations are unavoidable Proofex Top Hats arerecommended and should be stuck to membrane usingProofex Total Tape and sealed to pipe with Nitoseal MS50.

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EstimatingProofex Radon Barrier

Roll width: 4mRoll length: 20m

Proofex TOTAL Tape

Tape width: 50mmTape length: 30m

MaintenanceProofex Radon Barrier is robust and will resist punctureduring and after installation providing adequate care istaken to protect the membrane directly after installation.The membrane should be inspected prior to pouring aground slab or screed and, should any holes or tears befound, these should be repaired using patches of ProofexRadon Barrier taped in place using Proofex TOTALadhesive tape with at least a 150mm lap beyond theextremity of the puncture.

StorageStore in original unopened packaging, in cool dryconditions, away from direct sunlight.


There are no known health hazards associated withProofex Radon Barrier in normal use.



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Ancillary products

Proofex TOTAL TapeDouble-sided butyl tape for sealing of side and end lapsand for use in detailing work.

Typar SF5680 g/m2 geotextile as protection for membrane againstdamage.

Proofex Protection BoardPPPPProofex Protection BoardBitumen impregnated board designed to protectmembranes from damage through backfilling andtrafficking.

Proofex 3000MRMethane and water resistant self-adhesive membrane.

Proofex Top HatsMDPE sheathing, which encapsulates an aluminium foillayer.

271

High performance, totally gas-impervious,reinforced membrane

UsesReinforced gas membrane designed to protect buildingsand their occupants from the effects of methane, radon,carbon dioxide and other harmful gases. Likeconventional ground membranes, Proofex Total also actsas a damp-proof membrane to help protect the buildingagainst the ingress of moisture from the ground.

Advantages5-layer product design for maximum gas protection.Polyester reinforcing grid for puncture resistanceduring application.Loose-laid system for ease of application.Can be used on ground-bearing concrete floors or onsuspended concrete or beam and block floors.Can be used to form a cavity tray, eradicating the needfor a separate product.

DescriptionProofex Total is a black/silver, 5-layer, reinforced, gasimpermeable membrane comprising an aluminium foillayer and a polyester reinforcing grid sandwichedbetween three layers of polyolefins.

Maintenance

Proofex Total is extremely robust and will resist punctureduring and after installation providing adequate care istaken to protect the membrane directly after installation.The membrane should be inspected prior to pouring aground slab or screed and, should any holes or tears befound, these should be repaired using patches of ProofexTotal taped in place using Proofex Total adhesive tape withat least a 150mm lap beyond the extremity of the puncture.

PropertiesMembrane thickness 0.45 mmWeight 300 g/m2

Roll weight (2m x 25m) 17.5 kgWater vapour permeability 0.01 g/m2/24hr(ISO 9932)

Methane gas transmission rate <0.01 mls/m2/24hr(BR212)Bursting strength (ISO 2759) >900 kPa

Radon permeability 2.3 (10-12m2/24hr)

Standard compliancesBRE Digest 211 Radon : Guidance on protectivemeasures for new buildings

BRE Digest 212: Construction of new buildings on gascontaminated land.

Application instructionsPreparation

Underslab ground membranesThe hard-core bed should be blinded with soft sand andconsolidated to provide a smooth bed free of sharpprojections.

Overslab ground membranesThe top surface of the concrete slab should be free fromridges, undulations and sharp projections. If this is notthe case a sand bed may be necessary to reduce the riskof puncturing the membrane.

Laying

The membrane should be laid neatly and tucked well intoangles to prevent bridging, with the black surface facingupwards. At corners in upstands folded welts should beformed.

Lapping and jointing

Rolls of Proofex Total should be lapped by a minimum of150mm and sealed with a continuous strip of ProofexTotal Tape. Ensure that the membrane is clean and dry atthe time of jointing. For increased performance, seal theedge of the upper sheet with Proofex Detail Strip or stripsof Proofex 3000MR.

Proofex Total can also be heat welded by a specialistinstaller.

ProtectionProtect the completed membrane adequately to preventpuncturing using a geotextile or Proofex Protection Board.Alternatively, the overlying construction, such asinsulation, can be installed prior to pouring of concrete. Ifused in an overslab situation, unbonded screeds shouldbe at least 50mm thick and laid as soon as possible aftercompleting the membrane to reduce the risk of puncture.

Penetrations

Where possible services should be routed such that theydo not pass through the membrane, thus reducing thenumber of penetrations.

Where penetrations are required, Proofex Top Hats arerecommended and these should be stuck to membraneusing Proofex Total Tape and sealed to pipe with NitosealMS50

Ancillary productsProofex Total Tape

Double-sided butyl tape for sealing of side and end lapsand for use in detailing work.

Proofex Top Hats

MDPE sheathing, which encapsulates an aluminium foillayer.

Fosroc® Proofex Total constructive solutions

19CI/SfB: (13.9)Ln6 September 2009

272

Fosroc® Proofex Total


www.fosroc.com



EstimatingProofex Total

Roll width: 2mRoll length: 50m

Proofex Total Tape

Tape width: 50mmTape length: 30m

StorageStore in original unopened packaging, in cool dryconditions, away from direct sunlight.





19CI/SfB: (13.9)Ln6September 2009

273

Non shrink cementitious bridge bearing grout

Uses

Grouting beneath:Bridge bearingsParapet postsFlanged lighting columns

Conbextra BB can be used in section thicknesses10 mm to 100 mm.

Advantages

Complies fully with the Department of TransportSpecification for Highway Works March 1998Clause 2601Non shrinkHigh strengthExcellent flow, particularly at low temperatureLow permeability ensures durabilityCan be poured or pumped

Description

Conbextra BB is a ready to use cementitious groutsupplied in 25 kg moisture resistant bags. It has beenformulated specifically for grouting of bridge bearings andparapet post baseplates.

The dry powder is a blend of Portland cements, gradedsilica sands and additives to which only a controlledamount of clean water is added in situ to produce a highlyflowable, non shrink grout.


Conbextra BB has been independently tested, by aNAMAS accredited laboratory, in accordance with theDepartment of Transport Specification for Highway WorksMarch 1998 Clause 2601. Conbextra BB complies fullywith the requirements of this specification.

Properties

All properties at a water : powder ratio of 0.19

Property Test method

Compressive BS 1881:1983 1 day: 28 N/mm²strength (typical Part 116 7 days: 58 N/mm²results): 28 days: 67 N/mm²

Expansion: ASTM C827-87 0.25% - 1.0%

Elastic stability DTp SHW 1991 < 1%(compressive Clause 2601 (viii)strain):Total chloride ioncontent (as % ofmass of cement): — < 0.1%Total acid solublesulphate SO3 (as %of mass of cement): — < 4%



All grouting of bridge bearings and parapet postbaseplates must be carried out using a pre-packagednon-shrink cementitious grout manufactured by aregistered firm under the ISO 9001 quality assurancescheme.

The grout must comply fully with the Department ofTransport Specification for Highway Works, March 1998Clause 2601. The supplier shall confirm this complianceby providing test results from an independent NAMASaccredited laboratory.

The storage, mixing, placing and curing of the grout shallall be in accordance with the suppliers technical datasheet.


Preparation

Concrete surfaces

The substrate must be free from oil, grease or any looselyadherent material. If the concrete surface is defective orhas laitance, it must be cut back to a sound base. Boltholes or fixing pockets must be blown clean of any dirt ordebris.

Pre-soaking

For a minimum of two hours prior to grouting, the area ofcleaned substrate should be flooded with fresh water.Immediately before grouting takes place, any free watershould be removed. Particular care should be taken toblow out all bolt holes and pockets.

Fosroc® Conbextra BB constructive solutions

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274

Fosroc® Conbextra BB

Bearing plate / parapet post baseplate

It is essential that this is clean and free from oil, grease orscale.

Levelling shims

If these are to be removed after the grout has hardened,they should be treated with a thin layer of grease.

Formwork

The formwork should be constructed to be leak proof asConbextra BB is a free flowing grout. This can be achievedby using Fosroc Silicone Sealant 33HM beneath theconstructed formwork and between joints.

In some cases it is practical to use a sacrificial semi-drysand and cement formwork. The formwork should includeoutlets for the pre-soaking water.

The unrestrained surface area of the grout must be kept toa minimum. Generally the gap width between theperimeter formwork and the plate edge should not exceed100 mm on the pouring side and 50 mm on the oppositeside. There should be no gap at the flank sides.

Mixing

For best results a mechanically powered grout mixershould be used. For quantities up to 50 kg a slow speeddrill fitted with a high shear paddle is suitable. Largerquantities will require a high shear vane mixer. Do not usea colloidal impeller mixer.

It is essential that machine mixing capacity and labouravailability is adequate to enable the grouting operation tobe carried out continuously. This may require the use of aholding tank with provision for gentle agitation to maintainfluidity.

The water should be accurately measured into the mixer.Slowly add the total contents of the Conbextra BB bag, mixcontinuously for 5 minutes, ensuring a smooth, evenconsistency is obtained.

Water addition

Add 4.8 litres of water to each 25 kg bag of Conbextra BBto produce a fluid grout.

Placing

Place the grout within 20 minutes of mixing to gain the fullbenefit of the expansion process.

Conbextra BB can be placed in thicknesses up to 100 mmin a single pour.

Any bolt pockets must be grouted prior to groutingbetween the substrate and the bearing or base plate.


The mixed grout should be poured only from one side of

the void to eliminate the entrapment of air or surplus pre-soaking water. This is best achieved by pouring the groutacross the shortest distance of travel. The grout headmust be maintained at all times so that a continuousgrout front is achieved.

Where large volumes have to be placed Conbextra BBmay be pumped. A heavy duty diaphragm pump isrecommended for this purpose. Screw feed and pistonpumps may also be suitable.

Once the Conbextra BB has reached trowelableconsistency, the unrestained portion should be cut back tothe baseplate/bearing plate.

Curing

On completion of the grouting operation, exposed areasshould be thoroughly cured. This should be done by theuse of Concure curing membrane, continuous applicationof water and/or wet hessian.

Cleaning

Conbextra BB should be removed from tools andequipment with clean water immediately after use. Curedmaterial can be removed mechanically, or with FosrocAcid Etch.

Estimating

Allowance should be made for wastage when estimatingquantities required. The approximate yield per 25 kg bagis 13.5 litres.

Supply

Conbextra BB is supplied in 25 kg bags.

Limitations


Do not mix Conbextra BB at ambient temperatures below5°C.

For full cold weather working limitations, refer toDepartment of Transport Specification clause 2601 sub-clause 3


At ambient temperatures above 35°C the mixed groutshould be stored in the shade. Cool water (below 20°C)should be used for mixing the grout.

Storage

Store unopened bags in cool dry internal conditions.Conbextra BB has a shelf life of 12 months if kept in a drystore in sealed bags.

If stored in high temperature and high humidity locationsthe shelf life may be reduced to less than 6 months.



275

Fosroc® Conbextra BB

Precautions

Health and safety


Fire

Conbextra BB is non-flammable.


Conbextra is the trade mark of Fosroc International Limited


www.fosroc.com




276

General purpose non-shrink cementitiousgrout

Uses

Conbextra GP is used for general purpose, non-shrinkcementitious grouting of gap thicknesses 10 to 75 mm.Recommended applications at flowable consistencyinclude stanchion base plates, bolt pockets and voidfilling. At trowellable consistency Conbextra GP isrecommended for bedding load bearing components.

Advantages

Non-shrinkSimply add correct quantity of waterCan be used at flowable or trowellable consistencyChloride free

Non-staining

Description

Conbextra GP is supplied as a ready to use dry powder.The addition of a controlled amount of clean waterproduces a flowing non-shrink grout for gap thicknesses10 to 75 mm.

Conbextra GP is a blend of Portland cements, gradedfillers and chemical additives. The low water demandensures high early strength. The graded filler is designedto assist uniform mixing and produce a consistent grout.

Typical detail of stanchion base plate



All grouting must be carried out with pre-packaged non-shrink cementitious grout manufactured and supplied bya BSi registered firm.

It shall be mixed with clean water to the requiredconsistency. The grout must not bleed or segregate.

A volumetric expansion of up to 1% shall occur while thegrout is plastic by means of a gaseous system.

The compressive strength of the grout must reach40 N/mm² at 7 days and 60 N/mm² at 28 days.


Properties

The following results were obtained at flowableconsistency (ie 4.5 litres of water per 25 kg bag) and at atemperature of 20°C.

Test method for Typical result

Compressive strength(BS 1881, Part 116: 1983- restrained): 16 N/mm² @ 1 day

42 N/mm² @ 7 days60 N/mm² @ 28 days

Flexural strength(BS 6319, Part 3: 1990): 7.0 N/mm² @ 7 days

13.0 N/mm² @ 28 daysYoung’s modulus(BS 6319, Part 6: 1984): 23 kN/mm²Time for expansion —Start: 15 minutesFinish: 2 hoursFresh wet density: Approximately 2170 kg/

m³ depending on actualconsistency used

Expansion characteristics: An expansion of up to 1%overcomes plasticsettlement in the unsetmaterial

Fosroc® Conbextra GP constructive solutions


Baseplate

Conbextra GPto undersideof stanchionbase plate(second stage)

50 mmmax

Shims

Conbextra GPor Lokfix tobolt pocket(first stage)

277

Fosroc® Conbextra GP


Preparation

Foundation surface

The substrate surface must be free from oil, grease or anyloosely adherent material. If the concrete surface isdefective or has laitance, it must be cut back to a soundbase. Bolt holes and fixing pockets must be blown cleanof any dirt or debris.

Pre-soaking

For a minimum of 2 hours prior to grouting, the area ofcleaned foundation should be flooded with fresh water.Immediately before grouting takes place any free watershould be removed with particular care being taken toblow out all bolt holes and pockets.

Base plate

It is essential that this is clean and free from oil, grease orscale. Air pressure relief holes should be provided toallow venting of any isolated high spots.

Levelling shims


Formwork

The formwork should be constructed to be leakproof. Thiscan be achieved by using foam rubber strip or SiliconeSealant 33HM beneath the constructed formwork andbetween joints.

In some cases it is practical to use a sacrificial semi-drysand and cement formwork. The formwork should includeoutlets for pre-soaking.

Unrestrained surface area

This must be kept to a minimum. Generally the gap widthbetween the perimeter formwork and the plate edgeshould not exceed 150 mm on the pouring side and 50mm on the opposite side. It is advisable where practical tohave no gap at the flank sides.

Mixing

For best results a mechanically powered groutmixer should be used. When quantities up to 50 kg areused, a Bosch (or equivalent) 1150 watt, 280/640 rpm,110 volt drill fitted with a Conbextra mixing paddle issuitable. Larger quantities will require a high shear vanemixer. Do not use a colloidal impeller mixer.

To enable the grouting operation to be carried outcontinuously, it is essential that sufficient mixing capacityand labour are available. The use of a grout holding tankwith provision to gently agitate the grout may be required.The selected water content should be accurately

measured into the mixer. The total contents of theConbextra GP bag should be slowly added andcontinuous mixing should take place for 5 minutes. Thiswill ensure that the grout has a smooth even consistency.

Consistency of grout mix

The quantity of clean water required to be added to a25 kg bag to achieve the desired consistency is givenbelow.

Trowellable: 3.4 to 3.6 litresFlowable: 4.0 to 4.5 litres

Placing

At 20°C place the grout within 20 minutes of mixing to gainthe full benefit of the expansion process.

Conbextra GP can be placed in thicknesses up to 75 mmin a single pour when used as an underplate grout. Forthicker sections it is necessary to use Conbextra TS (thicksection) grout.

Any bolt pockets must be grouted prior to groutingbetween the substrate and the base plate.

Continuous grout flow is essential. Sufficient grout mustbe prepared before starting. The time taken to pour abatch must be regulated to the time to prepare the nextone.

When the Conbextra GP has reached trowelableconsistency, the unrestrained portion should be cut backto the baseplate/bearing plate.

Typical hopper system

Pouring should be from one side of the void to prevent anyair or pre-soaking water becoming trapped under thebase plate. It is advisable to pour the grout across theshortest distance of travel. The grout head must bemaintained at all times so that a continuous grout front isachieved.



Conbextra GP poured intoremovable hopper (second stage)

Removable hopper: For larger pours the grout may be hand placedor pumped into a removable hopper (trough)

75 mm maxConbextra GPor Lokfix(first stage)

50 mm max

278

Fosroc® Conbextra GP

Curing

On completion of the grouting operation, exposed areasshould be thoroughly cured with Concure curingmembrane, continuous application of water and/or wethessian.

Cleaning

Conbextra GP should be removed from tools andequipment with clean water immediately after use. Curedmaterial can be removed mechanically, or with FosrocAcid Etch.

Estimating

Supply

Conbextra GP is supplied in 25 kg bags.

Yield

Allowance should be made for wastage when estimatingquantities required. The approximate yield per 25 kg bag is:

Consistency Trowellable Flowable

Yield: 12 litres 13.25 litres

Limitations


When the air or contact surface temperatures are 5°C orbelow on a falling thermometer, warm water (30°C to 40°C)is recommended to accelerate strength development.

For ambient temperatures below 10°C the formworkshould be kept in place for at least 36 hours.

Normal precautions for winter working with cementitiousmaterials should then be adopted.


At ambient temperatures above 35°C cool water (below20°C) should be used for mixing the grout prior toplacement.

Storage

Store unopened bags in cool dry internal conditions.Conbextra GP has a shelf life of 12 months if kept in a drystore in sealed bags. If stored in high temperature andhigh humidity locations the shelf life may be reduced toless than 6 months.

Precautions

Health and safety


Fire

Conbextra GP is non-flammable.



www.fosroc.com





279

High flow non-shrink cementitious grout

Uses

Conbextra HF is used for free flow, non-shrink,cementitious grouting of gap thicknesses 10 to 100 mm.Recommended applications include:

Large stanchion baseplatesJoints between pre-cast concrete panelsPumped grouting applicationsGrouting applications where pouring accessis restricted

Advantages

Non-shrinkHighly flowableHigh strengthChloride freeSuitable for pumping

Description

Conbextra HF is supplied as a ready to use dry powder.The addition of a controlled amount of clean waterproduces a free-flowing grout for gap thicknesses up to100 mm. In addition the low water requirement ensureshigh early strength and long-term durability.

Conbextra HF is a blend of Portland cements, gradedfillers and chemical additives. The filler grading producesa highly flowable grout which will not segregate or bleed.


Conbextra HF conforms fully to U.S. Corps of EngineersSpecification for non-shrink grout CRD-C621-82A andASTM C1107-91 (Type C).



All grouting must be carried out with a pre-packaged, non-shrink cementitious grout manufactured and supplied bya registered firm. The grout shall be chloride free.

It shall be mixed with clean water to the requiredconsistency and not exhibit bleed or segregation.

A volumetric expansion of up to 1% shall occur while thegrout is in a plastic state by means of a gaseous system.

The compressive strength of the grout must exceed40 N/mm² at 7 days and 60 N/mm² at 28 days.

The grout shall fully conform to the requirements of USArmy Corps of Engineers Specification for non-shrinkgrout CRD-C621-82A.


Properties

The following results were obtained at fluid consistencyi.e. 4.8 litres of water per 25 kg bag.


Compressive strength 25 N/mm² @ 1 day(BS 1881, Part 116: 1983 44 N/mm² @ 7 days- restrained) 56 N/mm² @ 14 days

64 N/mm² @ 28 days 82 N/mm² @ 180 days

Flexural strength 2.5 N/mm² @ 1 day(BS 4551: 1980): 8.0 N/mm² @ 7 days

9.5 N/mm² @ 14 days10.0 N/mm² @ 28 days11.0 N/mm² @ 180 days

Young’s modulus(ASTM C-469-83): 29 kN/mm²Flow characteristics(Efflux time) CRD-C Cone: 19 to 25 secondsSetting time(BS 4550, Part 3: 1978) —Initial set: 5.5 hoursFinal set: 7.5 hoursTime for expansionPlastic state —Start: 15 minutesFinish: Initial setFresh wet density: Approximately 2200 kg/m³

depending on actualconsistency used

Expansion An expansion of up to 1%characteristics: when measured according

to ASTM C827 overcomesplastic settlement in theunset material


Preparation

Foundation surface

The substrate surface must be free from oil, grease or anyloosely adherent material. If the concrete surface isdefective or has laitance, it must be cut back to a soundbase. Bolt holes or fixing pockets must be blown clean ofany dirt or debris.

Pre-soaking

For a minimum of 2 hours prior to grouting, the area ofcleaned foundation should be flooded with fresh water.Immediately before grouting takes place, any free watershould be removed. Particular care should be taken toblow out all bolt holes and pockets. Where water soakingis impossible contact Fosroc Customer ServiceDepartment.

Fosroc® Conbextra HF constructive solutions


280

Fosroc® Conbextra HF

Base plate

It is essential that this is clean and free from oil, grease orscale. Air pressure relief holes should be provided toallow venting of any isolated high spots.

Levelling shims


Formwork

The formwork should be constructed to be leakproof asConbextra HF is a free-flowing grout. This can beachieved by using foam rubber strip or Silicone Sealant33HM beneath the constructed formwork and betweenjoints.

In some cases it is practical to use a sacrificial semi-drysand and cement formwork. The formwork should includeoutlets for the pre-soaking water.

The unrestrained surface area of the grout must be kept toa minimum. Generally the gap width between theperimeter formwork and the plate edge should not exceed150 mm on the pouring side and 50 mm on the oppositeside. There should be no gap at the flank sides.

Mixing

For best results a mechanically powered groutmixer should be used. For quantities up to 50 kg a Bosch(or equivalent) 1150 watt, 280 to 640 rpm, 110 volt drill,fitted with a Conbextra mixing paddle is suitable. Largerquantities will require a high shear vane mixer. Do not usea colloidal impeller mixer.


The selected water content should be accuratelymeasured into the mixer. Slowly add the total contents ofthe Conbextra HF bag, mix continuously for 5 minutes,ensuring a smooth, even consistency is obtained.

Consistency of mixed grout

To achieve the consistencies which are defined inCRD-C621-82A, the amount of clean water that is addedto a 25 kg bag at 20°C is:

Flowable: 4.5 litresFluid: 4.8 litres

Maximum flow distance at 20°C

The flow distances given below are intended as a guide.Actual flow distances will vary depending on siteconditions.

Grout Maximum flow distance in mmconsistency Gap depth 100 mm 250 mm

mm head headFlowable: 10 360 1200

20 950 260030 1500 300040 2200 3000+50 3000 3000+

Fluid: 10 900 250020 1900 300030 3000 3000+40 3000+ 3000+

Placing

Place the grout within 20 minutes of mixing to gain the fullbenefit of the expansion process.

Conbextra HF can be placed in thicknesses up to 100 mmin a single pour.

For thicker sections it is necessary to use Conbextra TS(thick section) grout.

Any bolt pockets must be grouted prior to groutingbetween the substrate and the base plate.


Example of a typical hopper system:

1 Conbextra HF or Lokfix* (first stage)2 Conbextra HF poured or pumped into removable

hopper (second stage)* Also available from Fosroc.

Sufficient grout must be available prior to starting and thetime taken to pour a batch must be regulated to the timetaken to prepare the next one.

The mixed grout should be poured only from one side ofthe void to eliminate the entrapment of air or surpluspre-soaking water. This is best achieved by pouring thegrout across the shortest distance of travel. The grout



50 mm max

t t

t

2

t

100 mm

t

t

1

281

head must be maintained at all times so that acontinuous grout front is achieved.

Where large volumes have to be placed Conbextra HFmay be pumped. Screw feed and piston pumps are alsosuitable for this purpose.

When the Conbextra HF has reached trowelableconsistency, the unrestained portion should be cut back tothe baseplate/bearing plate.

Curing

On completion of the grouting operation, exposed areasshould be thoroughly cured with Concure WB curingmembrane, continuous application of water and/or wethessian.

Cleaning

Conbextra HF should be removed from tools andequipment with clean water immediately after use. Curedmaterial can be removed mechanically, or with FosrocAcid Etch.

Estimating

Supply

Conbextra HF is supplied in 25 kg bags.

Yield

Allowance should be made for wastage when estimatingquantities required. The approximate yield per 25 kgbag for different consistencies is:

Consistency Flowable Fluid

Yield: 13.25 litres 13.5 litres

Fosroc® Conbextra HF

Limitations


When the air or contact surface temperatures are 5°C orbelow on a falling thermometer, warm water (30°C to40°C) is recommended to accelerate strengthdevelopment.

For ambient temperatures below 10°C the groutconsistency should be flowable and the formwork shouldbe maintained in place for at least 36 hours.

Normal precautions for winter working with cementitiousmaterials should then be adopted.


At ambient temperatures above 35°C the mixed groutshould be stored in the shade. Cool water (below 20°C)should be used for mixing the grout.

Storage

Store unopened bags in cool dry internal conditions.Conbextra HF has a shelf life of 12 months if kept in a drystore in sealed bags. If stored in high temperature andhigh humidity locations the shelf life may be reduced toless than 6 months.

Precautions

Health and safety


Fire

Conbextra HF is non-flammable.




www.fosroc.com




282

Shrinkage compensated cementitiousaggregate filled grout

Uses

Conbextra TS is used to grout gap thicknesses 75-500 mm.Applications include grouting thick section voids beneathbaseplates; voids around below-ground tanks; large boltpockets etc.

Conbextra TS is ideally suited to thick section grouting asit contains aggregates that reduces exothermic heatgeneration and risk of thermal cracking common with gapthicknesses in excess of 100 mm.

Advantages

Shrinkage compensatedHigh compressive strengthNo need to site batch aggregatesHighly flowableExtended workabilityCan be pumped or poured

Description

Conbextra TS is supplied as a ready to use dry powder.The addition of a controlled amount of clean water willproduce a fluid, aggregate-filled grout for pouring orpumping into large voids between structural elements.

Conbextra TS is a blend of Portland cements, gradedaggregates and additives.

The low water requirement produces a fluid grout of highstrength with good workability.

Technical service

Fosroc offers a comprehensive range of high quality, highperformance construction products. In addition Fosrocoffers worldwide technical support to specifiers and usersof its products.

Properties

At a water powder ratio of 0.13 at 20°C.


Compressive strength(BS1881 Part 116): 32 N/mm2 @ 3 days- restrained 48 N/mm2 @ 7 days

64 N/mm2 @ 28 daysInitial set (BS4550): 6.5 hoursFinal set (BS4550): 9 hoursExpansion characteristics(ASTM C827-87): Up to 2% at 24 hours



All grouting of gap thicknesses 75-500 mm must becarried out with a pre-bagged, shrinkage compensated,cementitious aggregate filled grout supplied by a BSiregistered firm. The compressive strength of the groutshall be at least 60 N/mm2 at 28 days.

The aggregate filled grout must be stored, handled andplaced in strict accordance with the manufacturersinstructions. No site batched additions to the pre-baggedgrout shall be allowed.

Supplier specification

All grouting of gap thicknesses 75-500 mm (specifydetails and areas of application) must be carried outusing Conbextra TS manufactured by Fosroc and used instrict accordance with the manufacturers instructions.


Preparation

The substrates must be free from oil, grease or anyloosely adherent material. If concrete surfaces aredefective or have laitance they must be cut back to asound base. Bolt holes and pockets must be blown cleanof any dirt and debris.

Pre soaking

Soak concrete substrates for a minimum of two hourscontinuously prior to placing the aggregate filled grout.Immediately before placing all free water should beremoved using wet vacuuming if required.

Baseplates

Must be clean and free from oil grease and scale. Airpressure relief holes should be provided to allow ventingof any isolated high spots.

Formwork

The unrestrained surface area of the grout must be kept toa minimum. Generally the gap width between theperimeter formwork and the plate edge should not exceed150 mm on the pouring side and 50 mm on the oppositeside. There should be no gap at the flank sides.Formwork should be made leak-proof by using FosrocSilicone Sealant 33HM beneath the formwork andbetween joints. Coat all formwork with Fosroc DemouluxH15 to enable easy formwork release.

Mixing and placing

Water addition is 3.3 litres per 25 kg bag. Do not attemptpart mixes.

25 kg bags of Conbextra TS may be mixed in a cleandrum using a Conbextra mixing paddle in a slow speed

Fosroc® Conbextra TS constructive solutions


283

Fosroc® Conbextra TS

drill. Carefully measure out the water in a calibratedvessel and pour into the drum and, with the paddlerotating, slowly add the contents of Conbextra TS to thewater and mix continuously for 3-5 minutes ensuring asmooth consistency is achieved.

For larger quantities a forced action grout mixer isrecommended. Refer to Fosroc Customer Services foradvice on suitable mixers. Always add the powder to thewater.

Continuous grout flow is essential and the necessarymixing equipment and labour must be available toachieve this.

Pour or pump Conbextra TS from one point only toeliminate the entrapment of air.

Conbextra TS is formulated to give extended workabilitybut must be placed within 20 minutes of mixing.

If pumping Conbextra TS, use a piston pump (egPutzmeizter P13) with a minimum pump line diameter of50 mm.

Curing

All exposed areas should be cured using FosrocConcure WB, continuous application of water or withwet hessian.

Cleaning

Conbextra TS should be removed from all tools andequipment with clean water immediately after use. Curedmaterial can be removed mechanically or with Fosroc AcidEtch.

Estimating

Supply

Conbextra TS is supplied in 25 kg bags.

Yield

Approximate yield per 25 kg bag is 12 litres (0.012 m³).

Limitations


When air or contact surface temperatures are 5°C orbelow on a falling thermometer warm water (30-40°C) isrecommended to accelerate strength gain. Normalprecautions for winter working with cementitiousmaterials should always be adopted.


At ambient temperatures above 35°C the mixed groutshould be kept in the shade prior to placement. Waterless than 20°C should be used for mixing.

Storage


If stored at high temperatures and/or high humidityconditions the shelf life may be reduced to less than 6months.

Precautions

Health and safety


Fire

Conbextra TS is non-flammable.



www.fosroc.com





284

Non-shrink cementitious grout forunderwater installations

Uses

Conbextra UW is used for free flow or pumped groutingapplications underwater or in tidal zones. There will be nosignificant ‘wash-out’ of the cement phase. Applicationsinclude bridge columns, quay pillars, concrete piling,slipways and dams.

Advantages

No risk of significant ‘wash-out’ of cement phasewhen placed underwaterDisplaces water effectivelyGaseous expansion system compensates forshrinkage and settlement in the plastic stateHigh early and ultimate strength and exceptionalresistance to freeze-thaw cycling ensure durability ofthe hardened groutChloride freePre-packaged needing only on-site addition of water

Description

Conbextra UW is supplied as a ready to use powder. Theaddition of a controlled amount of clean water produces afree flowing grout. The grout exhibits exceptionalresistance to ‘washing-out’ of the cement phase whenplaced in stationary or moving water.

Conbextra UW is a blend of cement, graded fineaggregate and chemical additives which impart controlledexpansion, water reduction and non ‘wash-out’characteristics. The aggregate grading minimisessegregation and bleeding whilst assisting the flowcharacteristics.

Properties

The following results were obtained at a water : powder ratioof 0.22.


Compressive strength 5°C 20°C(BS 4550, Part 3: 1978) —1 day: 6 N/mm² 25 N/mm²3 days: 24 N/mm² 38 N/mm²7 days: 36 N/mm² 44 N/mm²28 days: 50 N/mm² 53 N/mm²

Setting time 5°C 20°C(BS 5075, Part 1: 1982) —Initial: 13 hours 4.5 hoursFinal: 16.5 hours 5.5 hoursDensity of hardened grout: 2050 kg/m³

Expansion characteristics: Controlled expansionoccurs in the unsetmaterial to ensure that thegrout, when cured, willcontinue to occupy itsoriginal volume within theconfines of the void inwhich it was placed.


Preparation

The substrate surface must be free from oil, grease or anyloosely adherent material. If the concrete surface isdefective or has laitance, it must be cut to a sound base.

Substrates which are permanently immersed should begrit-blasted or cleaned with a high pressure water jet.Non-immersed or intermittently immersed substrates canbe prepared using these techniques. Alternativelyscabbling or bush hammering may be appropriate.

Formwork

The formwork should be constructed to be leakproof asConbextra UW is a free flowing grout. This can beachieved by using foam rubber strip or Silicone Sealant33HM beneath the constructed formwork and betweenjoints.

Mixing and placing

Mixing

For best results a mechanically powered grout mixershould be used.


Measure accurately 5.5 litres of water for each 25 kg baginto the mixer. Slowly add the Conbextra UW whilst mixingcontinuously. When all the powder is added mixcontinuously for 5 minutes ensuring a smooth evenconsistency is obtained. (Fluidity will increase withincreased mixing.)

Placing

Place the grout within 20 minutes of mixing to gain the fullbenefit of the expansion process. Continuous grout flow isessential.

The mixed grout should be poured or pumped through aflexible tube, having a minimum diameter of 50 mm, to thelowest point in the form.

Care must be taken at the start of the grouting operation torestrict the grout flow so that water is not entrapped.

Fosroc® Conbextra UW constructive solutions


285

Fosroc® Conbextra UW


The tube may be raised as necessary to reduce any backpressure. It should not be raised above the surface levelof the grout.

Conbextra UW can be placed in thicknesses up to 75 mmin one pour when used above water. When usedunderwater, the heat sink effect in this environment willallow thicknesses of up to 150 mm to be placed.

For thicker sections, up to 200 mm above water and400 mm underwater, it is necessary to fill outConbextra UW using a clean rounded well gradedaggregate ranging from 2 to 10 mm. The ratio ofaggregate added to Conbextra UW should not exceed1:1 by weight. For such mixes a concrete mixer should beused. Unrestrained surface area should be kept to aminimum.

Curing

Curing will not be required in intermittently or totallysubmerged situations. However, when cast above water,exposed areas should be thoroughly cured with Concurecuring membrane, continuous application of water and/orwet hessian.

Cleaning

Because of its water resisting properties, equipment usedfor Conbextra UW will be difficult to clean. The use of hotwater for cleaning purposes will assist. Cured materialcan be removed mechanically or with Fosroc Acid Etch.

Limitations

Conbextra UW must not be applied below 5°C.

Estimating

Supply

Conbextra UW is supplied in 25 kg bags.

Yield

Allowance should be made for wastage when estimatingquantities required. The approximate yield of a 25 kg bag

when mixed with 5.5 litres of water is 14.5 litres.

Storage

Store in unopened bags in cool dry internal conditions.The product has a shelf life of 12 months from the date ofmanufacture if kept in a dry storage in the original,unopened bags. If stored at high temperatures and/orhigh humidity conditions the shelf life may be reduced toless than 6 months.

Precautions

Health and safety


Fire

Conbextra UW is non-flammable.



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Polyester resin anchoring grout

Uses

Lokfix mix and place anchoring grouts are used for:

High-strength corrosion-resistant anchoring of bolts andbars into concrete, rock, masonry or brickwork where highspeed of installation and early application of load isrequired

Permanent installation of reinforcement starter bars, MOTbolts, foundation bolts, base plates, balustrading, barriersand safety fences, railway tracks and tie-back anchors.

Advantages

Easy to mix and applyRapid strength gainVibration resistantCorrosion resistantNon-expansiveCan be placed underwaterIncreased flowability

Description

The two versions of Lokfix are pre-measured, two-part,filled polyester resin grouts. After hardening, the groutproduces anchorages of consistent reproducible values.

The two versions are:

Lokfix S25 (pourable grade, 25 minute gel at 20°C):

For use where the hole is 8 to 40 mm greater in diameterthan the bar.

Lokfix P25 (pumpable grade, 25 minute gel at 20°C):

Used in overhead or horizontal holes where the hole is upto 25 mm greater in diameter than the bar. The thixotropicnature of Lokfix P25 reduces flow of grout out of the hole.


The material is tested in accordance with BS 5080,BS 7861 and BS 6319.

Properties

Gel time

Temperature Gel time Minimum timebefore load

(°C) (minutes) (hours)5 130 12

10 65 520 25 230 10 1

The following test results were obtained at a temperatureof 20°C:

Lokfix S25 Lokfix P25Compressive strength: 83 N/mm² 87 N/mm²(BS 6319 Part 2: 1983)Tensile strength: 11 N/mm² 11 N/mm²(BS 6319 Part 7: 1985)Flexural strength: 20 N/mm² 19 N/mm²(BS 6319 Part 3: 1983)Compressive modulus: 13 GPa 13 GPa(BS 7861 Part 1: 1996)Density: 1880 to 1880 to

1920 kg/m³ 1920 kg/m³

Chemical resistance

The cured resin is resistant to fresh and salt water, petrol,oils, grease and most acids, alkalis and solvents. ConsultFosroc Technical Department for specific chemicalresistance.

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Selection of grout version

The version of Lokfix grout chosen will depend on anchorconditions (see ‘Description’).

Parameters of anchor design

The high strength of the cured resin permits stronganchors to be created. Ultimate strength is varied by:

Strength of host material Length of resin bond to bar Hole preparation and formation Type and dimension of bar

Typical loads attained

Concrete: 20 N/mm² unreinforced.Bar: Deformed rebar to BS 4449.Hole: Air-flushed rotary percussive drilled.

Note: The graph illustrates typical failure loads. Minimumsafety factors of 1.5 in non-critical and 2 in critical casesshould be considered for design purposes. Whererelevant, the local codes of practice or standards must alsobe considered in relation to anchorage length.

Fosroc® Lokfix

Hole preparation and formation

Optimum performance of Lokfix grouts requires roughsided, dust-free holes. Use of rotary percussive drills withair or water flushing is recommended.

Diamond drilled holes should be under-reamed.

Cast holes should preferably be of inverse dovetailconfiguration. If parallel sided holes are cast they shouldbe rough to provide adequate keying.

Bar preparation

All bars should be deformed. They should preferably bedegreased and all flaky rust removed.

Mixing

A complete pack of resin and catalysed filler should bemixed in one operation. Mixing may be carried outmanually or mechanically. When a smooth, evenconsistency is achieved the grout is ready for use andshould be placed well within the gel time of the grout.

Packs have been designed to produce practical andeconomic volumes of grout.

DO NOT attempt to mix partial pack components.

Estimating

Refer to estimating guide table on the following page.


40

30

20

10

0

0 200 400 600 800

Resin embedded length (mm)

Load

(to

nnes

)21

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Installation

Lokfix S25

Using the calculated volume of grout based on theestimating guide table, the grout should be pouredsteadily into the prepared holes. The anchor bar is thenpressed into the hole to the required depth; slightagitation will assist in achieving a complete bond. The barshould be left undisturbed in the required position untilthe resin is set.

Lokfix P25

The grout should be injected to the rear of the hole toavoid air entrapment. The thixotropic nature of Lokfix P25will prevent significant flow of resin out of the hole.

Cleaning

Any mixing drums, pumps, etc., should be cleaned within

the pot life of the grout. Fosroc Solvent 105 is available forthis purpose.

Supply

Lokfix S25 - Blue Lid

The pack consists of a can of resin and a plastic bag ofhardener contained in a plastic mixing pail with a snap-onlid. Volume of mixed components: 2.5 litres.

Lokfix P25 - Yellow Lid

The pack consists of a can of resin and a plastic bag ofhardener contained in a plastic mixing pail with a snap-onlid. Volume of mixed components: 2.5 litres.


Estimating guide

To find the quantity of material required

The table below indicates the quantity of material in litres required for each 100 mm of hole depth.

Example

100 fixings, each using a 20 mm diameter bolt into a 38 mm diameter hole which is 300 mm deep.

From the table: 20 mm diameter bolt and 38 mm diameter hole gives 0.082 litre per 100 mm depth of hole

therefore 0.082 litre x 3 (300 mm deep hole) equals 0.246 litre per hole/fixing.

As 100 fixings are required: 100 x 0.246 litre = 24.6 litres total.

Lokfix S25 and Lokfix P25 are supplied in 2.5 litre packs

therefore = 9.84 10 packs required

NB: This example and the table below quotes net quantities and makes no allowance for overdrilling the hole or for anywastage. A typical allowance to cover these factors is approximately 10%.

To determine the quantity of material per 100 mm of hole depth

Hole Bolt diameterdiameter 12 mm 16 mm 20 mm 25 mm 32 mm 38 mm 44.5 mm 51 mm20 mm 0.020 litre — — — — — — —25 mm 0.038 litre 0.029 litre — — — — — —32 mm 0.069 litre 0.060 litre 0.049 litre 0.031 litre — — — —38 mm — 0.093 litre 0.082 litre 0.064 litre — — — —45 mm — — 0.128 litre 0.110 litre 0.079 litre 0.046 litre — —51 mm — — — 0.155 litre 0.124 litre 0.091 litre — —57 mm — — — 0.206 litre 0.175 litre 0.142 litre 0.100 litre —64 mm — — — 0.273 litre 0.241 litre 0.208 litre 0.166 litre 0.117 litre76 mm — — — — — 0.340 litre 0.298 litre 0.249 litre

24.62.5


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Flash points

Lokfix S25: 29°CLokfix P25: 29°CFosroc Solvent 105: 43°C


Storage

Store in accordance with the Highly Flammable Liquidsand Liquefied Petroleum Gases Regulations 1972.Shelf life of 12 months at 20°C will be reduced at highertemperatures.

Limitations

Fire resistance and creep

At operating temperatures above 40°C, the creep ofLokfix resin under load may become significant. Resinanchors should not be used where structural loadbearing performance has to be maintained in anchorssubjected to fire conditions. Conbextra GP or ConbextraHF would be suitable in this case.

Precautions

Health and safety


Fire

Lokfix products and Fosroc Solvent 105 are flammable.Do not expose to naked flames or other sources ofignition. No Smoking. Containers should be tightlysealed when not in use. In the event of fire, extinguishwith CO2 or foam.

FOS/v03-Jul04/00

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293

Fosroc® Cebex 100 constructive solutions

Expanding and plasticising grout admixture

Uses

Cebex 100 is an admixture for site batched cementitiousgrouts where a reduced water/cement ratio and positiveexpansion is required. Applications include bed grouting,duct grouting, non-shrink infilling and jointing.

AdvantagesGaseous expansion system compensates for plasticshrinkage and settlement in properly designedcementitious grout.Reduced water/cement ratio in the grout mix ensureslow permeability and long term durability in service.Gives high grout fluidity with low water/cement ratio,thus making placement or injection of the grout easy.No metallic iron content to corrode and cause stainingor deterioration due to rust expansion in the grout.Composition allows high early strength developmentin grouts, without the use of chlorides.

Standard compliance

Cebex 100 is a suitable pre-stressing grout admixturewhen complying with BS 8110 Part 1, 1997, Annex A.

DescriptionCebex 100 is supplied as a powder admixture. Thematerial is a combination of a plasticising agent and agas producing expansion medium. The plasticisingagent allows the use of a reduced water/cement ratio withconsequent increased strengths and durability. Theexpansive medium counteracts the natural settlement andplastic shrinkage of the grout and aids stability andcohesion.

Sufficient restrained expansion is developed to ensure ahigh degree of interfacial contact.

Specification clausesSupplier specification

All grouting (specify details and areas of application) mustbe carried out using a cement based grout, incorporatingCebex 100 manufactured by Fosroc and applied strictly inaccordance with the manufacturer’s technical data sheet.

Properties

Chloride content: Nil to BS 5075Compressive The plasticising action ofStrength: Cebex 100 allows reduction of

the water/cement ratio ofcementitious grouts whilstmaintaining flow properties.This gives improvement instrength and long termdurability when cured underrestraint.

Setting times: Cebex 100 does notsignificantly affect the settingtimes of cement basedgrouts.

Expansion The controlled positiveCharacter: expansion in unset grouts

incorporating Cebex 100overcomes plastic settlementwhen measured inaccordance with ASTM C827.An unrestrained expansion ofup to 4% is typical.

Time for: 15 minutes to 2 hours.expansion: Temperatures over 20oC may

slightly reduce these times.Compatibility: Cebex 100 is compatible with

all types of Portland cement.Cebex 100 may be used inmixes containing certain otherFosroc admixtures. ConsultFosroc for further information.


Mixing

For best results a mechanically powered grout mixer mustbe used. For quantities up to 50 kg a slow speed drillfitted with a Conbextra mixing paddle is suitable. Largerquantities will require a high shear vane mixer. It isessential that machine mixing capacity and labouravailability is adequate to enable the grouting operation tobe carried out continuously. This may require the use of aholding tank with provision for gentle agitation to maintainfluidity. The selected water content should be accuratelymeasured into the mixer. Slowly add the cement (andsand if required) and Cebex 100. Mix continuously for 5minutes, making sure that a smooth even consistency isobtained.

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Application

Areas to be grouted should be prepared to ensuresubstrates are clean, sound, and then pre-wetted. Theunrestrained surface area of the grout must be kept to aminimum. Place the grout within 20 minutes of mixing togain the full benefit of the expansion process. Adoptusual placing or pumping procedures ensuring acontinuous operation.

Curing

On completion of the grouting operation, any exposedareas which are not to be cut back should be thoroughlycured by means of water application, Concure curingmembrane or wet hessian.

Cleaning

Grouts mixed with Cebex 100 should be removed fromtools and equipment with clean water immediately afteruse. Remove cured material mechanically or with FosrocAcid Etch.

Estimating

Packaging

Cebex 100 is supplied in packs containing 24 x 225gunits.

Dosage

OPC Concreting Water Cebex Approx sand 100 yield50 kg -- 20 to 22 litres 225 g 36 litres50 kg 50 kg 22 to 24 litres 225 g 57 litres

Note: For grout, mortar or concrete mixes with anaggregate/cement ratio more than 1, use 4 x 225 g unitsof Cebex 100 per 100 kg of cement.

Effects of overdosing

Drastic overdosing of Cebex 100 increases expansionand may cause frothing.

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StorageCebex 100 has a shelf life of 12 months if kept in a drystore in its original packaging. High temperature andhumidity storage may reduce this period.

Precautions

Health and safety


Cebex is the trade mark of Fosroc International Limited


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295

Underwater grouting admixture

Uses

Cebex 250 is an anti-washout grouting admixture.

Advantages

Minimises the risk of washout of cement from groutsduring placing under water.

Description

Cebex 250 underwater grouting admixture is supplied asa ready to use, chloride-free white powder. When added tothe grout, the Cebex 250 produces a gel in the waterphase which surrounds the cement particles and protectsthem from washout. Cement hydration is not impaired bythe use of this admixture. The addition of Cebex 250 mayappear to thicken the grout, but this product forms alubricating layer between the cement particles, thusimproving the overall pumping ability of the grout.

PropertiesBulk density: 50 kg/m3Chloride content: Nil to BS 5075Compressive strength using a neat cement grout, atwater/cement ratio of 0.4 and dosage rate of 0.2% ofcement.


Compressive strength 13.5 N/mm2 @ 1 day(BS 1881): 26.5 N/mm2 @ 3 days

36.5 N/mm2 @ 7 days47.0 N/mm2 @ 28 days



All grouting (specify details and areas of application) mustbe carried out with ordinary Portland cement grout at awater/cement ratio of 0.4 and incorporating an anti-washout admixture. The admixture shall be added to thegrout at a dose of 0.05 to 0.2% by weight of cementdepending on the application. The admixture must be

stored, handled and placed strictly in accordance withmanufacturer’s instructions.


Mixing

Prepare the water cement grout in the usual manner.Sprinkle the admixture slowly onto the surface of the groutand continue mixing for a further 1 - 2 minutes. The groutis now ready for use.

Cleaning

Spillages should be removed in the dry state. Because ofits water resisting properties, Cebex 250 will be harder towash off equipment than normal cementitious grout. Useof hot water greatly reduces the time required for cleaning.Do not use hot water for mixing the grout.

Dosage

The dosage rate may be varied depending on ttheapplication. The range of dosage is between 0.05 to 0.2%by weight of cement.

Supply

Cebex 250 is supplied in a 1 kg bag.

Storage

Cebex 250 has a shelf life of 12 months if kept in dry storein its orginal packaging.

Limitations

Grout should not be applied below 3oC. Overdosing maylead to air entainment, result in a decrease incompressive strength.

Precautions

Health and Safety



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Thixotropic stabiliser for cement grouts

Uses

Stabilisation of cement grouts for pumping intocavities or fissures subject to water flowTunnel annulus grouting in soft ground or rockShaft grouting

Advantages

Enables cement grouts to be used in movingwater conditionsReduced wash-out saves cementEarly invert support gives increased productivity intunnel ring liningCan be used in marine environments in contactwith sea waterGives production flexibility derived from controlledgrout thixotropy

Desciption

A blend of water soluble, high molecular weightpolymers, supplied as a white powder. Cebex 653 isdesigned for addition to cementitious grout mixes toenable them to be placed in moving water conditionswithout excessive wash-out of cement.

Cebex 653 is a tunnel annulus grout admixture used toproduce an instantaneous gelation and fast set behindtunnel linings.



All grouting must be carried out with an OPC grout at awater/cement ratio of 0.3 to 0.45 and incorporating athixotropic admixture.

The admixture will ensure that the mixed grout is suffi-ciently thixotropic to avoid leakage and loss of grout. Theadmixture shall be added to the grout at a dose of 0.27kg per 300 kg of cement.

The admixture must be stored, handled and placedstrictly in accordance with the manufacturer’s instructions.

Properties

Rapid gel

Cebex 653 will not signficantly alter the initial hardnessof a cement grout but the gelation, which occurs almostimmediately after pumping has stopped, makes thegrout appear to have reached its initial setinstantaneously.

Setting times

Cebex 653 does not significantly affect the final settingtimes of cement based grouts.

Compressive strength

Grouts retain high compressive strengths even in movingwater.


Dosage

One 0.27 kg plastic bag of Cebex 653 is required per300 kg of cement.

Overdosing

Overdosing should be avoided to ensure the grout canbe pumped.

Mixing

Mix grout until homogenous as usual then add Cebex653 as a slow stream into the mixer. Mix for 30 secondsto disperse Cebex 653 through the grout.

Application

Mixes containing Cebex 653 may be produced instandard grout shear mixing equipment. The groutproduced is highly thickened and only non-valved pumpsare recommended for placement.

As the grout will thicken within 2 to 5 minutes, dischargeshould take place before this time. Holding tanks willrequire a discharge port of at least 75 mm to facilitate thepassage of thickened grout.

Estimating

Pack size

Cebex 653 is supplied in plastic bags containing 0.27 kg.


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Storage

Cebex 653 has a shelf life of 12 months if kept in a drystore in its original packaging.

Precautions

Health and Safety


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