Technical Data Sheet Catalogue - RIBA Product Selector

constructive solutions

Technical data sheet catalogue 10th edition

Alphabetical index C Cebex 100

Cebex 250 Cebex 653 Cemtop (S, GP12, GP30, XD) Colpor 200PF Conbextra BB Conbextra EP (EP10 & EPR) Conbextra GP Conbextra HF Conbextra TS Conbextra UW Concure WB

D

E

F

294 296 297 147 174 274 287 277 280 283 285 162

Dekguard Clear Dekguard E2000 Dekguard Elastic Dekguard S Dekguard Textured Dekguard W Demokret Eco D1

117 120 123 126 129 132 359

Expandafoam Expoband H45 Expocrete UA Expoflex 800

211 264 86 183

Famguard GS100 Flamex Fire Protection (Flamex One & Two) Flamex S Fosroc Acid Etch Fosroc Fibreboard Fosroc XR 45 Fosroc XR 90 Fosroc XR Cobbleset Fosroc XR PE20 Fosroc XR RSC

234 203


207 164 213 107 109 111 113 115

G

Galvafroid

145

H

Hilastic LM Hydrocell XL Hydromax

185 215 338

I

Integra

237

L

Lokfix (P25 & S25)

290

M

Mulseal DP

239

Nitobond AR/HAR Nitobond EP Nitobond SBR Nitocote CM210 Nitocote EP403 Nitocote EP405 Nitocote EP410 Nitocote SN502 Nitocote SN511 Nitofil LV/TH Nitoflor FC130/FC140 Nitoflor Hardtop S Nitoflor Lithurin Nitokit LV/TH Nitomortar FC Nitomortar HB Niomortar PE Nitomortar S Nitoprime Zincrich Plus Nitoseal MS50 Nitoseal MS100 Nitoseal MS300 Nitoseal MS600 Nitoseal 12 Nitoseal 333 Nitoseal 878

15 16 18 241 135 137 139 141 143 102 151 154 157 105 88 91 94 98 22 187 189 192 169 166 176 178

N

Alphabetical index

P

R

Patchroc GP Paveroc Plastijoint Plastiseal Pliastic (N2 & 77) Polyurea FLM Polyurea WPE Proofex 3000 Proofex 3000MR Proofex Cavitydrain Proofex Engage Proofex Hydromat Proofex LM Proofex Radon Barrier Proofex Sheetdrain Proofex Total Proofex WG 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


24 28 172 194 180 159 245 248 268 250 252 254 257 270 259 272 262 32 36 40 44 48 52 56 60 64 68 70 74 78 82

S

Secofoam Silicone Sealant 33HM Supercast Butyl-Nek Supercast PVC Supercast SW Supercast Synkoflex Supercast Twinstop

217 197 220 222 226 228 232

T

Thioflex 600

200

Product group index Concrete Repair & Remediation 1

2

3

4

Cementitious Repair Nitobond AR/HAR Nitobond EP Nitobond SBR Nitoprime Zincrich Plus Patchroc 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 repairs Expocrete UA Nitomortar FC Nitomortar HB Nitomortar PE Nitomortar S

Finishes

15 16 18 22 24 28 32 36 40 44 48 52 56 60 64 68 70 74 78 82

86 88 91 94 98

Crack injection resins Nitofil LV/TH Nitokit LV/TH

102 105

Road rehabilitation Fosroc XR 45 Fosroc XR 90 Fosroc XR Cobbleset Fosroc XR PE20 Fosroc XR RSC

107 109 111 113 115

5

Anti-carbonation & chloride resistant coatings Dekguard Clear Dekguard E2000 Dekguard Elastic Dekguard S Dekguard Textured Dekguard W Nitoprime DG (see Dekguard)

117 120 123 126 129 132

6

Chemical resistant coatings Nitocote EP403 Nitocote EP405 Nitocote EP410

135 137 139

7

Water resistant coatings Nitocote SN502 Nitocote SN511 Polyurea WPE

141 143 245

Metal protective coating Galvafroid

145

Flooring materials Cemtop (S, GP30, GP12, XD) Nitoflor FC130/FC140 Nitoflor Hardtop S Nitoflor Lithurin Polyurea FLM

147 151 154 157 159

Surface treatments Concure WB Fosroc Acid Etch

162 164

8 9

10

Product group index Barriers Waterproofing

Joint Sealants

11

12

13

14

15

Water industry sealants Nitoseal 12 Nitoseal MS600 Plastijoint

166 169 172

Road & pavement sealants Colpor 200PF Nitoseal 333 Nitoseal 878 Pliastic (N2 & 77)

174 176 178 180

Building sealants Expoflex 800 Hilastic LM Nitoseal MS50 Nitoseal MS100 Nitoseal MS300 Nitoseal MS600 Plastiseal Silicone Sealant 33HM Thioflex 600

183 185 187 189 192 169 194 197 200

16

17

18

Fire protection sealants Flamex Fire Protection(Flamex One & Two) Flamex S

203 207

Joint fillers Expandafoam Fosroc Fibreboard Hydrocell XL Secofoam

211 213 215 217

Waterstops Supercast Butyl-Nek Supercast PVC Supercast SW Supercast Synkoflex Supercast Twinstop

220 222 226 228 232

Waterproofing membranes Famguard GS100 Integra Mulseal DP Nitocote CM210 Polyurea WPE Proofex 3000 Proofex Cavitydrain Proofex Engage Proofex Hydromat Proofex LM Proofex Sheetdrain Proofex WG

234 237 239 241 245 248 250 252 254 257 259 262

Joint overbanding system Expoband H45

264

Gas membranes

19

Gas membranes Proofex 3000MR Proofex Engage Proofex Radon Barrier Proofex Total

268 252 270 272

Cement & Concrete Technology Grouts & Anchors Cementitious grouts Conbextra BB Conbextra GP Conbextra HF Conbextra TS Conbextra UW

274 277 280 283 285

21

Epoxy resin grouts Conbextra EP (EP10 & EPR) Lokfix (Lokfix P25 & S25)

287 290

22

Grout admixtures Cebex 100 Cebex 250 Cebex 653

294 296 297

20

7

9

10

11

12

13

14

1 ®

CI/SfB: June 2008

Fosroc Nitobond AR Nitobond HAR


Polymer emulsion bonding agents

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

Uses

Cleaning

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

Wash all equipment with clean water immediately after use.

Nitobond AR is also recommended as a curing membrane for Renderoc repairs. It may also be used as an economical dust proofer for non-trafficked cementitious surfaces.

Estimating Supply Nitobond AR

1 litre and 5 litre bottles, 25 litre drums

Nitobond HAR

1 litre and 5 litrebottles, 25 litre drums

Advantages Single component

No site mixing

Easy to use

Ready to use straight from the container

High bond strength

Excellent bond strength between Renderoc systems and concrete

As Primer

Cost effective

Economical in use

As Curing Membrane

Curing aid

Can be used as curing membrane for Renderoc systems

Nitobond AR

Coverage and yield Nitobond AR & Nitobond HAR

2

4-6m /litre

2

6-8m /litre

As Surface Sealer

Description

Nitobond AR

2

6-10m /litre

Nitobond AR and Nitobond HAR are single component polymer emulsion systems designed as bonding agents and curing membranes for Renderoc repair products. They may also be used as concrete surface sealers in non-traffic areas.

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

Application instructions

Storage

Preparation

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

Limitations

All surfaces should be clean and free from dust and contamination.

Precautions Health and safety

Application

For further information refer to appropriate Product Safety Data Sheet.

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

Fire Nitobond AR and Nitobond HAR are non-flammable.

Nitobond is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.

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

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

15

email: [email protected] Certificate number FM 610

1 CI/SfB: Yt3 June 2008

Fosroc® Nitobond EP


Epoxy-resin concrete bonding agent

Application instructions Preparation

Uses

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

For bonding new cementitious materials to existing cementitious surfaces For use on horizontal surfaces and on vertical surfaces where mortar or concrete can be supported by formwork

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

Ideal for extensions and repairs to concrete in factories, loading bays, trucking aisles, bridges, roads, bonded or granolithic floor toppings, etc

Expose fully any corroded steel and remove all loose scale and corrosion deposits. Steel should be cleaned to a bright condition paying particular attention to the back of exposed steel bars. Grit-blasting is recommended for this process.

Advantages Can be applied to dry or damp surfaces High mechanical strength

Reinforcing steel priming

Good positive adhesion

The cleaned steel should be coated within 3 hours. Apply one full coat of Nitoprime Zincrich and allow to dry before continuing. If any doubt exists about having achieved an unbroken coating, a second application should be made and, again, allowed to dry before continuing.

Can be applied where a substrate/repair barrier is required Standard and slow set grades

Description

Mixing

Nitobond EP is based on solvent-free epoxy resins containing pigments and fine fillers. It is supplied as a two-part material in pre-weighed quantities ready for onsite mixing and use.

The contents of the base and hardener cans should be stirred thoroughly to disperse any settlement. The entire contents of the hardener can should be added to the base container and mixed thoroughly for at least 3 minutes until a uniform colour is obtained, taking particular care to scrape the sides and bottom of the container. It is recommended that mechanical mixing be employed, using a Jiffy mixer on a heavy duty, slow speed electric drill.

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 hours

Initial hardness:

24 hours

48 hours

Full cure:

7 days

7 days

Maximum overlay time @ 20°C:

90 minutes

24 hours

Minimum application temperature:

5°C

5°C

To facilitate application at temperatures below 10°C the separate components should be warmed in hot water to a maximum of 25°C before mixing. However, the mixed material will need to be used speedily as the pot life of the standard grade will be reduced to 20 minutes. Alternatively the materials should be stored in a heated building and only removed immediately before use.

Application

The following results were obtained at a temperature of 20°C for Nitobond EP standard:

The thoroughly mixed material should be applied with a suitable stiff nylon-type brush and must be firmly scrubbed into the surface, ensuring an even coating. The new concrete or screed should be applied to Nitobond EP standard within 1½ hours at 20°C, or within 1 hour at 30°C and Nitobond EP slow set within 24 hours at 20°C, or within 8 hours at 30°C.

Compressive strength (BS 6319, Pt. 2): 50 N/mm² @ 7 days Flexural strength (BS 6319, Pt. 3):

35 N/mm² @ 7 days

Tensile strength (BS 6319, Pt. 7):

20 N/mm² @ 7 days

Slant shear bond (BS 6319, Pt. 4):

25 N/mm² @ 7 days

Adhesive strength to concrete:

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

In general, the bond will always exceed the tensile strength of the concrete 16


Fosroc® Nitobond EP Apply a second coat of Nitobond EP standard and leave for 30 minutes before the overlay is applied to the tacky surface.

Precautions

Alternatively Nitobond EP slow set can be used to allow for application prior to the fixing of shuttering or reinforcement. The concrete, Renderoc LA55 or screed can then be placed up to 24 hours after the application of Nitobond EP slow set. However, it should be left for 1 hour before the overlay is applied to the tacky surface.


Health and safety

Fire Nitobond EP is non-flammable.

Cleaning Tools and equipment should be cleaned with Fosroc Solvent 102 immediately after use.

Limitations Nitobond EP is formulated for application to clean, sound concrete. Nitobond EP should not be applied over existing coatings. Application should not be undertaken if the temperature is below 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 Nitobond EP standard:

Pack weight

Coverage

2.5 kg

5.5 m²

4.5 kg

10 m²

Nitobond EP slow set:

4.5 kg

10 m²

Fosroc Solvent 102:

5 and 25 litre tins

The coverage figures are theoretical — due to wastage factors and the variety and nature of substrates, practical coverage figures may be substantially reduced. Important: Unless otherwise specified, Nitobond EP is supplied with the standard hardener. Where the slow set hardener is required, care should be taken to ensure this is specifically requested.

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

Nitobond is the trademark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 0 (1827) 262222

fax: +44 0 (1827) 262444

17


1 CI/SfB: (4-) Vt3 August 2007

Fosroc® Nitobond SBR


Polymer bonding aid and mortar additive

Test method

Typical result

Control

Uses

Compressive 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

For improving and bonding concrete repair mortars, floor toppings and screeds, waterproof renders and cementitious slurries. Mortars and bonding slurries produced with Nitobond SBR may be used for horizontal, vertical and overhead repair work and are suitable for permanent immersion. Nitobond SBR may be used to form a bonding agent for slip bricks, ceramic tiles, etc.

Chemical resistance:

Advantages Single component liquid can be easily gauged as required Improves cohesion and workability Improves mortars to provide waterproof repairs, renders and toppings which are highly resistant to freeze/thaw cycling Improved tensile and flexural properties allow thin applications Excellent bond to concrete, masonry, stonework, plaster and blockwork Contains no chloride admixtures Can be applied to damp substrates

Cementitious materials have limited chemical resistance. The addition of Nitobond SBR to cement mortars reduces permeability and therefore helps reduce the rate of attack by aggressive chemicals, acid gases and water.

Application instructions Preparation Saw cut or cut back the extremities of the repair locations to a depth of at least 10 mm to avoid feather-edging and to provide a square edge. Break out the complete repair area to a minimum depth of 6 mm up to the sawn edge. Clean the surface and remove any dust, unsound or contaminated material, plaster, oil, paint, grease, corrosion deposits or algae. Where breaking out is not required, roughen the surface and remove any laitance by light scabbling or grit-blasting.

Description Nitobond SBR is a modified styrene butadiene rubber emulsion which is supplied as a ready to use white liquid. It is designed to improve the qualities of site-batched cementitious mortars and slurries. Being resistant to hydrolysis, it is ideal for internal and external applications in conjunction with cement.


Specification clauses Polymer bonding aid and mortar additive. The polymer bonding aid and site-batched mortar shall be modified by the use of Nitobond SBR, a single component styrene butadiene rubber emulsion.

Expose fully any corroded steel in the repair area and remove all loose scale and corrosion deposits. Steel should be cleaned to a bright condition paying particular attention to the back of exposed steel bars. Grit-blasting is recommended for this process.

Properties

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

The results listed below were achieved by assessing the mechanical properties of a 3:1 sand:cement mortar containing Nitobond SBR in the proportions 10 litres per 50 kg cement against a 3:1 sand:cement control mortar. The test methods used were in full accordance with BS 6319 at 28 days — air cured.

Reinforcing steel priming Apply one full coat of Nitoprime Zincrich Plus to any exposed steel reinforcement and allow to dry before continuing. If any doubt exists about having achieved an unbroken coating, a second application should be made and, again, allowed to dry before continuing.

18


Fosroc® Nitobond SBR Substrate priming

3. Render: 50 kgs Ordinary Portland Cement 150 kgs grade C/M sharp sand 10 litres Nitobond SBR 6 litres (approximately) clean water The render should be of a semi-dry cohesive consistency. Recommended thickness: 6 mm to 9 mm.

The substrate should be thoroughly soaked with clean water and any excess removed prior to commencement. A slurry primer should be prepared consisting of 1 volume Nitobond SBR to 1 volume clean water to 3 volumes fresh cement. To obtain a smooth consistency, the cement should be blended slowly into the premixed liquids. The slurry primer should be stirred frequently during use to offset settlement.

4. Bonding mortar for slip bricks, tiles, etc: 50 kgs Ordinary Portland Cement 125 kgs grade C/M sharp sand 10 litres Nitobond SBR 7 litres (approximately) clean water

The slurry primer should be scrubbed well into the surface of the concrete. Avoid applying too thickly and avoid ‘puddling’. The repair mortar, topping or render must be applied on to the wet slurry primer. If the slurry primer dries before application of the mortar, it must be removed and the area reprimed before continuing.

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

In exceptional circumstances, e.g. where a substrate / repair barrier 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 Nitobond SBR mortars are thoroughly mixed. A forced-action mixer is essential. Mixing in a suitably sized drum using an approved spiral paddle in a slow speed (400/500 rpm) heavy-duty drill is acceptable for occasional use.

50 kgs Ordinary Portland Cement 150 kgs grade C/M sharp sand 10 litres Nitobond SBR 8 litres (approximately) clean water Recommended thickness: 6 mm to 40 mm.

Weigh the cement, sand and, where required, aggregate into the mixer and dry blend together for one minute. With the machine in operation, add the pre-mixed Nitobond SBR and clean water. Continue mixing for 3 minutes to ensure complete dispersal into the sand and cement. Make any small adjustment to the quantity of clean water but do not significantly exceed the literage shown above. Additional water should be kept to a minimum. Continue mixing up to a maximum of 5 minutes until a smooth and fully homogeneous consistency is achieved with the required workability and application properties. It is critical that allowance is made for the moisture content of the sand and aggregate, particularly where they are stored on site.

2. Heavy-duty floor screed:

Application

50 kgs Ordinary Portland Cement 75 kgs 3 to 6 mm granite chips 75 kgs grade C/M sharp sand 10 litres Nitobond SBR 6 litres (approximately) clean water The screed should be of a semi-dry cohesive consistency. Recommended thickness: 10 mm to 40 mm.

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

A wide range of mix designs is achievable using Nitobond SBR. Typical designs are detailed below: 1. Patching and repair mortar:

Nitobond SBR mortars can be applied at a minimum thickness of 6 mm and up to 40 mm thickness, dependent on the location and configuration of the repair zone. Where thicknesses over 40mm are to be applied in one application, reduce the Nitobond SBR content by 40%.

19 constructive solutions


Fosroc® Nitobond SBR

from the application of a barrier/decorative coating to limit the advance of chlorides and carbon dioxide, thus bringing them up to the same protective standard as the repair itself. Fosroc recommend the use of the Dekguard range of protective, anti-carbonation coatings. These products provide a decorative and uniform appearance as well as protecting areas of the structure which might otherwise be at risk from the environment. Dekguard products may be applied over the repair area without prior removal of the Nitobond AR curing membrane. Concure WB curing membrane must be removed prior to the application of Dekguard products. This is best achieved by light grit or sand-blasting.

The thickness achievable in overhead locations without the use of formwork is largely dependent on the profile of the substrate. Refer to the recommended thicknesses shown in the ‘Mix design’ section above. If the recommended thickness is exceeded and sagging occurs, the affected section must be completely removed and reapplied in accordance with the procedure described above. The use of formwork may facilitate achieving the required build. If formwork is used, it should have properly sealed faces to ensure that no water is absorbed from the repair material. Where thicker sections up to a total thickness of 40 mm are to be built up by hand or trowel application, the surface of the intermediate layers should be scratch-keyed and cured with Nitobond AR. Application of the slurry primer and a further application of Nitobond SBR mortar may proceed as soon as this layer has set.

Cleaning

Finishing

Nitobond SBR and Nitobond AR should be removed from tools, equipment and mixers with clean water immediately after use. Cured material can only be removed mechanically.

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

Equipment used with Nitoprime Zincrich Plus, Nitobond EP and Concure WB should be cleaned with Fosroc Solvent 102. Cured material can only be removed mechanically.

Low temperature working

Estimating

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

Supply

High temperature working

Nitobond SBR:

5, 25 and 210 litre drums

Nitoprime Zincrich Plus:

1.9 litre and 800ml cans

Nitobond EP:

4.5 kg packs

Nitobond AR:

5 litre drums

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

Concure WB:

20 litre drums

Fosroc Solvent 102:

5 litre cans

Curing

Coverage and yield

o

Nitobond SBR: Nitobond SBR mortars, toppings and renders are cementbased. In common with all cementitious materials, they must be cured immediately after finishing in accordance with good concrete practice. The use of Nitobond AR or Concure WB, sprayed on to the surface of the finished mortar in a continuous film, is recommended. In harsh drying conditions, supplementary curing with polythene sheeting must be used.

Nitobond SBR (as slurry primer):

Approximately 2 to 3 m2/litre


8 m2/litre

Nitobond EP:

10 to 11.5 m2/pack

Nitobond AR:

6 to 8 m2/litre

Concure WB:

3.5 to 5 m2/litre

Limitations

Overcoating with protective decorative finishes

Nitobond SBR mortars, toppings and renders should not be applied when the temperature is below 5oC and falling. Neither should they be exposed to moving water during application. Exposure to heavy rainfall prior to the final set

Nitobond SBR mortar repairs are extremely durable and will provide excellent protection to the embedded steel reinforcement within the repaired locations. The surrounding parts of the structure will generally benefit


Refer to mix designs


Fosroc® Nitobond SBR Precautions

may result in surface scour. If any doubts arise concerning temperature or substrate conditions, consult the local Fosroc office.

Health and safety For further information refer to appropriate Product Safety Data Sheet.

Storage Shelf Life

Fire

Store in unopened packaging in cool dry internal conditions. Nitobond SBR and Nitobond AR should be protected from frost.

Nitobond SBR, Nitobond AR, Concure WB and Nitobond EP are non-flammable.

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

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

Nitoprime Zincrich Plus must be stored in accordance with the Highly Flammable Liquids and Liquefied Petroleum Gases Regulations 1972.

Flash points Nitoprime Zincrich Plus:

41 oC

Fosroc Solvent 102:

33 oC

For further information, refer to the Product Safety Data Sheet.

Nitobond is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.

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

telephone: +44 0 (1827) 262222

fax: +44 0 (1827) 262444


www.fosroc.com

21

1 CI/SfB: October 2006

Fosroc® Nitoprime Zincrich Plus


Single component epoxy zinc primer

Properties

Uses Nitoprime Zincrich Plus is the recommended anticorrosion primer for exposed steel reinforcement for use with Fosroc concrete repair mortars. It is fully compatible with all Renderoc mortars and fluid micro-concretes.

Advantages

Test method

Typical result

Specific gravity:

2.0

Recommended thickness per coat:

40 microns (dry)

Application thickness per coat:

100 microns (wet)

Drying times — Touch dry: Fully dry/recoatable:

@ 20°C 90 minutes 3 hours

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

‘Active’ zinc-rich system combats corrosion by electrochemical means


Formulated for use with Renderoc repair products

Preparation

Single component product — easy to use with no restrictive pot-life

Expose fully any corroded steel in the repair area and remove all loose scale and corrosion deposits. Steel should be cleaned to a bright condition paying particular attention to the back of exposed steel bars. Grit-blasting is recommended for this process.

Economical — single component ensures almost no waste

Description

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

Nitoprime Zincrich Plus is supplied as a single component grey-coloured liquid based on metallic zinc and epoxy resins.

Standards compliance

Application

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

The application of Nitoprime Zincrich Plus must take place as soon as possible to a dry steel surface after completion of the preparation work but always within 3 hours. Although a single component product, it should be stirred thoroughly before use in order to redisperse any settlement.

Specification clauses Steel reinforcement primer The steel reinforcement primer shall be Nitoprime Zincrich Plus, a single-component zinc-rich liquid packed and supplied ready to use. An unbroken 40 microns thick coating shall be capable of providing ‘active’ galvanic protection. It shall be a suitable viscosity to enable the coating to penetrate imperfections and pits within the surface of corrosion-damaged steel bars.

Apply one full and unbroken coat of Nitoprime Zincrich Plus by suitable brush, making sure that the back of exposed steel reinforcing bars are properly coated. A small brush is generally more suitable for this purpose. Allow to dry fully before continuing. If any doubt exists about having achieved an unbroken coating, a second application should be made as soon as the first coat is fully dry (generally after 90 minutes).

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

The primed surfaces should not be left exposed to the elements for longer than necessary before overcoating or application of the repair material. Nitoprime Zincrich Plus will, however, protect steel under clean interior exposure conditions for a period of several months. In nonaggressive exterior environments, a maximum interval of 14 days will be tolerated but in industrial and/or marine environments this interval should be reduced to the practical minimum.

It shall be fully compatible with the Renderoc system of concrete repair.

22


Fosroc® Nitoprime Zincrich Plus Storage

The application of concrete repair materials should proceed as soon as the Nitoprime Zincrich Plus is touch dry (generally 90 minutes — see under Properties).

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

Low temperature working The minimum application temperature is 5°C. The material should not be applied when the substrate and/or air temperature is 5°C and falling. At 5°C static temperature or at 5°C and rising, the application may proceed.

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

Precautions

Cleaning

Health and safety

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

For further information refer to the appropriate Product Safety Data Sheet Fire

Estimating


1.9 litre and 800ml cans

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

Fosroc Solvent 102 :

5 and 25 litre tins

Flash points

Supply

Coverage Nitoprime Zincrich Plus:

8 m2 / litre


41°C

Fosroc Solvent 102:

33°C

For further information, refer to the Product Material Safety Data Sheet.

Note: this coverage figure is theoretical — due to wastage factors and the variety and nature of possible steel substrates, practical coverage figures will be reduced.

Additional information Limitations

Nitoprime Zincrich Plus is the approved reinforcing steel primer for use with the Renderoc, Patchroc and Paveroc systems of concrete repair.

Nitoprime Zincrich Plus should not be applied when the temperature is below 5°C or is 5°C and falling. If any doubts arise concerning temperature or application conditions, consult the local Fosroc office.

Nitomortar is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

23


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

Fosroc® Patchroc GP


Fast setting emergency patching mortar for concrete pavements and floors conforming to the requirements of BS EN 1504-3 Class R4

Specification Clause The repair mortar shall be Patchroc GP, a one component cementitious mortar conforming to the requirements of BS EN 1504-3 Class R4

Uses

The cured mortar shall achieve a compressive strength of 65 MPa at 28 days and a drying shrinkage of 55 wet

C lass III

Fire rating

EN 13501-1

Test method

C ompressive Strength

B ond strength by pull off:

R esistance to carbonation dk Elastic Modulus in C ompression

Setting time

S tandard

C lass A1 Non-C ombusti ble

BS 4551 Pt14:1980

Working life:

-

Traffic time Pedestrian: Vehicular:

-

-

@ 10°C 40 mi n @ 10°C 3 hours 3 hours

@ 20°C 20 mi n @ 20°C 2 hours 2 hours

The low permeabi li ty of Patchroc GP severely retards chemi cal attack i n aggressi ve envi ronments. The cured mortar i s i mpermeable to aci d gases, waterborne chloi rde i ons and oxygen.

C hemical resistance

B uild C haracteristics (hand applied) Minimum thickness: Maximum thickness Max bay area

Ini ti al set: 40 mi ns Fi nal set: 60 mi ns

-

-

-

12 mm 100 mm 4 m2

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


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

Expose fully any corroded steel in the repair area and remove all loose scale and corrosion deposits. Steel should be cleaned to a bright condition paying particular attention to the back of exposed steel bars. Abrasive-blasting is recommended for this process.

Clean the surface and remove any dust, unsound or contaminated material, plaster, oil, paint, grease, corrosion deposits or algae. Where breaking out is not required, roughen the surface and remove any laitance by light scabbling or abrasive-blasting.

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



Fosroc® Patchroc GP For normal applications, place 2.4 to 2.8 litres of drinking quality water into the mixer.

clean water immediately after abrasive-blasting to remove corrosion products from pits and imperfections within its surface. Reinforcing steel priming

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

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

The consistency may be adjusted by the addition of small amounts of water up to the maximum total water content of 2.8 litres. Note that the powder must always be added to the water.

Concrete Priming

Mixing warning

Pedestrian traffic

As with other ‘one pack’ repair mortars, Patchroc GP may exhibit satisfactory handling characteristics even though inadequately mixed. This will result in a significantly lower level of performance or possible failure. It is therefore essential that mixing instructions are strictly adhered to with particular emphasis on the quantity of water used and the time of the mixing operation.

The concrete substrate should be saturated surface dry immediately before the application of the primer i.e. it should be thoroughly saturated with clean water and any residual surface water removed prior to applying Renderoc Primer. Under severe drying conditions repeated soaking may be necessary to ensure the substrate is still saturated at the time of application of the primer.

Application

Add 3 parts by volume of Renderoc Primer Part A to 1 part by volume Renderoc Primer Part B (4 to 1 by weight) in a clean mixing vessel and mix with a spatula or slow speed drill until a homogeneous smooth paste is produced.

Exposed steel reinforcing bars should be firmly secured to prevent movement during application. While the Renderoc Primer/Nitobond EP is still tacky, apply the mixed Patchroc GP evenly by trowel and tamp in place with a wood float to ensure complete compaction. Thoroughly compact the mortar around any exposed steel reinforcement. Patchroc GP can be applied up to 100 mm in a single application.

Scrub Renderoc Primer slurry into the surface. Patchroc GP can be applied immediately to the primed surface. If the primer dries apply another coat of primer before continuing. Open bags of Renderoc Primer Part A should be sealed and stored in a dry area. Use within 14 days.

Patchroc GP should be struck off to the correct level and finished with a steel trowel to a fully closed surface. A textured surface can be achieved with a suitable roller or brush. The finshed surface should not be overworked.

Vehicular traffic Prime using Nitobond EP. Thoroughly stir the individual components to disperse any settlement. Add the entire contents of the hardener to the base container and mix thoroughly for at least 3 minutes until a uniform colour is obtained, taking particular care to scrape the sides and bottom of the container. It is recommended that a Jiffy mixer on a heavy duty, slow speed electric drill is used.

Build-up Additional build-up can be achieved by application of multiple layers. The surface of the intermediate layers should be comb scratch-keyed. A further application of Patchroc GP may proceed as soon as this layer has set.

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

Reprime with Renderoc Primer or Nitobond EP and apply further Patchroc GP as described above. Low temperature working 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 cementitious materials should then be adopted. The material should not be applied when the substrate and/or air temperature is 5°C and falling. At 5°C static temperature or at 5°C and rising, the application may proceed.

Mixing Care should be taken to ensure that Patchroc GP is thoroughly mixed. A forced-action mixer is essential. Mixing in a suitably sized drum using an approved Renderoc Spiral Paddle with a slow speed (400/500 rpm) heavy-duty drill is acceptable for the occasional one-bag mix.


Free-fall mixers must not be used. Mixing of part bags should never be attempted.

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



Fosroc® Patchroc GP Curing

Coverage and yield

Patchroc GP is a cement-based repair mortar. In common with all cementitious materials, it must be cured immediately after finishing in accordance with good concrete practice. The use of Concure WB, sprayed on to the surface of the finished mortar in a continuous film, is recommended. A low pressure atomising sprayer is essential for applying the Concure WB

Patchroc GP:

Approximately 12 litres / 25 kg bag (approximately 12 m² at 12 mm thickness)


8 m2/litre

Nitobond EP

Approximately 2 m2 / kg

Renderoc Primer

Approximately 13 litres- 2m2/ litre

Concure WB

5 m2/ litre

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

Notes: the actual yield per bag of Patchroc GP will depend on the consistency used.

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

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

Overcoating with protective decorative finishes Patchroc GP is extremely durable and will provide an excellent hard wearing surface to the repaired locations. Surrounding floor areas may benefit from the application of an abrasion or chemical-resistant protective coating. For internal locations, Fosroc recommend the use of the Nitoflor FC range of protective coatings.

Patchroc GP should not be exposed to moving water during application. Exposure to heavy rainfall prior to the final set may result in surface scour. If any doubts arise concerning temperature or substrate conditions, consult the local Fosroc office.

These products provide a decorative and uniform appearance as well as protecting areas of the floor which might otherwise be at risk. Nitoflor FC products may be applied over the repair area after prior removal of the curing membrane; generally after 3 days. The local Fosroc office should be contacted for advice about external protective overlayments.

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

Cleaning Patchroc GP should be removed from tools, equipment and mixers with clean water immediately after use. Cured material can only be removed mechanically. Clean tools used with Nitoprime Zincrich Plus and Nitobond EP before curing, with Fosroc Solvent 102.

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

Estimating

Fire

Supply

Patchroc GP, Nitobond EP and Renderoc Primer are nonflammable.

Patchroc GP:

25 kg bags


1.9 litre and 800 ml cans

Nitobond EP

2.5 and 4.5 Kg packs

Renderoc Primer

20 Kg Part A + 5 litres part B

Concure WB

20 and 200 litre drums

Fosroc Solvent 102:

5 and 25 litre tins


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

41°C

Fosroc Solvent 102:

33°C

Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

27


1 CI/SfB: q4 (D7) October 2009

Fosroc® Paveroc


High performance reinstatement mortar for concrete pavements and floors conforming to the requirements of BS EN 1504-3 Class R4

Specification Clause The repair mortar shall be Paveroc a one component cementitious mortar conforming to the requirements of BS EN 1504-3 Class R4

Uses For the reinstatement of large areas of concrete pavements and floors to avoid the total replacement of bays

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

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

Standards compliance Paveroc complies with the classification R4 according to EN 1504-3, repair methods 3.1, 4.4, 7.1 and 7.2.

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

Fosroc Ltd, Drayton Manor Business Park, Coleshill Road, Tamw orth, STAFFS, B78 3TL 09 0370-CPD-0845

Advantages Rapid strength gain — will generally accept pedestrian traffic at 12 hours, significantly reducing down-time High strength, abrasion and weather resistance

EN 1504-3 Concrete repair products for structural repair mortar CC (based on hydraulic cement)

One component, pre-bagged to overcome site-batched variations requires only the site addition of clean water Excellent bond to the concrete substrate Shrinkage compensated

Compressive strength

Contains no chloride admixtures

Chloride ion content

Description Paveroc is supplied as a ready to use blend of dry powders which requires only the site addition of clean water to produce a highly consistent repair mortar. It is based on Portland cements, graded aggregates, and chemical additives providing a mortar with good handling characteristics while minimising water demand. The low water requirement ensures good strength gain and longterm durability.

≥ 2.0 MPa

Adhesive bond strength after freeze thaw thermal cycling

≥ 2.0 MPa

Skid resistance Elastic modulus in compression Reaction to fire Dangerous substances

28

≤ 0.05%

Adhesive bond strength

Carbonation resistance

Paveroc is designed for horizontal use. It may be applied up to a maximum thickness of 100 mm. Thicker sections can be built up in layers. Material should not be applied at less than 12 mm thickness. Individual bay sizes should not exceed 18 m². Consult the local Fosroc office for further information.

Class R4 (≥ 45 MPa)

dk ≤ control concrete Class III ≥ 20 GPa Class A1 Complies with 5.4


Fosroc® Paveroc Properties The following results were obtained at a water : powder ratio of 0.088 and a temperature of 20°C unless otherwise stated.

Standard

EN 1504 R4 Requirement

Result

EN 12190:1999

≥ 45

@ 1 Day 20 MPa @ 7 Days 45 MPa @ 28 Days 65 MPa

EN 1542:1999

≥ 2.0 MPa

2.2 MPa

Chloride ion content:

EN 1015-17:2000

≤ 0.05 %

0.01%

Freez e thaw cycling:

EN 13687-1:2002

≥ 2.0 MPa

2.0 MPa

EN 13295:2005

≤ ref concrete

Conforms

E N 13412

≥ 20 GPa

46 GPa @ 28 days

Skid Resistance

EN 13036-4

Class III >55

Class III

Fire rating

EN 13501-1

Test method

Compressive Strength Bond strength by pull off:

Resistance to carbonation dk Elastic Modulus in Compression

Setting time Working life: Traffic time Pedestrian: Vehicular:

Class A1 Non-Combustible

BS 4551 Pt14:1980

-

-

-

-

-

@ 1 0 oC 60 min @ 10°C 18 hours 36 hours

@ 2 0 oC 55 min

@30oC 30min

@ 20°C 12 hours 24 hours

@ 30°C 8 hours 16 hours

The low permeability of Paveroc severely retards chemical attack in aggressive environments. The cured mortar is impermeable to acid gases, waterborne chloirde ions and oxygen.

Chemical resistance

Build Characteristics (hand applied) Minimum thickness: Maximum thickness Max bay area

Initial set: 3.5 hours Final set: 5.0 hours

-

-

12 mm 100 mm 18 m-2

Clarification of property values: The typical properties given above are derived from laboratory testing. Results derived from field applied samples may vary. Application instructions Preparation roughen the surface and remove any laitance by light scabbling or abrasive-blasting.

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


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



Fosroc® Paveroc level of performance or possible failure. It is therefore essential that mixing instructions are strictly adhered to with particular emphasis on the quantity of water used and the time of the mixing operation.

Expose fully any corroded steel in the repair area and remove all loose scale and corrosion deposits. Steel should be cleaned to a bright condition paying particular attention to the back of exposed steel bars. Abrasive-blasting is recommended for this process.

Application

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

Exposed steel reinforcing bars should be firmly secured to prevent movement during application. While the Nitobond EP is still tacky, apply the mixed Paveroc evenly by trowel and tamp in place with a wood float to ensure complete compaction. Thoroughly compact the mortar around any exposed steel reinforcement. Paveroc can be applied up to 100 mm in a single application.

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

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

Concrete Priming Prime using Nitobond EP. Thoroughly stir the individual components to disperse any settlement. Add the entire contents of the hardener to the base container and mix thoroughly for at least 3 minutes until a uniform colour is obtained, taking particular care to scrape the sides and bottom of the container. It is recommended that a Jiffy mixer on a heavy duty, slow speed electric drill is used.

Build-up Additional build-up can be achieved by application of multiple layers. The surface of the intermediate layers should be comb scratch-keyed. A further application of Paveroc may proceed as soon as this layer has set.

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

Reprime with Nitobond EP and apply further Paveroc as described above. Low temperature working 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 cementitious materials should then be adopted. The material should not be applied when the substrate and/or air temperature is 5°C and falling. At 5°C static temperature or at 5°C and rising, the application may proceed.

Mixing Care should be taken to ensure that Paveroc is thoroughly mixed. A forced-action mixer is essential. Mixing in a suitably sized drum using an approved Renderoc Spiral Paddle with a slow speed (400/500 rpm) heavy-duty drill is acceptable for the occasional one-bag mix.


Free-fall mixers must not be used. Mixing of part bags should never be attempted.

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

For normal applications, place 1.9 to 2.2 litres of drinking quality water into the mixer.

Curing Paveroc is a cement-based repair mortar. In common with all cementitious materials, it must be cured immediately after finishing in accordance with good concrete practice. The use of Concure WB, sprayed on to the surface of the finished mortar in a continuous film, is recommended. A low pressure atomising sprayer is essential for applying the Concure WB

With the machine in operation, add one full bag of Paveroc and mix, for a minimum of 3 minutes and a maximum of 5 minutes, until fully homogeneous. The consistency may be adjusted by the addition of small amounts of water up to the maximum total water content of 2.2 litres. Note that the powder must always be added to the water.

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

Mixing warning As with other ‘one pack’ repair mortars, Paveroc may exhibit satisfactory handling characteristics even though inadequately mixed. This will result in a significantly lower

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



Fosroc® Paveroc Overcoating with protective decorative finishes

Limitations

Paveroc is extremely durable and will provide an excellent hard wearing surface to the repaired locations. Surrounding floor areas may benefit from the application of an abrasion or chemical-resistant protective coating. For internal locations, Fosroc recommend the use of the Nitoflor FC range of protective coatings.

Paveroc should not be used when the temperature is below 5°C and falling. Do not mix part bags.

These products provide a decorative and uniform appearance as well as protecting areas of the floor which might otherwise be at risk. Nitoflor FC products may be applied over the repair area after prior removal of the curing membrane generally after 3 days. The local Fosroc office should be contacted for advice about external protective overlayments.

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

Paveroc should not be exposed to moving water during application. Exposure to heavy rainfall prior to the final set may result in surface scour.

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

Cleaning Paveroc should be removed from tools, equipment and mixers with clean water immediately after use. Cured material can only be removed mechanically.


Clean tools used with Nitoprime Zincrich Plus and Nitobond EP before curing, with Fosroc Solvent 102.

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

Estimating

Fire

Supply Paveroc:

25 kg bags


1.9 litre and 800 ml cans

Nitobond EP

2.5 and 4.5 Kg packs

Concure WB


Fosroc Solvent 102:

5 and 25 litre tins

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

Coverage and yield Paveroc:

Approximately 11.5 litres / 25 kg bag (approximately 0.9 m² at 12 mm thickness)


8 m2/litre

Nitobond EP

Approximately 2 m2 / kg

Concure WB

5 m2/ litre


41°C

Fosroc Solvent 102:

33°C

Notes: the actual yield per bag of Paveroc will depend on the consistency used. The yield will be reduced if the material is applied by a spray technique.



www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

31


1 CI/SfB: (4-) Pr4

November 2009

Fosroc® Renderoc DS


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

Specification Clause The repair mortar shall be Renderoc DS a one component polymer modified cementitious dry spray mortar conforming to the requirements of BS EN 1504-3 Class R4.

Uses Renderoc DS is designed for large area repairs such as bridges, tunnels, retaining walls, dams, etc. The aggregates are chosen so as to be classified as ‘non-reactive’, and the product has an alkali content (expressed as Na2O) of less than 3.0 kg/m³.

The cured mortar shall achieve a compressive strength of 60 MPa at 28 days and a drying shrinkage of 60N/mm 2

Compressive Strength cured @ 5oC

60 mins: 20N/mm2

Tensile strength

3N/mm 2

Working life

5 –10 minutes*

Setting time

5 –15 minutes*

Return to service

45 minutes*

Fresh wet density

2200 kg/m³

*dependant on temperature Fosroc® XR 45 is used for the installation and levelling of street ironwork. It is particularly useful where interruption to traffic flow must be minimised. It allows the bedding and installation of manhole frames and gulleys and their return to use in less than 45 minutes.

Instructions for use Preparation Saw cut or cut back the extremities of the repair locations to a depth of at least 10 mm to avoid feather-edging and to provide a square edge. Break out the complete repair area to a minimum depth of 12 mm up to the sawn edge.

Fosroc® XR 45 can also be used for the emergency repair of industrial floors, roads, runways, bridge decks and car park decks.

Clean the surface and remove any dust, unsound or contaminated material, plaster, oil, paint, grease, corrosion deposits or algae. Where breaking out is not required, roughen the surface and remove any laitance by light scabbling or abrasive-blasting.

Advantages

Rapid bedding and levelling of manhole frames

Rapid fixing of signposts and street furniture

Rapid deck repairs

Trafficable within 1 hour

Part bag mixing

Pre-mixed, only requires addition of clean water

Manufactured under an approved BS EN ISO 9001 Quality System.

Oil and grease deposits should be removed by steam cleaning, detergent scrubbing or the use of a proprietary degreaser. The effectiveness of decontamination should then be assessed by a pull-off test. Where repairs are required due to steel corrosion, then standard concrete repair practices should be followed. For more information contact Fosroc.


Substrate priming

Conforms to Department of Transport Specification, HD27/04.

Pre-wet the area with clean water and remove any excess to leave a damp surface.

Design Manual for Roads and Bridges, Vol. 7:Sec 2: 3.11. requirements for rapid repair.

Mixing Mixing should be carried out using gloved hands. Fosroc® XR45 should be added to clean water. Use enough water to initially produce a fluid grout and then mix in sufficient powder to produce a mortar of the required consistency. Ensure that all the powder is thoroughly wetted and mixed. 25 kg of dry powder requires 3.5 litres of clean water. Due to its rapid set characteristics do not mix more than can be placed and finished in 5 minutes. This is typically 3 – 5 kilos. When sufficient labour is available it can be mixed with a slow

Description Fosroc® XR 45 is supplied as a ready to use blend of cements, graded aggregates and additives. It only requires addition of clean water to form a rapid setting mortar. Fosroc® XR45 can be applied in thicknesses from 10mm to 75mm in one application. 107

4 CI/SfB: 12_Yq4 October 2008

FOSROC® XR 45 speed drill and paddle. Due to its rapid setting characteristics the paddle should be cleaned immediately after each mixing operation.

Estimating Supply 25 kg bags

When ambient temperature is between 1ºC and 10ºC the use of warm water up to a maximum of 25ºC is recommended.

Coverage and yield

Apply the mixed Fosroc® XR 45 mortar over the prewetted substrate. Apply within 5 minutes of mixing, ensuring maximum contact before the material sets. Level the manhole/gulley frame before the mortar sets.

Approximately 12.0 litres / 25 kg bag (1.0 m² at 12 mm thickness). Notes: The actual yield per bag of Fosroc® XR 45 will depend on the consistency used. The coverage figures for liquid products are theoretical — due to wastage factors and the variety and nature of possible substrates, practical coverage figures will be reduced.

Cleaning

Health & safety

Fosroc® XR 45 should be removed from tools, equipment and mixers with clean water immediately after use. Cured material can only be removed mechanically.

For further information refer to appropriate Product Safety Data Sheet

Application

Fire Limitations Fosroc® XR 45 is non-flammable.

Fosroc® XR 45 should not be used when the temperature is below 1°C and falling. For cold weather working below 5°C, preheat mixing equipment and gauging water to a temperature of 25-30°C, Large/deep repairs may be subject to cracking. This may be minimised by limiting repair volumes and reducing layer thicknesses. Exposure to heavy rainfall prior to the final set may result in surface scour. The product should not be exposed to moving water during application or totally immersed in water for the first 24 hours after application. If any doubts arise concerning temperature or substrate conditions, consult the local Fosroc office. Storage Store in dry conditions in the original, unopened bags or tubs at between 5°C and 35°C. The product has a shelf life of 6 months if stored as above. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced to less than 3 months.



www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

108


4 CI/SfB: 12_Yq4 June 2008

FOSROC® XR 90


and can be applied in thicknesses of 10mm to 75mm in one application.

General purpose fast-setting cementitious bedding and repair mortar.

FOSROC® XR 90 has been specifically formulated for bedding highway ironwork, with return to service within 120 minutes of placing and is particularly useful where delays to construction need to be avoided. FOSROC® XR 90 can be applied in thicknesses of 10mm to 75mm in one application. Properties Property

Typical result o

Compressive Strength@ 20 C

120mins: 20N/mm2 1 day: >30N/mm 2 28 days:

Uses FOSROC® XR 90 is used for bedding levelling and installation of street ironwork and applications which require high early strength to help reduce road closure times.

>50N/mm2

Total chloride ion content

0

Tensile strength @ 28 days

3.5N/mm 2

Working life

5 -10 minutes*

Setting time

10 -15 minutes*

Return to service

120 minutes*

Fresh wet density

2200 Kg/m3

*dependant on temperature

FOSROC® XR 90 can be used for emergency and general concrete repairs.

Instructions for use

Advantages

Preparation

Rapid strength gain – will accept traffic in 120 minutes

Pre-mixed and bagged material which only requires the addition of clean water

Saw cut or cut back the extremities of the repair locations to a depth of at least 10 mm to avoid feather-edging and to provide a square edge. Break out the complete repair area to a minimum depth of 12 mm up to the sawn edge.

Less expensive than epoxy and polyester resin mortars

Shrinkage compensated formulation

Part bags may be mixed

Hand or mechanical mixing

Manufactured under an approved BS EN ISO 9001 Quality System

Easy to use

Clean the surface and remove any dust, unsound or contaminated material, plaster, oil, paint, grease, corrosion deposits or algae. Where breaking out is not required, roughen the surface and remove any laitance by light scabbling or abrasive-blasting. Oil and grease deposits should be removed by steam cleaning, detergent scrubbing or the use of a proprietary degreaser. The effectiveness of decontamination should then be assessed by a pull-off test..


Substrate priming


Pre-wet the area with clean water and remove any excess to leave a damp surface


When used as a repair mortar, an excellent bond strength can be achieved by mixing FOSROC® XR 90 into a slurry and using it as a primer immediately prior to applying FOSROC® XR 90 mortar.

Description

Mixing

FOSROC® XR 90 is supplied as a pre-mixed blend of cements, silica sands and additives, which only requires mixing with clean water to produce a consistent mortar. It has excellent bond strength without the use of a primer

Mixing should be carried out using gloved hands. Fosroc® XR90 should be added to clean water. Use enough water 109


FOSROC® XR 90 to initially produce a fluid grout and then mix in sufficient powder to produce a mortar of the required consistency. Ensure that all the powder is thoroughly wetted and mixed. 25 kg of dry powder requires 3.5 litres of clean water. Due to its rapid set characteristics do not mix more than can be placed and finished in 5 minutes. This is typically 3 – 5 kilos. When sufficient labour is available it can be mixed with a slow speed drill and paddle. Due to its rapid setting characteristics the paddle should be cleaned immediately after each mixing operation

Estimating Supply 25 kg bags Coverage and yield Approximately 12.0 litres / 25 kg bag (1.0 m² at 12 mm thickness). Notes: The actual yield per bag of FOSROC® XR 90 will depend on the consistency used. The coverage figures for liquid products are theoretical — due to wastage factors and the variety and nature of possible substrates, practical coverage figures will be reduced.

When ambient temperature is between 1ºC and 10ºC the use of warm water up to a maximum of 25ºC is recommended. Application

Health & safety ®

Apply the mixed FOSROC XR 90 mortar over the prewetted substrate. Apply within 5 minutes of mixing, ensuring maximum contact before the material sets. Level the manhole/gulley frame before the mortar sets

For further information refer to appropriate Product Safety Data Sheet Fire

Cleaning

FOSROC® XR 90 is non-flammable.

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 the temperature is below 1°C and falling. Exposure to heavy rainfall prior to the final set may result in surface scour. The product should not be exposed to moving water during application or totally immersed in water for the first 24 hours after application. If any doubts arise concerning temperature or substrate conditions, consult the local Fosroc office. Storage Store in dry conditions in the original, unopened bags or tubs at between 5°C and 35°C. 6 months if stored as above. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced to less than 3 months.



www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

110


FOS/v04-May06/00


FOSROC® XR Cobbleset


return to service and is particularly useful when a fast reopening to pedestrians is required.

High flow, shrinkage compensated rapid setting grout

Technical Service Fosroc offers a comprehensive range of high quality, high performance construction products. In addition Fosroc offers worldwide technical support to specifiers and users of its products. Properties

Fixings bollards and street furniture

Grouting beneath signpost base plates

Working life

5 –15 minutes*

Return to service

30 minutes*

Fresh wet density

2.22 Kg/m³

Preparation The granite sett surfaces should be free from contamination, oil and any loose material. All loose material must be removed from joints to be filled. Blow clean the prepared area with oil-free compressed air. The base must be sound and pre-wetted prior to FOSROC® XR Cobbleset being applied.

Recommended applications include: Pointing of granite setts

120 mins: 25N/mm 2 7 days: >35N/mm 2 28 days: >40N/mm 2


FOSROC® XR Cobbleset is used for the rapid pointing of granite setts, pre-cast concrete stone paviours and slabs. FOSROC® XR Cobbleset is especially beneficial in heavily pedestrianised areas, where a rapid reopening to the public is required.

Typical result

Compressive Strength @ 20oC (BS 1881, Part 116:1983)

*dependant on temperature

Uses

Property

Remove all free standing water prior to application.

Advantages

Mixing

Rapid strength gain – will accept foot traffic in 30 minutes

Pre-mixed and bagged material which only requires the addition of clean water

For quantities up to 50 kg a suitable drill and paddle is suitable. Larger quantities will require a mechanically powered grout mixer.

Shrinkage compensated formulation

Excellent bond strength

Easy to mix


The selected water content (between 3.7-3.9 litres depending on whether grouting is carried out on a level surface or slopping area) should be measured into a suitable bucket. Slowly add the total contents of the FOSROC® XR Cobbleset bag, mix continuously for 3 minutes ensuring a smooth, even consistency is obtained.

Description

Application

FOSROC® XR Cobbleset is supplied as a pre-mixed blend of cements, silica sands and additives, which only require mixing with clean water to produce a consistent mortar. It has excellent bond strength without the use of a primer and can be applied in thicknesses of 5mm to 100mm in one application. FOSROC® XR Cobbleset has been specifically formulated for grouting between granite setts with rapid

111

FOSROC® XR Cobbleset can be applied in thicknesses up to 100mm in one pour

FOSROC® XR Cobbleset can be applied over small areas using a watering can or spouted container. For larger areas FOSROC® XR Cobbleset is poured over the entire area and worked into the joints using a squeegee

After application any excess must be removed from the area by a suitable method


FOSROC® XR Cobbleset Cleaning

Health & safety

Clean any mixing equipment with water immediately after mixing and prior to the initial set

Irritating to respiratory system and skin

Risk of serious damage to eyes

Cured material can only be removed mechanically

May cause sensitisation by skin contact

Wash all tools frequently

Do not breathe dust

Avoid contact with eyes

Wear suitable gloves and eye/face protection

In case of contact with eyes, rinse immediately with plenty of water. If discomfort continues seek medical advice

Limitations Temperature Should not be applied when the substrate and/or air temperature is 1°C and falling. At 1°C static temperature or at 1°C and rising, the application may proceed. If in doubt contact the local Fosroc office.

Fire FOSROC® XR Cobbleset is non-flammable.

Never remix or add water. Storage Storage conditions Store in dry conditions in the original, unopened bags or tubs at between 5°C and 35°C. Shelf life 6 months if stored as above. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced to less than 3 months. Estimating Supply

25 kg bags

Yield

13 litres approx



www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

112


FOS/v03-Mar05/00

4 CI/SfB: 12_Yr4 June 2008

FOSROC® XR PE20


Polyester Resin Mortar for bedding road ironwork where heavily trafficked

Properties

Bond strength: FOSROC® XR PE20 forms a bond to most structural materials provided the surfaces are dry and suitably prepared

Durability: FOSROC® XR PE20 performs at temperatures as high as 60oC and at sub zero temperatures

Chemical resistance: Fully cured FOSROC® XR PE20 is unaffected by water, petrol, oil and many corrosive chemicals

Property

Typical result

Compressive Strength @ 20oC

1 hour:

50N/mm 2

2 hours: >60N/mm2 28 days: >70N/mm 2 Tensile strength @ 20oC

Uses

28 days:

9N/mm2

Flexural strength @ 20 C

7 days:

20Nmm2

Working life

5-10 minutes*

Setting tim

15 minutes*

Return to service

60 minutes*

Fresh wet density

2140 K/m3

o

For the rapid installation of manhole frames in Type 1 & 2 carriageways. For bedding and fixing kerbstones. Repairing and re-rpofiling precast units

Advantages

* dependant on temperature

Fast development of strength minimises disruption


Versatile mix part packs to consistency required

No primer required

High chemical and oil resistance

Will cure down to 0oC


Mixed by hand or mechanical mixing

High flexural and tensile strengths

Preparation For bedding applications:

The surface should be free from contamination, oil and any loose material The substrate should be roughened by mechanical means such as grit blasting or scabbling Blow clean the prepared area with oil-free compressed air

Standards compliance For concrete repair applications:


Saw-cut square the extremities of repair to a depth of at least 5mm. Break out to a minimum of 5mm up to sawn edge. Clean surface and remove dust and any other contaminants

Expose any reinforcing steel and remove loose corrosion, cleaning to a bright condition including the backs of the bars. Abrasive blasting and high pressure washing of the steel are recommended

Blow clean the prepared area with oil-free compressed air

Prime reinforcing steel with Nitoprime Zincrich Plus. No priming of concrete is required with FOSROC® XR PE20.


Description FOSROC® XR PE20 is a two-component material based on a liquid polyester resin and a powder activator/filler. The consistency of FOSROC® XR PE20 can be varied from pourable to trowellable mortar by adjusting the resin to powder ratio, without significant affects on setting time or strength.

113

4 CI/SfB: 12_Yr4 June 2008

FOSROC® XR PE20 Mixing

Estimating

Pour the required quantity of liquid resin into the mixing bucket and add the powdered hardener slowly, stirring continuously for 3 minutes until a uniform consistency is achieved.

Supply

15 kg poly tubs

Yield

7 litres approx

Application

Storage

For bedding applications:

Store in dry conditions in original, unopened packs.

Apply the mixed material immediately after mixing

Do not try to remix after initial hardening is evident

Shelf life is 12 months if kept in a dry store in original, unopened packs.

Do not apply onto wet substrates

General information Do not apply to damp or wet surfaces in applications where the bond is critical.

For concrete repairs:

Apply by steel trowel, pressing firmly into place for good adhesion and compaction, compacting well around any exposed reinforcing bars. Finish to a tight surface with a steel trowel

Do not expose to rainfall or moving water prior to the final set.

FOSROC® XR PE20 can be applied in sections up to 75mm in one layer. Maximum bay size is 0.25m2 and a maximum lineal run of 1 metre

Minimum application thickness 5mm.

Do not apply when the concrete and/or air temperature is below freezing, or where the surface is contaminated with frost or ice


Health & safety

Flashpoint : 29oC.

Cleaning Remove all product from tools with Fosroc Solvent 105 immediately after use. Limitations FOSROC® XR PE20 should not be applied to damp or wet surfaces where a bond is required, nor should it be exposed to moving water during application. Exposure to heavy rainfall prior to the final set may result in surface scour. Apply the mixed FOSROC® XR PE20 immediately after mixing. Do not re-mix once initial hardening has started. Do not add water to the mix.



www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

114


4 CI/SfB:12_Yq4 June 2008

FOSROC® XR RSC



Rapid setting concrete.

Preparation Saw cut or cut back the extremities of the repair locations to a depth of at least 10 mm to avoid feather-edging and to provide a square edge. Break out the complete repair area to a minimum depth of 12 mm up to the sawn edge. Clean the surface and remove any dust, unsound or contaminated material, plaster, oil, paint, grease, corrosion deposits or algae. Where breaking out is not required, roughen the surface and remove any laitance by light scabbling or abrasive-blasting. Oil and grease deposits should be removed by steam cleaning, detergent scrubbing or the use of a proprietary degreaser. The effectiveness of decontamination should then be assessed by a pull-off test. Uses

Substrate priming

For rapid reinstatement/backfill around manhole frames in roadways and installation of street furniture. FOSROC® XR RSC is particularly useful where minimum traffic interruption is required. For the emergency repair and reinstatement of concrete in roads, airfields and factories.

Pre-wet the area with clean water and remove any excess to leave a damp surface Mixing Mixing can be carried out using a spot board and shovel for one or two bags and slow speed drill and paddle for larger quantities. A 25 kg bag requires between 2 to 2.7 litres of water. When mixing with a drill and paddle place the water into a suitable mixing container and add the powder slowly and mix for 2 minutes. Ensure that all the powder is thoroughly wetted and mixed to a smooth homogeneous consistency. Due to its rapid set characteristics do not mix more than can be placed and finished in 10 minutes.

Advantages

Rapid strength gain – will accept traffic in 60 minutes

Pre-mixed, only requires the addition of clean water

High strength, abrasion and weather resistant

Hand or mechanical mixing

Self compacting, does not require vibrating


When ambient temperature is between 1ºC and 10ºC the use of warm water up to a maximum of 25ºC is recommended.

Description FOSROC® XR RSC is supplied as a ready to use blend of cements, graded aggregates and additives. It only requires the addition of clean water to form a rapid setting concrete. FOSROC® XR RSC can be applied in thicknesses from 12mm to 100mm.

Application At trowellable consistency apply the mixed FOSROC® XR RSC on to the primed substrate as soon as possible after mixing. The mortar should be applied evenly by trowel and tamped in place with a wood float to ensure full compaction. Thoroughly compact the mortar around any exposed steel reinforcement. FOSROC® XR RSC can be applied from a minimum of 12 mm to a maximum of 100 mm thickness in a single application.

Properties Property

Typical result

Compressive strength: (BS1881, Pt 116:1983) @20OC

1 hour: 20N/mm 2 7 days: >50N/mm 2 28 days: >60N/mm 2

Working life:

5-10 minutes*

Setting time:

10-15 minutes*

Traffic time:

60 minutes

Fresh wet density:

2200 Kg/m3

Finishing FOSROC® XR RSC should be struck off to the correct level and finished with a steel trowel to fully close the surface. If a textured surface is required, this can be achieved using a suitable roller or brush. The completed surface should not be overworked.

* dependent on temperature 115

4 CI/SfB:12_Yq4 June 2008

FOSROC® XR RSC Low temperature working

Estimating

In cold conditions down to 1°C, the use of warm water (up to 25°C) is advisable to accelerate strength development. Normal precautions for winter working with cementitious materials should then be adopted. The material should not be applied when the substrate and/or air temperature is 1°C and falling. At 1°C static temperature or at 1°C and rising, the application may proceed.

Supply


Notes: The actual yield per bag of FOSROC® XR RSC will depend on the consistency used. The coverage figures for liquid products are theoretical — due to wastage factors and the variety and nature of possible substrates, practical coverage figures will be reduced.

25 kg bags Coverage and yield Approximately 12.0 litres / 25 kg bag (1.0 m² at 12 mm thickness).

At ambient temperatures above 30°C, the material should be stored in the shade and cool water used for mixing. Curing FOSROC® XR RSC is a cement-based repair mortar. In common with all cementitious materials, FOSROC® RSCmust be cured immediately after finishing in accordance with good concrete practice. The use of Nitobond AR or Concure WB, sprayed on to the surface of the finished mortar in a continuous film, is recommended. In fast drying conditions, supplementary curing with polythene sheeting taped down at the edges must be used. In cold conditions, the finished repair must be protected from freezing.

Storage Store in dry conditions in the original, unopened bags or tubs at between 5°C and 35°C. Shelf life is 6 months if stored as above. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced to less than 3 months. Health & safety

Cleaning For further information refer to appropriate Product Safety Data Sheet

Clean any mixing equipment with water immediately after mixing and prior to the initial set. Cured material can only be removed mechanically.

Fire

Limitations

FOSROC® XR RSC is non-flammable

FOSROC® XR RSC should not be used when the temperature is below 1°C and falling. Exposure to heavy rainfall prior to the final set may result in surface scour. The product should not be exposed to moving water during application or totally immersed in water for the first 24 hours after application. If any doubts arise concerning temperature or substrate conditions, consult the local Fosroc office.



www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

116


5 CI/SfB: Vu6 January 2009

Fosroc® Dekguard Clear


Clear protective coating system for exposed concrete and masonry

Properties The values obtained are for the Dekguard Clear system applied at the minimum recommended application rate.

Uses

Volume solids Dekguard Clear:

To protect atmospherically exposed reinforced concrete structures from attack by acid gases, chloride ions, sulphates, oxygen and water. The product is also suitable to protect other cementitious substrates and masonry. Dekguard Clear is suitable for use on all types of structures, car parks, commercial and industrial buildings, subways, underpasses and bridges. It is equally suitable for new and existing structures. Dekguard Clear is a component of Fosroc’s Renderoc system of concrete reinstatement.

35%

Carbon dioxide diffusion resistance (Taywood method). Equivalent thickness of air initial: 11 m per 18 m d.f.t.

Advantages Highly resistant to weathering Good barrier to chloride ingress Breatheability allows water vapour to escape from structure Provides a barrier to carbon dioxide and other atmospheric acid gases

Description The Dekguard Clear system comprises a single component, penetrating silane-siloxane primer and a single component clear coating, both ready for immediate site use.

Equivalent thickness of 30 N/mm² concrete cover (Taywood method):

30 mm per 18 m d.f.t.

Water vapour diffusion resistance (Taywood method):

SD 0.07 m @ 172 d.f.t.

Reduction in chloride ion penetration (Aston Page method):

> 90%

Freeze/thaw salt scaling ASTM C672 (50 cycles):

Unaffected

Reduction in water absorption ASTM C642:

>84%

Application instructions All coating work to be carried out in accordance with the relevant sections of BS6160:2006, Painting of Buildings Code of Practice.

The primer (Dekguard Primer) is supplied as a clear liquid and is based on a silane-siloxane dissolved in a penetrating organic carrier. The primer is reactive and capable of producing a chemically-bound hydrophobic barrier, thus inhibiting the passage of water and waterborne contaminants.

Preparation All surfaces should be dry and free from contamination such as oil, grease, loose particles, decayed matter, moss, algal growth, laitance, and all traces of mould release oils and curing compounds. This is best achieved by lightly grit-blasting the surface. Where moss, algae or similar growths have occurred, treatment with a proprietary biocide should be carried out after the gritblasting process.

Dekguard Clear is a solvent based clear methacrylate coating which will provide resistance to aggressive elements, weathering and rain. A major feature of the system is its ability to allow water vapour to escape from the structure.

Note: If Nitobond AR has been used as a curing membrane over Renderoc patch repairs, it is not necessary to remove this prior to the application of Dekguard Clear.

Specification clauses Clear methacrylate protective / weather resistant surface coating.

Where application over existing sound coatings is required, trials should be conducted to ensure compatibility and retention of the bond between the underlying coating and the substrate. For further advice, consult the local Fosroc office.

The protective coating shall comprise a penetrating oligomeric siloxane primer and Dekguard Clear, a single component methacrylate coating. The total dry film thickness of the system shall not be less than 60 microns and shall give a reduction in chloride ion penetration not less than 90%.

It is essential to produce an unbroken coating of Dekguard Clear. To ensure this is achieved, surfaces containing blow-holes or similar areas of pitting should

117


Fosroc® Dekguard Clear

All primed substrates should be treated with Dekguard Clear top coat. The material should be applied to all areas by the use of suitable brushes or rollers to achieve a uniform coating with a wet film thickness not less than 300 microns.

first be filled using Renderoc FC, a cementitious fairing coat. Rougher substrates can be levelled using Renderoc RP252, a cementitious reprofiling and protection mortar. Separate data sheets must be referred to before commencing overcoating of Renderoc RP252 with Dekguard Clear.

Subsequent coats should be applied exactly as detailed above, again achieving a uniform coating with a wet film thickness not less than 300 microns per coat. Each coat should be allowed to dry for not less than 6 hours at 20°C.

Application In order to obtain the protective properties of the Dekguard Clear system, it is important that the correct rates of application and overcoating times are observed.

Cleaning Renderoc FC and Renderoc RP252 should be removed from tools and equipment with clean water immediately after use. Dekguard Clear and Dekguard Primer should be removed from tools and equipment using Fosroc Solvent 102.

Dekguard Clear Number of coats:

As necessary to give required carbon dioxide diffusion resistance

Theoretical application rate:

0.316 litres/m²/coat

Minimum dry film thickness:

60 microns per coat

Supply

Overcoating time at 20°C:

6 hours

Renderoc FC:

Estimating

25 kg bags

Renderoc RP252:

Dekguard Primer

20 kg bags

Renderoc RP252 surface conditioner: Number of coats:

Flood coat

Theoretical application rate:

0.4 litre/m2

Theoretical dry film thickness:

N/A


12 hours

Dekguard Primer:

25 litre drums

Nitoprime DG:

25 litre drums

Dekguard Clear: Fosroc Solvent 102:

25 litre drums 5 and 25 litre tins

Coverage

Application should not commence if the temperature of the substrate is below 2°C. Any areas of glass and window frames should be masked. Plants, grass, joint sealants, asphalt and bitumen-painted areas should be protected during application. The primer should be applied in one or more coats until the recommended application rate of 0.4 litre per square metre has been achieved. This is best accomplished by using portable spray equipment of the knapsack-type. Porous surfaces may require the application of Nitoprime DG as an alternative primer, or may require other special treatment. Nitoprime DG should be applied at the same coverage rate as Dekguard Primer but in continuous, multiple coats as necessary. If in doubt about the condition of the substrate, contact the local Fosroc office.

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 litre

Nitoprime DG:

2.5 m2 per litre

Dekguard Clear:

3.2 m² per litre per coat

The coverage figures given are theoretical — due to wastage factors and the variety and nature of possible substrates, practical coverage figures will be reduced.

Limitations The Dekguard Clear system is formulated for application to clean, sound concrete or masonry. Where application over existing sound coatings or paints is required, trials should be conducted to ensure compatibility and retention of the bond between the underlying coating and the substrate. When applied over existing coatings or paints, the performance characteristics of Dekguard Clear may be impaired. Compatibility and soundness should be assessed on a trial area. For further advice, consult Fosroc Technical Department.

The primer should be allowed to dry for a minimum of 12 hours at 20°C before continuing. Under no circumstances should the primer be overcoated with Dekguard Clear until the surface is properly dry. Dekguard Clear may be applied by the use of suitable brushes, or rollers. For further information about application techniques, please consult the local Fosroc office.

The application of the Dekguard Clear System should not commence if the temperature of the substrate is below 2°C.


5 litre bottles

5

®

CI/SfB: Vu6 January 2009

Fosroc Dekguard Clear A single coat application may produce a patchy appearance due to variation in the porosity of the substrate. Dekguard Clear should not be applied in windy conditions where early-age dust adhesion may occur, or where rain is likely within 2 hours at 20°C or 20 hours at 5°C (up to 80% RH). It should not be applied when the prevailing relative humidity exceeds 90%.

Storage All products have a shelf life of 12 months if kept in a dry store in the original, unopened packs. Material from different batches shall be stored separately. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced.

Precautions Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Dekguard Primer, Dekguard Clear, Nitoprime DG and Fosroc Solvent 102 are flammable. Keep away from sources 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°C

Dekguard Primer:

38°C

Nitoprime DG:

38°C

Fosroc Solvent 102:

33°C


Dekguard is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

119


5 5

CI/SfB: Vv9 CI/SfB: Vu6 February 2005 June 2008

Fosroc® Dekguard E2000


Crack-accommodating elastomeric protective coating for reinforced concrete structures

100 days when evuated by the Taywood method. It shall exhibit a water vapour transmission resistance (SD) of not more than 0.14 metres (by the Klopfer method) at a dry film thinkness of 200 microns. It must be capable of bridging a 2mm incipient crack at 20°C before failure when evaluated by the UK BRE method.

Uses To protect atmospherically exposed reinforced concrete structures from attack by acid gases, chloride ions, oxygen and water, especially where there is a danger of subsequent cracks appearing within the substrate. Dekguard E2000 is suitable for use on all types of structures, including those in coastal environments.

Properties The values obtained are for the Dekguard E2000 system using Nitoprime DG applied at the minimum recommended application rate. Volume solids Dekguard E2000:

Advantages Can accommodate substrate cracking up to 2mm and cyclic movement up to 0.3mm

Carbon dioxide diffusion resistance (Taywood method). Equivalent thickness of air — Initial: After 2000 hours accelerated weathering:

Excellent barrier to carbon dioxide, chloride ions, oxygen and water Special acrylic polymer minimises dirt retention Allows water vapour to escape from the structure

Water vapour diffusion resistance (Klopfer method):

Resistant to the effects of ultra-violet light Water-based

Chloride resistance (Taywood method):

Range of decorative colours

Description The Dekguard E2000 system comprises a single component penetrating primer and a single component elastomeric pigmented coating, both ready for immediate site use.

50%

> 50 metres > 50 metres SD 0.14 m, 200 dft No chloride ion diffusion after 100 days

Static crack accommodation capability (UK BRE method):

2mm

Dynamic crack accommodation (cyclic):

0.3mm


The system is available with a choice of priming systems, i.e. Nitobond AR or Nitoprime DG. Nitoprime DG, a film forming stabilising primer may be utilised when chloride resistance is of primary importance. Nitoprime DG is supplied as a clear liquid and is based on an acrylic resin and a silane-siloxane dissolved in a penetrating organic carrier. The primer is reactive and capable of producing a chemically-bound hydrophobic barrier, thus inhibiting the passage of water and water-bourne contaminants. A thin surface film is produced which consolidates and stabilises porous substances.

All coating work to be carried out in accordance with the relevant sections of BS6150:2006, Painting of Buildings Code of Practice. Preparation All surfaces should be dry and free from contamination such as oil, grease, loose particles, decayed matter, moss, algae growth, laitance, and all traces of mould release oils and curing compounds. This is best achieved by lightly grit-blasting the surface. Where moss, algae or similar growths have occurred, treatment with a proprietary biocide should be carried out after the gritblasting process.

Nitobond AR may be used where chloride resistance is of secondary importance to carbonation resistance.

Specification clauses

If Nitobond AR has been used as a curing membrane over Renderoc patch repairs, it is not necessary to remove this prior to the application of Dekguard E2000.

Crack-accommodating protective/decorative surface coating. The protective coating system shall comprise Nitoprime DG, an acrylic film-forming penetrating siliane-siloxane primer and Dekguard E2000, a single component elastomeric coating suitable for application by brush, roller or spray.

Where application over existing sound coatings is required, trials should be conducted to ensure compatibility and retention of the bond between the underlying coating and the substrate. For further advice, consult Fosroc Technical Department. It is essential to produce an unbroken coating of Dekguard E2000. To ensure this is achieved, surfaces

The total dry film thickness must be capable of providing carbon dioxide diffusion resistance equivalent to not less than 50 metres of air and no chloride ion diffusion after 120

5 5 CI/SfB: CI/SfB:Vv9 Vu6 February 2005 June 2008

Fosroc® Dekguard E2000

knapsack-type. A uniform surface appearance (sheen) should be achieved. If any matt porous patches remain, a further application of primer should be made.

containing blow-holes or similar areas of pitting should first be filled using Renderoc FC, a cementitious fairing coat. Rougher substrates can be levelled using Renderoc RP252, a cementitious reprofiling and protection mortar. Separate data sheets must be referred to before commencing overcoating of Renderoc RP252 with Dekguard E2000.

The primer should be allowed to dry for a minimum of 12 hours (at 20°C), longer at lower temperatures, before continuing. Under no circumstances should the primer be overcoated with Dekguard E2000 until the surface is properly dry.

Application

Dekguard E2000 may be applied by the use of suitable brushes, rollers or spray equipment. For further information about application techniques, please consult Fosroc Technical Department.

In order to obtain the protective properties of the Dekguard E2000 system, it is important that the correct rates of application and overcoating times are observed.

All primed substrates should be treated with one coat of Dekguard E2000. It is important that no gaps or ‘raw edges’ appear in the finished coating. Special care should be taken to provide an unbroken coating at external corners and similar exposed protrusions. This should be applied to all areas by the use of suitable brushes or rollers to achieve a uniform coating with a wet film thickness not less than 400 microns. It should be allowed to dry until firm to the touch. Typically, this will be after about 16 hours in dry weather at 20°C.

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.D Nitoprime DG Number of coats:

Flood coat

Theoretical application rate per coat:

0.4 litres/m2

Theoretical wet film thickness per coat:

N/A

Overcoating time:

12 hours @ 20°C

Cleaning Renderoc FC, Renderoc RP252, Dekguard E2000 and Nitobond AR should be removed from tools and equipment with clean water immediately after use. Nitoprime DG should be removed from tools and equipment using Fosroc Solvent 102.

Nitobond AR Number of coats:

1 or 2


0.15 litres/m2


150 microns

Supply

Overcoating time:

12 hours @ 20°C

Renderoc FC:

25kg bags

Renderoc RP252:

20kg bags

Nitoprime DG:

25 litre drums

Estimating

Dekguard E2000 Number of coats: Theoretical application rate per coat: Theoretical wet film thickness per coat:

1 0.4 litres/m2 400 microns

25 litre drums

Dekguard E2000:

10 litre drums

Fosroc Solvent 102:

5 litre drums

Coverage

Application of Nitoprime DG should not commence if the temperature of the substrate is below 2°C. Application of Dekguard E2000 should not commence if the temperature of the substrate is below 5°C. Any areas of glass and window frames should be masked. Plants, grass, joint sealants, asphalt and bitumen-painted areas should be protected during application.

Renderoc FC:

15 litres (5 m2 at 3mm thickness)

Renderoc RP252: thickness)

12 litres (2.4 m2 at 5mm

Nitoprime DG:

2.5 m2 / litre (total)

Nitobond AR:

6 to 8m2 / litre

Dekguard E2000:

2.5m2 / litre (total)


The Nitoprime DG should be applied in one or more coats until the recommended application rate of 0.4 litre per square metre has been achieved. This is best accomplished by using portable spray equipment of the


Nitobond AR:

5 5 CI/SfB: CI/SfB:Vv9 Vu6 February 2005 June 2008

Fosroc® Dekguard E2000 Limitations

different batches shall be stored separately. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced.

The Dekguard E2000 system is formulated for application to clean, sound concrete or masonry. Where application over existing sound coatings or paints is required, trials should be conducted to ensure compatibility and retention of the bond between the underlying coating and the substrate. When applied over existing coatings or paints, the performance characteristics of Dekguard E2000 may be impaired and its fire rating invalidated. Compatibility and soundness should be assessed on a trial area. For further advice, consult Fosroc Technical Department.

Precautions Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Renderoc FC, Renderoc RP252, Nitobond AR and Dekguard E2000 are non-flammable.

Application of Nitoprime DG should not commence if the temperature of the substrate is below 2°C. Application of Nitobond AR and Dekguard E2000 should not commence if the temperature of the substrate is below 5°C.

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

Dekguard E2000 and Nitobond AR should not be applied where there is a likelihood of exposure to frost within 48 hours of the application. The product should not be applied in windy conditions where early-age dust adhesion may occur, or where rain is likely within 2 hours at 20°C or 20 hours at 5°C (up to 80% RH). It should not be applied when the prevailing relative humidity exceeds 90%.

Flash points Nitoprime DG:

38°C

Fosroc Solvent 102:

33°C


The use of Dekguard E2000 should not be considered for areas subjected to ponded water. Dekguard E2000 is unsuitable for use in areas subject to direct physical attack by vandals. Where appropriate, Dekguard S or Graffitiguard should be considered. The manufacture of Dekguard coatings is a batch process and despite close manufacturing tolerances variation may occur between batches. Fosroc recommends using material from one batch only as the finish topcoat.

Storage Store in cool, dry conditions, away from sources of heat and 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 dry store in the original, unopened packs. Material from



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fax: +44 (0) 1827 262444

122



®

Fosroc Dekguard Elastic


High performance crack-accommodating elastomeric acrylic protective and decorative coating for concrete and masonry

Fire tested to BS 476, Pt 7: 1987. Spread of flame Class 1. Fire tested to BS 476, Pt 6: 1989. Propagation index I — 0.0. Sub index i1 — 0.0. Building Regulations rating — Class 0.

Uses


To protect atmospherically exposed reinforced concrete structures from attack by acid gases, chloride ions, oxygen and water, especially where there is a danger of subsequent cracks appearing within the substrate. The product is also suitable to protect other cementitious substrates and masonry. Dekguard Elastic is suitable for use on all types of structures, including those in coastal environments. It is equally suitable for new and existing structures. Dekguard Elastic is a component of Fosroc’s Renderoc system of concrete reinstatement.

Elastomeric protective/decorative surface coating The protective coating system shall comprise Nitoprime DG, an acrylic film-forming penetrating silane-siloxane primer and Dekguard Elastic, a single component elastomeric coating suitable for application by brush, roller or spray. The total dry film thickness of the coating shall be not less than 400 microns and shall be capable of providing carbon dioxide diffusion resistance equivalent to not less than 125 mm of 30N/mm2 concrete cover (by the Taywood method) and a reduction in chloride ion penetration not less than 99% (by the Aston University Diffusion Cell method).

Advantages Can accommodate substrate cracking up to 6mm and cyclic movement up to 1mm True elastomeric coating with excellent elongation and recovery properties which are maintained at sub-zero temperatures

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.

Excellent barrier to carbon dioxide, chloride ions, oxygen and water

Wide range of decorative colours

The coating must be capable of withstanding 20,000 0mm – 1mm – 0mm cycles at 20°C without failure. In static testing, it must be capable of bridging an 6 mm incipient crack @ 20°C before failure and a 4 mm incipient crack @ 0°C before failure. When tested to BS 476, Pt 7 : 1987, it must exhibit a Class 1 spread of flame and achieve a Class 0 Building Regulations rating when tested to BS 476, Pt 6 : 1989 and Pt 7 : 1987.

Description

Properties

The Dekguard Elastic system comprises a single component penetrating primer and a single component elastomeric pigmented coating, both ready for immediate site use.

The values obtained are for the Dekguard Elastic system applied at the minimum recommended application rate.

Special acrylic polymer minimises dirt retention Allows water vapour to escape from the structure UV-resistant with high resistance to the effects of longterm weathering Water-based

The film-forming, stabilising primer (Nitoprime DG) is supplied as a clear liquid and is based on an acrylic resin and a silane-siloxane dissolved in a penetrating organic carrier. The primer is reactive and capable of producing a chemically-bound hydrophobic barrier, thus inhibiting the passage of water and water-borne contaminants. A thin surface film is produced which consolidates and stabilises porous substrates. Dekguard Elastic is an elastomeric, water based protective coating based on a special acrylic polymer. It provides excellent elongation and recovery, low dirt pickup, resistance to aggressive elements, UV light and rain. It is available in a wide range of colours.

Standards compliance Dekguard Elastic has been approved by the British Board of Agrément under Certificate No. 98/3461. 123

Volume solids Dekguard Elastic:

49%

Carbon dioxide diffusion resistance (BRE method). Equivalent thickness of air — Initial: After 2000 hours QUV:

> 100 metres > 100 metres

Equivalent thickness of 30 N/mm2 concrete cover (Taywood method):

> 125 mm

Water vapour diffusion resistance (Klopfer method):

SD 0.11 m @ 400 microns dft

Reduction in chloride ion penetration (Aston University Diffusion Cell method):

> 99%


Fosroc® Dekguard Elastic Incipient crack spanning capability @ 400 microns dft — static test (ASTM C836-84modified) 20°C: 0°C: –15°C:

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. 6 mm 4 mm 1.3 mm

Dynamic crack bridging capability 0 mm - 1 mm - 0 mm cycling 20°C: 20,000 cycles 0°C: 15,000 cycles –5°C: 4,000 cycles

(no failure) (no failure) (no failure)

Tear resistance (ASTM D624-84):

12 N/mm2

Fire testing (BS 476, Pt 7: 1987) — Spread of flame:

Class 1

Fire testing (BS 476, Pt 6: 1989) — Propagation index I: Sub index i1: Building Regulations rating:

0.0 0.0 Class 0

Number of coats:

Dekguard Elastic

Flood coat

2

Theoretical application rate per coat: 0.4 litres/m2

0.4 litres/m2


400 microns

Overcoating time:

N/A

12 hours @ 20°C when firm to the touch

Application of Nitoprime DG should not commence if the temperature of the substrate is below 2°C. Application of Dekguard Elastic should not commence if the temperature of the substrate is below 5°C. Any areas of glass or window frames should be masked. Plants, grass, joint sealants, asphalt and bitumen-painted areas should be protected during application.


Apply Nitoprime DG in one or more coats until the recommended application rate of 0.4 litre per square metre has been achieved. This is best accomplished by using portable spray equipment of the knapsack-type. A uniform surface appearance (sheen) should be achieved. If any matt porous patches remain, a further application of primer should be made.

All coating work to be carried out in accordance with the relevant sections of BS6150:2006, Painting of Buildings Code of Practice. Preparation All surfaces should be dry and free from contamination such as oil, grease, loose particles, decayed matter, moss, algal growth, laitance, and all traces of mould release oils and curing compounds. This is best achieved by lightly grit-blasting the surface. Where moss, algae or similar growths have occurred, treatment with a proprietary biocide should be carried out after the grit-blasting process.

Allow the primer to dry for a minimum of 12 hours (at 20°C), longer at lower temperatures. Under no circumstances should the primer be overcoated with Dekguard Elastic until the surface is properly dry. Dekguard Elastic may be applied by the use of suitable brushes, rollers or spray equipment. For further information about application techniques, please consult Fosroc Technical Department.

If Nitobond AR has been used as a curing membrane over Renderoc patch repairs, it is not necessary to remove this prior to the application of Dekguard Elastic.

All primed substrates should be treated with two coats of Dekguard Elastic. It is important that no gaps or ‘raw edges’ appear in the finished coating. Special care should be taken to provide an unbroken coating at external corners and similar exposed protrusions. Apply the first coat to all areas until a uniform coating with a wet film thickness not less than 400 microns is achieved. Allow to dry until firm to the touch. Typically, this will be after about 16 hours in dry weather at 20°C.

Where application over existing sound coatings is required, trials should be conducted to ensure compatibility and retention of the bond between the underlying coating and the substrate. For further advice, consult Fosroc Customer Services Department. It is essential to produce an unbroken coating of Dekguard Elastic. To ensure this is achieved, surfaces containing blow-holes or similar areas of pitting should first be filled using Renderoc FC, a cementitious fairing coat. Rougher substrates can be levelled using Renderoc RP252, a cementitious reprofiling and protection mortar. Separate data sheets must be referred to before commencing overcoating of Renderoc RP252 with Dekguard Elastic.

Apply the second coat of Dekguard Elastic as above. Under poor drying conditions at low temperatures it may be more practical to apply three thinner coats (270 microns wet film thickness each) of Dekguard Elastic to achieve better ‘through-drying’. This method will achieve the correct recommended dry film thickness.

Application In order to obtain the protective properties of the Dekguard Elastic system, it is important that the correct rates of application and overcoating times are observed.

Cleaning Renderoc FC and Dekguard Elastic should be removed from tools and equipment with clean water immediately 124


Nitoprime DG


Fosroc® Dekguard Elastic after use. Nitoprime DG should be removed from tools and equipment using Fosroc Solvent 102.

subjected to exposure to ponded water. In such cases use Dekguard S.

Estimating

The elastomeric properties and high tear strength of Dekguard Elastic make it unsuitable for use in areas subject to direct physical attack by vandals. Where appropriate, Dekguard S should be considered.

Supply Renderoc FC:

25kg bags

Renderoc RP252:

25kg bags

Nitoprime DG:

25 litre drums

Dekguard Elastic:

10 litre drums

Fosroc Solvent 102:

5 litre drums

The manufacture of Dekguard coatings is a batch process and despite close manufacturing tolerances variation may occur between batches. Fosroc recommends using material from one batch only as the finish topcoat.

Renderoc FC:

15 litres (5 m2 at 3 mm thickness)

Storage

Renderoc RP252:


Nitoprime DG:

2.5 m2 per litre

Dekguard Elastic:

2.5 m2 per litre per coat

Store in cool, dry conditions, away from sources of heat and naked flames, in the original, unopened packs. Dekguard Elastic should be protected from frost. All products have a shelf life of 12 months if kept in a dry store in the original, unopened packs. Material from different batches shall be stored separately.

Dekguard Elastic should not be used on soffits subject to possible water ingress. In these cases use Dekguard S or W.

Coverage


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

Limitations

Precautions

Where application over existing sound coatings or paints is required, trials should be conducted to ensure compatibility and retention of the bond between the underlying coating and the substrate. When applied over existing coatings or paints, the performance characteristics of Dekguard Elastic may be impaired and its fire rating invalidated. Compatibility and soundness should be assessed on a trial area. For further advice, consult Fosroc Customer Services Department.


Application of Nitoprime DG should not commence if the temperature of the substrate is below 2°C. Application of Dekguard Elastic should not commence if the temperature of the substrate is below 5°C.

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

Health and safety

Fire Renderoc FC, Renderoc RP252 and Dekguard Elastic are non-flammable.

Flash points

Dekguard Elastic should not be applied where there is a likelihood of exposure to frost within 48 hours of application. Do not appy in windy conditions where earlyage dust adhesion may occur, or where rain is likely within 2 hours at 20°C or 20 hours at 5°C (up to 80% RH). It should not be applied when the prevailing relative humidity exceeds 90%.

Nitoprime DG:

38°C

Fosroc Solvent 102:

33°C


Dekguard Elastic should not be considered for areas Dekguard is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


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telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

125


5 CI/SfB: Vu6 June 2008

Fosroc® Dekguard S


High performance aliphatic acrylic protective and decorative coating for concrete and masonry

To protect atmospherically exposed reinforced concrete structures from attack by acid gases, chloride ions, sulphates, oxygen and water. The product is also suitable to protect other cementitious substrates and masonry. Dekguard S is suitable for use on all types of structures, especially those in aggressive marine and coastal environments. It is equally suitable for new and existing structures. Dekguard S is a component of Fosroc’s Renderoc system of concrete reinstatement.

component aliphatic acrylic coating. The total dry film thickness of the coating shall be not less than 150 microns and shall be capable of providing carbon dioxide diffusion resistance equivalent to not less than 650 mm of 30 N/mm2 concrete cover (by the Taywood method). It shall provide a reduction in chloride ion penetration not less than 99% (by the Aston University Diffusion Cell method) and no chloride ion diffusion after 600 days (by the Taywood method). It must exhibit a water vapour transmission resistance (SD) of not more than 0.98 metres (by the Taywood method) at a dry film thickness of 150 microns. When tested to BS 476, Pt 7:1987, it must exhibit a Class 1 spread of flame and achieve a Class 0 Building Regulations rating when tested to BS 476, Pt 6:1989 and Pt 7:1987.

Advantages

Properties

Excellent barrier to carbon dioxide, chloride ions, sulphates, oxygen and water

The values obtained are for the Dekguard S system applied at the minimum recommended application rate.

Uses

Allows water vapour to escape from the structure Highly UV-resistant aliphatic acrylic gives exceptional resistance to the effects of long-term weathering

Volume solids Dekguard S:

43%

Highly durable in all climatic conditions

Carbon dioxide diffusion resistance (Taywood method). Equivalent thickness of air — Initial: 2,000 hours QUV weathered:

>250 metres >250 metres

Equivalent thickness of 30 N/mm2 concrete cover (Taywood method):

>650 mm

Wide range of decorative colours Excellent resistance to dirt pick-up

Description The Dekguard S system comprises a single component, penetrating silane-siloxane primer and a single component pigmented coating, both ready for immediate site use.


The primer (Dekguard Primer) is supplied as a clear liquid and is based on a silane-siloxane dissolved in a penetrating organic carrier. The primer is reactive and capable of producing a chemically-bound hydrophobic barrier, thus inhibiting the passage of water and waterborne contaminants.


Reduction in chloride ion penetration (Aston University Diffusion Cell method) : >99% Chloride ion diffusion coefficient (Taywood method):

Dekguard S is an aliphatic acrylate, solvent based, protective coating, providing outstanding resistance to aggressive elements, UV light and rain. It is available in a wide range of colours.

Standards compliance Dekguard S has been approved by the British Board of 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. Propagation index I - 1.5. Sub index i1 - 1.3. Building Regulations rating - Class 0.

Specification clauses Protective/decorative surface coating The protective coating shall comprise a penetrating silane-siloxane primer and Dekguard S, a single

126

2,000 hours QUV weathered

No chloride ion diffusion after 600 days immersion

Freeze/thaw salt scaling (50 cycles) — (ASTM C672-84): Good quality concrete (control):

Unaffected Severe scaling

Fire testing (BS 476, Pt 7 : 1987) — Spread of flame:

Class 1

Fire testing (BS 476, Pt 6 : 1989) — Propagation index I: Sub index i1: Building Regulations rating:

1.5 1.3 Class 0


Fosroc® Dekguard S Any areas of glass and window frames should be masked. Plants, grass, joint sealants, asphalt and bitumen-painted areas should be protected during application.


The primer should be applied in one or more coats until the recommended application rate of 0.4 litre per square metre has been achieved. This is best accomplished by using portable spray equipment of the knapsack-type. Porous surfaces may require the application of Nitoprime DG as an alternative primer, or may require other special treatment. Nitoprime DG should be applied at the same coverage rate as Dekguard Primer but in continuous, multiple coats as necessary. If in doubt about the condition of the substrate, contact Fosroc Technical Department.

Preparation All surfaces should be dry and free from contamination such as oil, grease, loose particles, decayed matter, moss, algal growth, laitance, and all traces of mould release oils and curing compounds. This is best achieved by lightly grit-blasting the surface. Where moss, algae or similar growths have occurred, treatment with a proprietary biocide should be carried out after the gritblasting process. If Nitobond AR has been used as a curing membrane over Renderoc patch repairs, it is not necessary to remove this prior to the application of Dekguard S.

The primer should be allowed to dry for a minimum of 12 hours (at 20°C), longer at lower temperature, before application of Dekguard S. Under no circumstances should the primer be overcoated until the surface is properly dry.

Where application over existing sound coatings is required, trials should be conducted to ensure compatibility and retention of the bond between the underlying coating and the substrate. For further advice, consult Fosroc Technical Department.

All primed substrates should be treated with two coats of Dekguard S. The material should be stirred thoroughly before use. The first coat should be applied to all areas by the use of suitable brushes or rollers to achieve a uniform coating with a wet film thickness not less than 175 microns. This coat should be allowed to dry before continuing.

It is essential to produce an unbroken coating of Dekguard S. To ensure this is achieved, surfaces containing blowholes or similar areas of pitting should first be filled using Renderoc FC, a cementitious fairing coat. Rougher substrates can be levelled using Renderoc RP252, a cementitious reprofiling and protection mortar. Separate data sheets must be referred to before commencing overcoating of Renderoc RP252 with Dekguard S.

The second coat of Dekguard S should be applied exactly as detailed above, again achieving a wet film thickness not less than 175 microns. Cleaning Renderoc FC and Renderoc RP252 should be removed from tools and equipment with clean water immediately after use. Dekguard Primer, Nitoprime DG and Dekguard S should be removed from tools and equipment using Fosroc Solvent 102.

Application In order to obtain the protective properties of the Dekguard S system, it is important that the correct rates of application and overcoating times are observed.

Estimating

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.

Number of coats:

Supply Dekguard S:

10 litre drums

Dekguard Primer

Dekguard S

Dekguard Primer:

25 litre drums

Flood coat

2

Nitoprime DG:

25 litre drums

Theoretical application rate per coat: 0.4 litres/m2

0.175 litres m2


N/A

175 microns

Overcoating time — @ 20°C:

12 hours

6 hours

Nitobond AR:


Fosroc Solvent 102:

5 and 25 litre tins

Coverage

Application should not commence if the temperature of the substrate is below 2°C.

Dekguard S:

6 m2 per litre per coat

Dekguard Primer:

2.5 m2 per litre

Nitoprime DG:

2.5 m2 per litre

Nitobond AR:

6 m2 per litre

The coverage figures given are theoretical — due to wastage factors and the variety and nature of possible substrates, practical coverage figures will be reduced. 127 constructive solutions


Fosroc® Dekguard S Limitations

Precautions

The Dekguard S system is formulated for application to clean, sound concrete or masonry. Where application over existing sound coatings or paints is required, trials should be conducted to ensure compatibility and retention of the bond between the underlying coating and the substrate. When applied over existing coatings or paints, the performance characteristics of Dekguard S may be impaired and its fire rating invalidated. Compatibility and soundness should be assessed on a trial area. For further advice, consult Fosroc Technical Department.

Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Renderoc FC, Renderoc RP252 and Renderoc RP252 surface conditioner are non-flammable. Dekguard Primer, Nitoprime DG, Dekguard S and Fosroc Solvent 102 are flammable. Keep away from sources of ignition. No Smoking. In the event of fire, extinguish with CO2 or foam. Do not use a water jet.

Application of Dekguard S, Dekguard Primer or Nitoprime DG should not commence if the temperature of the substrate is below 2°C. Nitobond AR application should not commence if the temperature of the substrate is below 5°C.

Flash points

The manufacture of Dekguard coatings is a batch process and despite close manufacturing tolerances variation may occur between batches. Fosroc recommends using material from one batch only as the finish topcoat.

Dekguard Primer:

38°C

Nitoprime DG:

38°C

Dekguard S:

42°C

Fosroc Solvent 102:

33°C


Storage Store in cool, dry conditions, away from sources of heat and naked flames, in the original, unopened packs. All products have a shelf life of 12 months if kept in a dry store in the original, unopened packs. Material from different batches shall be stored separately. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced.



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telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

128



Fosroc® Dekguard Textured


Textured weather-resistant coating system for exposed concrete and masonry


Uses

All coating work to be carried out in accordance with the relevant sections of BS6150:2006, Painting of Buildings Code of Practice.

To enhance the appearance of exposed reinforced concrete. Suitable for use on all types of structures both new and existing. Dekguard Textured is a component of the Renderoc system of concrete reinstatement.

Preparation All surfaces should be dry and free from contamination such as oil, grease, loose particles, decayed matter, moss, algal growth, laitance, and all traces of mould release oils and curing compounds. This is best achieved by lightly grit blasting the surface. Where moss, algae or similar growths have occurred, treatment with a proprietary biocide should be carried out after the grit blasting process.

Advantages High resistance to the effects of long-term weathering and durable in all climatic conditions Allows water vapour to escape from the structure Water based Choice of water based or solvented primers

Where application over existing sound coatings is required, trials should be conducted to ensure compatibility and retention of the bond between the underlying coating and the substrate. For further advice, consult the local Fosroc office.

Wide range of decorative colours Helps disguise patchy or unsightly substrates Can be used in combination with Dekguard S to obtain protection against acid gases, chloride ions, oxygen and water

It is essential to produce an unbroken coating of Dekguard Textured. To ensure this is achieved, surfaces containing blow-holes or similar areas of pitting should first be filled using Renderoc FC, a cementitious fairing coat. Rougher substrates can be levelled using Renderoc RP252, a cementitious reprofiling and protection mortar. Separate data sheets must be referred to before commencing overcoating of Renderoc RP252 with Dekguard Textured.

Description Dekguard Textured is a water based coating with a textured surface profile. The Dekguard Textured system comprises a single component, penetrating silane-siloxane primer and a single component pigmented coating which provides a textured surface finish. Both components are ready for on-site use.

Application

The primer (Dekguard Primer) is supplied as a clear liquid and is based on a silane-siloxane dissolved in a penetrating organic carrier. The primer is reactive and capable of producing a chemically bound hydrophobic barrier, thus inhibiting the passage of water and waterborne contaminants.

In order to obtain the full properties of the Dekguard Textured system, it is important that the correct rates of application 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 Textured is a textured water based protective coating based on a special acrylic polymer. It provides low dirt pick-up, resistance to aggressive elements, UV light and rain. It is available in a wide range of colours.

Dekguard Primer

Dekguard Textured

Specification Clauses

Number of coats:

Flood coat

1

Protective/decorative surface coatings

Theoretical application rate per coat

0.4 litres/m²

0.5 litres/m²

Thoretical wet film thickness per coat:

N/A

500 microns

Overcoating time @ 20°C:

12 hours

N/A

The weather-resistant coating shall be the Dekguard Textured system, comprising a silane-siloxane primer and a water based, single component, pigmented textured coating. The finished coating shall be unbroken and representative of the texture approved from a site applied sample panel and/or as agreed with the Contract Administrator.

Any areas of glass or window frames should be masked. Plants, grass, joint sealants, asphalt and bitumenpainted areas should be protected during application.

129


Fosroc® Dekguard Textured Limitations

The primer should be applied in one or more coats until the recommended application rate of 0.4 litre per square metre has been achieved. This is best accomplished by using portable spray equipment of the knapsack-type. Porous surfaces may require the application of Nitoprime DG as an alternative primer, or may require other special treatment. Nitoprime DG should be applied at the same coverage rate as Dekguard Primer but in continuous, multiple coats as necessary. If in doubt about the condition of the substrate, consult the local Fosroc office.

Where application over existing sound coatings or paints is required, trials should be conducted to ensure compatibility and retention of the bond between the underlying coating and the substrate. When applied over existing coatings or paints, the performance characteristics of Dekguard Textured may be impaired. Compatibility and soundness should be assessed on a trial area. For further advice, consult the local Fosroc office.

The primer should be allowed to dry for a minimum of 12 hours (at 20°C) longer at lower temperature, before application of Dekguard Textured. Under no circumstances should the primer be overcoated until the surface is properly dry.

The application of Dekguard Textured should not commence if the temperature of the substrate is below 5°C. Dekguard Textured should not be applied where there is a likelihood of exposure to frost within 48 hours of the application, or in windy conditions where early-age dust adhesion may occur, or where rain is likely within 2 hours at 20°C or 20 hours at 5°C (up to 80% RH). Dekguard Textured should not be applied when the prevailing relative humidity exceeds 90%.

All primed substrates should be treated with one coat of Dekguard Textured. Stir the material thoroughly before use. Apply to all areas by the use of suitable brushes or rollers to achieve a uniform coating with a wet film thickness not less than 500 microns. Achieve the desired texture with a suitable roller. Care must be taken to ensure that a uniform coverage rate is achieved. Nonuniform coverage may provide varying textures. Cleaning

Dekguard Textured should not be considered for areas subjected to exposure to ponded water. Use Dekguard S where occasional ponded water is anticipated.

Renderoc FC, Renderoc RP252 and Dekguard Textured should be removed from tools and equipment with clean water immediately after use. Dekguard Primer and Nitoprime DG should be removed from tools and equipment using Fosroc Solvent 12.

Where protection against the ingress of atmospheric acid gases is required, a single application of Dekguard S should be made in between the primer and application of the textured top coat. For further details on Dekguard S, refer to separate data sheet. The manufacture of Dekguard coatings is a batch process and despite close manufacturing tolerances variation may occur between batches. Fosroc recommends using material from one batch only as the finish topcoat.

Estimating Supply Renderoc FC:

25 kg bags

Renderoc RP252:

20 kg bags

Dekguard Primer

25 litre drums

Nitoprime DG:

25 litre drums

Storage

Dekguard Textured: 10 litre drums

Store in cool, dry conditions, away from sources of heat and naked flames, in the original, unopened packs. Material from different batches shall be stored separately. Dekguard Textured should be protected from frost.

Fosroc Solvent 102: 5 litre drums Coverage Renderoc FC:


Dekguard Textured has a shelf life of 12 months if kept in a dry store in the original, unopened container. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced.

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 to wastage factors and the variety and nature of possible substrates, practical coverage figures will be reduced.



Fosroc® Dekguard Textured Precautions Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Nitoprime DG: Dekguard Primer:

Flash Point 38 °C Flash Point 38 °C

Dekguard Textured : non-flammable

Dekguard is the trade mark of Fosroc International Limited


Fosroc Limited Coleshill Road, Tamworth, Staffordshire B78 3TL. UK

www.fosroc.com

telephone: +44 0 (1827) 262222

fax: +44 0 (1827) 262444

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Fosroc® Dekguard W


Water-based acrylic copolymer protective and decorative coating for concrete and masonry

When tested to BS 476, Pt 7:1987, it must exhibit a Class 1 spread of flame and achieve a Class 0 Building Regulations rating when tested to BS 476, Pt 6:1989 and Pt 7:1987.

Uses Properties To protect atmospherically exposed reinforced concrete structures, cementitious substrates and masonry from aggressive elements, weathering and rain. Dekguard W is suitable for use on all types of structures, including those in coastal environments. It is equally suitable for new and existing structures. Dekguard W is a component of Fosroc’s Renderoc system of concrete reinstatement.

The values obtained are for the Dekguard W system applied in two coats at the minimum recommended application rate.

Advantages Excellent barrier to carbon dioxide, chloride ions, oxygen and water Allows water vapour to escape from the structure High resistance to the effects of long-term weathering and durable in all climatic conditions Water-based Wide range of decorative colours

Standards compliance 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.

Volume solids Dekguard W:

41%

Carbon dioxide diffusion resistance (Taywood method). Equivalent thickness of air Initial: After 2000 hours QUV:

133 metres 91 metres

Equivalent thickness of 30 N/mm² concrete cover (Taywood method):

279 mm



Reduction in chloride ion penetration when primer is used (Aston University Diffusion Cell method):

> 84%

Fire testing (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 component pigmented coating, both ready for immediate site use.


A range of reactive primers are available to suit substrate porosity and site conditions and inhibit the passage of water and waterborne contaminants.

Preparation All surfaces should be dry and free from contamination such as oil, grease, loose particles, decayed matter, moss, algal growth, laitance and all traces of mould release oils and curing compounds. This is best achieved by lightly grit-blasting the surface. Where moss, algae or similar growths have occurred, treatment with a proprietary biocide should be carried out after the gritblasting process.

Specification clauses Protective/decorative surface coating The protective coating shall comprise a penetrating silane-siloxane primer and Dekguard W, a single component aliphatic acrylic coating. The total dry film thickness of the coating shall be not less than 150 microns and shall be capable of providing carbon dioxide diffusion resistance equivalent to not less than 279 mm of 30 N/mm2 concrete cover (by the Taywood method). It shall provide a reduction in chloride ion penetration not less than 84% (by the Aston University Diffusion Cell method) and no chloride ion diffusion after 600 days (by the Taywood method). It must exhibit a water vapour transmission resistance (SD) of not more than 0.066 metres (by the Taywood method) at a dry film thickness of 150 microns.

If Nitobond AR has been used as a curing membrane over Renderoc patch repairs, it is not necessary to remove this prior to the application of Dekguard W. Where application over existing sound coatings is required, trials should be conducted to ensure compatibility and retention of the bond between the underlying coating and the substrate. For further advice, consult the local Fosroc office.

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Fosroc® Dekguard W Semi protected surfaces

It is essential to produce an unbroken coating of Dekguard W. To ensure this is achieved, surfaces containing blow-holes or similar areas of pitting should first be filled using Renderoc FC, a cementitious fairing coat. Rougher substrates can be levelled using Renderoc RP252, a cementitious reprofiling and protection mortar. Separate data sheets must be referred to before commencing overcoating of Renderoc RP252 with Dekguard W.

For semi-protected surfaces, such as multi storey car park interiors, a reduced specification may be adopted whilst still achieving a carbon dioxide diffusion resistance of > 50m of air. Omit Dekguard Primer and apply two coats of Dekguard W at a wet film thickness of 140 microns per coat, diluting the first coat with 10% v/v water, to achieve a total dry film thickness of not less than 110 microns.

Application Cleaning

In order to obtain the protective properties of the Dekguard W system, it is important that the correct rates of application and overcoating times are observed.

Dekguard W should be removed from tools and equipment with clean water immediately after use.

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 Primer

Dekguard W

Number of coats:

Flood coat

2


0.4 litres/m2 0.18 litres/m2


N/A

Overcoating time @ 20°C: 12 hours

Limitations When applied over existing coatings or paints, the performance characteristics of Dekguard W may be impaired and its fire rating invalidated. For further advice, consult the local Fosroc office. The application of the primer should not commence if the temperature of the substrate is below 2°C. Application of Dekguard W should not commence if the temperature of the substrate is below 5°C.

180 microns

Dekguard W should not be applied where there is a likelihood of exposure to frost within 48 hours of the application. The product should not be applied in windy conditions where early-age dust adhesion may occur, or where rain is likely within 2 hours at 20°C or 20 hours at 5°C (up to 80% RH) or when the prevailing relative humidity exceeds 90%.

16 hours

Any areas of glass and window frames should be masked. Plants, grass, joint sealants, asphalt and bitumen-painted areas should be protected during application. The primer should be applied in one or more coats until the recommended application rate of 0.4 litre per square metre has been achieved. This is best accomplished by using portable spray equipment of the knapsack-type. Porous surfaces may require the application of Nitoprime DG as an alternative primer, or may require other special treatment. Nitoprime DG should be applied at the same coverage rate as Dekguard Primer but in continuous, multiple coats as necessary. If in doubt about the condition of the substrate, the local Fosroc office should be consulted.

Dekguard W should not be considered for areas subjected to exposure to ponded water. Dekguard S should be considered where occasional ponded water is anticipated. The manufacture of Dekguard coatings is a batch process and despite close manufacturing tolerances variation may occur between batches. Fosroc recommends using material from one batch only as the finish topcoat.

Estimating

All primed substrates should be treated with two coats of Dekguard W. Stir material before use. The first coat should be applied to achieve a uniform coating with a wet film thickness not less than 180 microns. This coat should be allowed to dry until firm to the touch. Typically, this will be after 16 hours in dry weather at 20°C.

Supply

Renderoc FC:

25kg bags

The second coat of Dekguard W should be applied as detailed above, again achieving a wet film thickness not less than 180 microns and a total dry film thickness not less than 150 microns.

Renderoc RP252:

20kg bags

Nitobond AR:


Fosroc Solvent 102:

5 litre drums


Dekguard W:

10 litre drums

Dekguard Primer:

25 litre drums

Nitoprime DG:

25 litre drums

5 CI/SfB: June 2008

Fosroc® Dekguard W Coverage

Precautions

Dekguard W: Dekguard Primer:

5.5 m2 per litre per coat 2.5 m2 per litre

Nitoprime DG:

2.5 m2 per litre


2

Renderoc FC:

15 litres (5 m at 3mm thickness)

Renderoc RP252:

12 litres (2.4 m2 at 5mm thickness)

Nitobond AR:

6 m2 per litre

Fire Dekguard W is non-flammable.


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

Storage

Flash points

Dekguard W has a shelf life of 12 months if kept in a dry store in the original, unopened packs. Material from different batches shall be stored separately. Store in cool, dry conditions, away from sources of heat and naked flames.

Dekguard Primer:

38°C

Nitoprime DG:

38°C

Fosroc Solvent 102: 33°C

If stored at high temperatures and/or high humidity conditions the shelf life may be reduced. Dekguard W should be protected from frost.




www.fosroc.com

telephone: +44 0 (1827) 262222

fax: +44 0 (1827) 262444

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®

Fosroc Nitocote EP403


Damp-tolerant, solvent free epoxy resin coating


Uses As a protective coating for concrete and mild steel. The cured film is corrosion, chemical and abrasion resistant and is suitable for application to sewage works, marine environments, basements and tunnels. It is particularly useful where concrete surfaces are damp and cannot be dried out.

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 and free from any traces of shuttering release oils and curing compounds.

Advantages High build application Can be applied directly to mild steel and concrete

Spalled surfaces, those containing large blow holes or surface imperfections should be repaired or rendered using a Fosroc approved repair mortar or render. Contact the local Fosroc office for further advice on suitable materials.

Smooth, glossy, easy to clean surface Corrosion, chemical and abrasion resistant Can be applied to damp surfaces Waterproof Provides protection against water vapour and ground gases such as radon, cabon dioxide and methane.

All surfaces should then be grit blasted to remove all foreign matter and open up all blow-holes, and provide a suitable key for Nitocote EP403.

Description

All blow-holes and imperfections should be filled with Nitomortar FC. Consult the data sheet for pot life and overcoating time.

Nitocote EP403 is a two pack, solvent free, epoxy resin material. It is supplied in pre-measured quantities ready for site mixing and use. The material cures to provide a smooth, tough and resistant finish. It is available in light grey.

Steel surfaces All surfaces should be grit blasted to meet the requirements of BS 7079 Sa2.5. The lining work should be programmed so that newly cleaned steel is coated as soon as possible before the formation of rust or scale.

Specification clauses Corrosion, chemical and abrasion resistant lining

Mixing

The chemical and abrasion resistant coating shall be Nitocote EP403, a solvent free epoxy, specifically designed for application to damp surfaces and to provide a tough, impermeable and resistant film.

Volume solids:

100%

The contents of the base can should be stirred thoroughly to disperse any settlement. The entire contents of the hardener can should be added to the base container and mixed thoroughly until a uniform consistency is obtained, taking particular care to scrape the sides and bottom of the container. It is recommended that mechanical mixing be employed, using a Jiffy mixer on a heavy duty, slow speed electric drill.

Viscosity:

Pourable, spreadable liquid

Application

Pot life — @ 20°C: @ 35°C:

30 to 40 minutes 10 to 15 minutes

Properties

The fully cured film is resistant to:

Distilled water Petrol Xylene 25% sulphuric acid Saturated sodium chloride 50% sodium hydroxide

The local Fosroc office should be consulted for resistance to specific chemicals, or operating temperatures greater than 20oC. 135

Number of coats:

2


0.2 litres per m2


200 microns

Overcoating times — @ 5°C: @ 20°C: @ 30°C:

18 to 48 hours 6 to 18 hours 3 to 9 hours

Fully cured — @ 5°C: @ 20°C: @ 30°C:

14 days 7 days 7 days


Fosroc® Nitocote EP403 The minimum application temperature is 5°C.

Although Nitocote EP403 may be applied to damp concrete, there must be no standing or running water.

All surfaces should be treated with two coats of Nitocote EP403.

Nitocote EP403 is not colour stable when exposed to direct sunlight nor when in contact with some chemicals. On curing Nitocote EP403, the final colour can vary with curing conditions, and in adverse conditions such as low temperature and/or high humidity, a white bloom may appear on the surface. However, this does not affect the performance of the coating.

The thoroughly mixed material should be applied with a suitable brush. The first coat must be firmly applied and be well scrubbed into the surface, ensuring a uniform coating with a wet film thickness not less than 200 microns. The first coat should be allowed to dry for not less than 6 hours and not more than 18 hours at 20°C.

Storage

The second coat should be applied exactly as above, again achieving a wet film thickness not less than 200 microns.

Store in dry conditions at temperatures between 5°C and 30°C in the original, unopened containers. Material from different batches shall be stored separately. Products have a shelf life of 12 months if kept in these conditions.

For cold weather working, it is recommended that Nitocote EP403 be stored in a heated building and removed immediately before use, as workability deteriorates and curing times increase at lower temperatures.

If stored at high temperatures the shelf life may be reduced.

Cleaning

Precautions

Nitocote EP403 should be removed from tools and equipment with Fosroc Solvent 102 immediately after use. Cured material can only be removed mechanically.

Health and safety

Estimating

Fire

Supply

Nitocote EP403 is non-flammable.


Nitocote EP403:

2.5 kg packs (1.5 litres)

Fosroc Solvent 102:

5 and 25 litre tins

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

3 m2 per kg per coat (5 m2 per litre)

Flash point

Coverage Nitocote EP403:

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

Fosroc Solvent 102:

33°C


Limitations Nitocote EP403 is formulated for application to clean, sound concrete and steel. Nitocote EP403 should not be applied over existing coatings. Application should not be undertaken if the temperature is below 5°C, or is 5°C and falling, nor when the prevailing relative humidity exceeds 90%.



telephone: +44 0 (1827) 262222

fax: +44 0 (1827) 262444

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6 CI/SfB: Pn6 May 2009

Fosroc® Nitocote EP405


Solvent-free epoxy resin coating for water retaining structures

All surfaces should then be grit blasted to remove all foreign matter and open up blow-holes and provide a suitable key for Nitocote EP405.

Uses

All blow holes and imperfections should be filled with Nitomortar FC. Consult the local data sheet for pot life and overcoating time.

For lining and waterproofing potable water retaining structures* and surfaces subject to contact with foodstuffs. The cured film is corrosion, chemical and abrasion resistant and is suitable for application to tanks, silos, reservoirs*, water treatment works*, breweries, dairies and meat and food processing plants. The cured film is non toxic and meets the requirements of BS 6920. (* See ‘Limitations’.)

Spalled surfaces, those containing large blow holes or surface imperfections should be repaired or rendered using a Fosroc approved repair mortar or render. Contact the local Fosroc office for further advice on suitable materials. Steel surfaces

Advantages

All surfaces should be grit blasted to meet the requirements of BS 7079 Sa2.5.. The lining work should be programmed so that newly cleaned steel is coated as soon as possible before the formation of rust or scale.

High build application Can be applied directly to mild steel and concrete Smooth, glossy, easy to clean surface Corrosion, chemical and abrasion resistant

Mixing

Can be applied to damp surfaces

Thoroughly stir the contents of the base can. Empty the entire contents of the hardener can into the base container and mix thoroughly until a uniform consistency is obtained, taking particular care to scrape the sides and bottom of the container. It is recommended that mechanical mixing be employed, using a Jiffy mixer on a heavy duty, slow speed electric drill.

Water Regulations Advisory Service - approved product

Description Nitocote EP405 is a two-part, solvent free, epoxy resin material. It is supplied in pre-measured quantities ready for site mixing and use and is available in blue and white.

Application

Standards compliance Nitocote EP405 meets the requirements of BS 6920, the Water Regulations Advisory Service, tests of effect on water quality.

Properties Volume solids:

100%

Viscosity:


Pot life — @ 20°C: @ 35°C:

30 to 40 minutes 10 to 15 minutes

The local Fosroc office should be consulted for resistance to specific chemicals.

Number of coats:

2


0.2 litres per m²


200 microns

Overcoating times — @ 5°C: @ 20°C: @ 30°C:


Fully cured *— @ 5°C: @ 20°C: @ 30°C:


* see Limitations


The minimum application temperature is 5°C.


All surfaces should be treated with two coats of Nitocote EP405. The thoroughly mixed material should be applied with a suitable stiff nylon type brush.

Preparation

The first coat must be firmly applied and be well scrubbed into the surface, ensuring a uniform coating with a wet film thickness not less than 200 microns. The first coat should

Concrete surfaces All surfaces must be smooth, sound and free from contamination and areas of standing water. Concrete surfaces must be fully cured, laitance free and free from any traces of shuttering release oils and curing compounds.

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6 CI/SfB: Pn6 May 2009

Fosroc® Nitocote EP405 be allowed to dry for not less than 6 hours and not more than 18 hours at 20°C.

requirements of BS 6920 the United Kingdom Water Regulations Advisery Scheme but not Regulation 31 of the Water Supply (Water Quality) Regulations 2000.

The second coat should be applied exactly as above, again achieving a wet film thickness not less than 200 microns.

In accordance with WRAS listing, when Nitocote EP405 is used in contact with potable water, curing conditions are 21 days at 7oC.

For ease of overcoating, it is recommended that the first coat be white and the second coat blue, or vice-versa.

Storage

For cold weather working, it is recommended that Nitocote EP405 be stored in a heated building and removed immediately before use, as workability deteriorates and curing times increase at lower temperatures.

All products have a shelf life of 12 months if kept in a dry store between 5°C and 30°C in the original, unopened containers. Material from different batches shall be stored separately.

Cleaning

If stored at high temperatures the shelf life may be reduced.


Precautions

Estimating

Health and safety

Nitocote EP405 is supplied in 2.5 kg packs (1.5 litres) each yielding 3 m² per kg per coat (5 m² per litre).

For further information refer to appropriate Product Safety Datasheet.

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

Disposal To eliminate risk of exotherm, only mix product when ready for use and then apply without delay. Any unused residue should be poured on to a disposable impervious surface to allow cure before disposal.

Limitations Nitocote EP405 should not be applied over existing coatings.

Fire

Application should not be undertaken if the temperature is below 5°C, or is 5°C and falling, nor when the prevailing relative humidity exceeds 90%.

For further information, refer to Product Safety Data Sheet.

Nitocote EP405 is non-flammable.

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

Although Nitocote EP405 may be applied to damp concrete, there must be no standing or running water. Nitocote EP405 is not colour stable when exposed to direct sunlight nor when in contact with some chemicals. On curing Nitocote EP405, the final colour can vary with curing conditions, and in adverse conditions such as low temperature and/or high humidity, a white bloom may appear on the surface. However, this does not affect the performance of the coating.

Flash point Fosroc Solvent 102:

33°C


* Before commencing application it is important to ensure that Nitocote EP405 meets all current compliance requirements. Note: Nitocote EP405 meets the

Nitocote is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

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Fosroc® Nitocote EP410 Highly chemical resistant two pack epoxy system Uses To provide protection to concrete and steel structures in aggressive chemical immersion conditions. The material is particularly suitable for applications in process plants and sewage works.

Advantages Excellent chemical resistance Excellent adhesion to concrete and steel Excellent abrasion resistance

Description Nitocote EP410 is a high build, solvent free, two pack epoxy formulation. It is supplied in pre-measured quantities ready for site mixing and use. Nitocote EP410 is designed to be applied in one coat to achieve a minimum total dry film thickness of 250 microns. When used in conjunction with glass fibre reinforcement to bridge fine cracks, it is applied in two coats to achieve a minimum total dry film thickness of 500 microns. Nitocote EP410 is designed to be used with Nitoprime 25 on concrete surfaces and Nitoprime 28 on mild steel. It is green in colour. The coating shall be appliec in accordance with the Fosroc data sheet.

Specification clauses The chemical resistant, solent free epoxy coating shall be Fosroc Nitocote EP410. It shall be applied in one coat at a dry film thickness of 250 microns or, where incorporating fibreglass reinforcsement, in 2 coats with a dry film thickness of 500 microns.


100%

Viscosity:


Pot life @ 20°C: Pot life @ 35°C:

90 minutes 35 minutes

Number of coats:

1


0.25 litres/0.36kg per m²


250 microns

Overcoating times @ 5°C: @ 20°C: @ 35°C:


Fully cured @ 5°C: @ 20°C: @ 35°C:



The minimum application temperature is 5°C. 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 of other chemicals, or at operating temperatures greater than 20°C.

Application instructions All coating work to be carried out in accordance with the relevant sections of BS6150:2006, Painting of Buildings Code of Practice. Preparation Concrete surfaces All surfaces must be dry, smooth, free from contamination and loose material. Concrete surfaces must be fully cured, laitance-free and free from any traces of shuttering release oils and curing compounds. All surfaces should be grit blasted to provide a suitable key and all blow holes and imperfections should be filled with Nitomortar FC. Spalled surfaces, those containing large blow holes or surface imperfections should be repaired or rendered using a Fosroc approved repair mortar or render. Contact the local Fosroc office for further advice on suitable materials. All surfaces should then be primed with Nitoprime 25. Mix in the proportions supplied and apply in a thin, continuous film. The primer should be touch dry but allowed to cure for no more than 24 hours at 20°C or no more than 18 hours at 35°C before the application of Nitocote EP410. Steel surfaces All surfaces should be prepared to meet the requirements of BS 7079, Sa2.5, abrasive blasting is recommended. The lining work should be programmed so that newly cleaned steel is primed before the formation of rust or scale. All surfaces should then be primed with Nitoprime 28. Mix in the proportions supplied and apply as a thin continuous film. The primer should be touch dry but allowed to cure for no more than 24 hours at 20°C or no more than 18 hours at 35°C before the application of Nitocote EP410. Mixing Thoroughly stir the contents of the base can, then the entire contents of the hardener can should be stirred and added to the base container and mixed thoroughly until a uniform colour and consistency are obtained, taking particular care to scrape the sides and bottom of the container. Mechanical mixing is recommended using a Jiffy mixer on a heavy duty, slow speed electric drill. In cold 139


Fosroc® Nitocote EP410 weather, materials should be stored between 15°C and 20°C for 24 hours before use.

Limitations Nitocote EP410 is formulated for application to clean, sound concrete and steel. It should not be applied over existing coatings. Application should not be undertaken if the temperature is below 5°C or is 5°C and falling, nor when the prevailing relative humidity exceeds 90%.

Application All primed surfaces should be treated with one coat of Nitocote EP410. The mixed material should be applied by a nylon brush and finally smoothed out with a steel trowel to achieve a uniform coating with a wet film thickness not less than 250 microns. Any movement joints in the structure should be expressed through the coating and sealed with an appropriate sealant.

Nitocote EP410 is not colour stable when exposed to direct sunlight, nor when in contact with some chemicals.

Storage Shelf life: Nitocote EP410 has a shelf life of 12 months if kept in a dry store between 5°C and 30°C in the original, unopened containers. Material from different batches shall be stored separately. Storage at higher temperatures may reduce shelf life.

Use of glass fibre reinforcement Nitocote EP410 may be used in conjunction with glass fibre cloth to increase thickness or, where necessary, bridge fine cracks in the substrate. The cloth should be laid directly on the first coat whilst wet and should be pressed in and smoothed out with a stiff nylon brush or split washer roller. A second coat should then be applied, allowing no more than 24 hours at 20°C and no more than 18 hours at 35°C between coats, and again achieving a wet film thickness not less than 250 microns.Suitable cloth is open weave 110 g/m² glass cloth.

Precautions Health and safety For further information refer to appropriate Product Safety Data Sheet. Disposal

Cleaning

To eliminate risk of exotherm, only mix product when ready for use and then apply without delay. Unused residue should be poured on to a disposable impervious surface to allow cure before disposal.


Fire

Estimating

Nitocote EP410 is non-flammable. Nitoprime 25, Nitoprime 28 and Fosroc Solvent 102 are flammable. Keep away from sources of ignition. In the event of fire, extinguish with CO2 or foam. Do not use a water jet.

Supply Nitocote EP410:

5.6kg packs

Nitoprime 25:

0.95kg ‘Handy’ packs 5kg ‘Industrial’ packs

Nitoprime 28:

0.45kg ‘Handy’ packs 4.2kg ‘Industrial’packs

Fosroc Solvent 102:

Flash points

5 and 25 litre tins

Coverage Nitocote EP410:

15.68m2/5.6kg pack 5m /0.95kg ‘Handy’ pack 26m2/5kg ‘Industrial’ pack

Nitoprime 28:

2.4m2/0.45kg ‘Handy’ pack 20m2/4.2kg ‘Industrial’pack

33 oC

Nitoprime 25:

55 oC

Nitoprime 28:

27 oC

For further information, consult the Product Safety Data Sheet.

2

Nitoprime 25:

Fosroc Solvent 102:



www.fosroc.com

telephone: +44 0 (1827) 262222

fax: +44 0 (1827) 262444

140



Fosroc® Nitocote SN502


Penetrating, hydrophobic silane-siloxane treatment for concrete and masonry


Uses

All surfaces should be dry and free from contamination such as oil, grease, loose particles, decayed matter, moss, algal growth, laitance and all traces of mould release oils and curing compounds. This is best achieved by lightly grit-blasting the surface. Where moss, algae or similar growths have occurred, treatment with a proprietary biocide should be carried out after the gritblasting process.

Preparation

To protect atmospherically exposed reinforced concrete structures from attack by chloride ions and water intrusion. The product is also suitable to protect other cementitious substrates and masonry. Nitocote SN502 is suitable for use on all types of structures, including those in coastal environments. It is equally suitable for new and existing structures.

Application

Advantages

In order to obtain the penetrating properties of Nitocote SN502, it is important that the correct rates of application and overcoating times are observed.

Penetrates into substrates Non-staining Reduces water and chloride intrusion

Number of coats:

2 flood coats

Minimises efflorescence


0.2 litres/m2

Allows water vapour to escape from the structure

Overcoating time:

2 hours @ 20°C

Increases freeze thaw resistance

Chemically resistant to ice melting compounds, fuels, oils and atmospheric contaminants

Nitocote SN502 should be applied in two flood coats until the recommended total application rate of 0.4 litre per square metre has been achieved. This is best accomplished by using portable spray equipment of the knapsack-type. If in doubt about the condition of the substrate, the local Fosroc office should be consulted.

Description Nitocote SN502 is a single component penetrating silanesiloxane system which penetrates into porous substrates and then reacts to produce a bonded hydrophobic lining to the pores. Although allowing passage of water vapour from the substrate it significantly reduces the absorption of water and water borne salts.

Nitocote SN502 should be allowed to dry for a minimum of 2 hours (at 20°C) before continuing. Cleaning

Nitocote SN502 does not discolour most substrates and has excellent resistance to weathering.

Nitocote SN502 should be removed from tools and equipment using Fosroc Solvent 102 immediately after use.

Specification clauses Silane-siloxane penetrating treatment

Limitations

The penetrating treatment shall be a silane-siloxane system with a reduction in chloride ion penetration not less than 92% and a reduction in water absorption of not less than 85% when tested to the NCHRP 244 standard.

Nitocote SN502 should not be contaminated with water. The application of Nitocote SN502 should not commence if the temperature of the substrate is below 2°C.

Properties

Nitocote SN502 may darken some polymer modified substrates and white cement. A trial area is recommended.

The values obtained are for Nitocote SN502 applied at the minimum recommended application rate.

Estimating Supply

Reduction in chloride ion penetration — To NCHRP 244 Standard: Australian C.T.I. method:

92% 98%

Reduction in water absorption — To NCHRP 244 Standard: Australian C.T.I. method:

85% 94%

Nitocote SN502:

25 and 200 litre containers

Fosroc Solvent 102:

5 and 25 litre tins

Coverage and yield Nitocote SN502:

141

5 m2 per litre per coat


Fosroc® Nitocote SN502 Storage Store in cool, dry conditions, away from sources of heat and naked flames, in the original, unopened containers. Nitocote SN502 has a shelf life of 12 months if kept in a dry store in the original, unopened containers. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced.

Precautions Health and safety For further information refer to appropriate Product dafety Data Sheet. Fire Nitocote SN502 and Fosroc Solvent 102 are flammable. Do not expose to naked flames or other sources of ignition. No Smoking. Containers should be tightly sealed when not in use. In the event of fire, extinguish with CO2 or foam. Flash point Nitocote SN502:

38°C

Fosroc Solvent 102:

33 oC

Nitocote is the trademark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

142


7 CI/SfB: January 2006

®

Fosroc Nitocote SN511


Monomeric silane water repellant penetrant

Application In order to obtain the penetrating properties of Nitocote SN511, it is important that the correct rates of application and overcoating times are observed.

Uses A penetrating treatment designed to protect concrete from both water and chloride ingress whilst still permitting water vapour transmission (breatheability).

Advantages Markedly reduces water and chloride ingress

Number of coats:

2 flood coats


0.3 litres/m²


Minimum 6 hours

Nitocote SN511 should be applied by a continuously circulating pumped system at a nozzle pressure of 0.06 to 0.07 N/mm² (8 to 10 lbf/in²). Nitocote SN511 should be applied evenly by saturation flooding using a wet spray without misting, working from the bottom up. Two applications shall be made, each at a minimum rate of 300 ml/m². The interval between applications shall be a minimum of 6 hours (at 20°C) before continuing.

Deep penetration into substrates Non-staining Increases freeze thaw resistance Minimises efflorescence Chemically resistant to de-icing compounds and atmospheric contaminants

Surfaces should be protected from rain and spray during application and for at least 6 hours after completion.

Description Nitocote SN511 has a 95% active content of monomeric alkyl (isobutyl) trialkoxy silane which penetrates deeply into porous substrates and then reacts to produce a bonded hydrophobic lining to the pores.

Cleaning Equipment should be cleaned with Fosroc Solvent 102 immediately after use. Any spillages should be absorbed with sand or sawdust etc., and disposed of in accordance with local regulations.

This treatment markedly reduces absorption of water and water-borne salts, but still permits passage of water vapour.

Estimating

The treatment is not affected by UV light and does not produce any discolouration of the substrate.

Packaging

Standards compliance Conforms to DTp Specification BD43/03 and BD43/90 and BA33/90.

Nitocote SN511:

25 litre container

Fosroc Solvent 102:

5 and 25 litre tins

Coverage and yield Nitocote SN511:

Properties

0.3 litres/m² per coat (minimum)

Specific gravity:

Approximately 0.9

Limitations

Purity:

Minimum 95%

Refractive index

1.396 +/- 0.004

The application of Nitocote SN511 should not commence if temperatures are below 5°C and falling or if the concrete surface temperature is above 25°C.


Nitocote SN511 hydrolises with atmospheric moisture. Material from opened containers should be used within 48 hours or discarded.

Preparation Surfaces should be dry and free from contamination such as oil, grease, loose particles, decayed matter, moss or algal growth, laitance and traces of mould oils and curing compounds, or other mechanical means.

There is a possibility of colour change on some types of polymer modified facing materials and white cement. A trial area is recommended.

Protect plants, glass, asphalt, bitumen, plastics and all painted surfaces prior to application.

143

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CI/SfB: January 2006

Storage Shelf life 12 months when stored in original unopened containers. Storage conditions Nitocote SN511 and Fosroc Solvent 102 should be stored in a cool dry place away from sources of heat or naked flames.

Precautions Health and safety For further information refer to appropriate Product Safety Data Sheet. Overspray Precautions must be taken to control overspray when working adjacent to vehicular roadways, pedestrian walkways and water courses. Fire Nitocote SN511 and Fosroc Solvent 102 are flammable. Do not expose to naked flames or other sources of ignition. No Smoking. Containers should be tightly sealed when not in use. In the event of fire, extinguish with CO2 or foam. Flash points Nitocote SN511:

39°C

Fosroc Solvent 102:

33°C

(Abel closed cup method IP33)

Nitocote is the trademark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

144


8 CI/SfB: Vu1 October 2005

Fosroc® Galvafroid


Zinc rich cold galvanising coating

contents are stirred periodically during application to avoid settlement.

Uses Galvafroid is supplied at the correct consistency for direct application from the tin but, should it be found necessary to thin, only Fosroc Thinner/Cleaner should be added, at a rate not exceeding 1 litre of thinners to 8 litres of Galvafroid.

To provide a galvanic protection on iron and steel. It can be used as a self-finish or as a durable rust inhibiting primer beneath selected top coats. It is recommended for the protection of structural steelwork, agricultural and construction plant and machinery, gates, railings, iron pipework and guttering, and the rust prevention of in-situ welding work.

Application In order to obtain the protective properties of Galvafroid, it is 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 more coats of Galvafroid. The material should be liberally applied without any attempt to brush or roll out. The required thickness of coating may be built up by successive applications of Galvafroid when the previous coat is completely dry.

Advantages Protects ferrous metals against rust Suitable as a primer or self-finish Easily applied by brush or roller

Description Galvafroid zinc rich coating is formulated as an easily applied, cold galvanising protection against corrosion on all ferrous metals. Galvafroid has a mid-grey, matt finish.

Overcoating Where required, Galvafroid may be painted to improve durability or to enhance appearance. The Galvafroid coating should not be rubbed down to obtain a smooth surface for finishing paints, but it should be given a generous coat of a suitable filling primer and this, when thoroughly dry, should be sanded to a smooth surface.


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: hard dry: recoating time:

For general purposes, a good oil bound or alkyd paint should be used. Where the work is subject to corrosive and marine conditions, however, a non-saponifiable finishing paint should be used, i.e. Chlorinated rubber paint. It is advisable to allow the Galvafroid coating to weather for at least 3 days before applying the finishing coat. Cellulose and bituminous paints are not generally suitable for over-painting Galvafroid.

2 hours 24 hours 24 hours minimum

Specification clause The anti-corrosive primer shall be Galvafroid, a zinc rich material specifically designed to provide a rust inhibiting protection to ferrous metalwork.

Cleaning


Estimating

Galvafroid should be removed from tools and equipment with Fosroc Thinner/Cleaner immediately after use. Dried material can only be removed mechanically.

Supply

Preparation All ferrous surfaces must be clean and free from oil, grease, mill scale, rust and existing coatings. This is best achieved by grit blasting, although thorough wire brushing can be sufficient. Some rust removers based on phosphoric acid tend to leave an electrically insulating film on ferrous metals and must not be used.

Galvafroid:

Pack of 6 x 400 ml tins Pack of 4 x 800 ml tins 1.9 litre tin

Fosroc Thinner/Cleaner:

0.5 litre tins

Coverage Galvafroid:

Mixing Galvafroid must be thoroughly stirred to give a uniform product prior to application. It is recommended that the 145

16 m2/litre when used as a primer 8 m2/litre when used as a self-finish

8 CI/SfB: Vu1 October 2005

Fosroc® Galvafroid Limitations

Precautions

Galvafroid is formulated for application to clean ferrous substrates and should not be used on rusty, corroded surfaces.


Galvafroid should not be applied over existing coatings. Galvafroid should not be used on surfaces in contact with drinking water.

Fire

Galvafroid should not be used on surfaces exposed to soft water at temperatures above 60°C.

Galvafroid and Fosroc Thinner/Cleaner are flammable. Keep away from sources of ignition. No smoking. In the event of fire, extinguish with CO2 or foam. Do not use a water jet.

Galvafroid should not be used on surfaces treated with phosphoric acid based rust removers.

Flash points

Galvafroid should not be overcoated with materials containing strong solvents such as chlorinated and aromatic hydrocarbons, esters and ethers.

Galvafroid:

41°C

Fosroc Thinner/Cleaner:

41°C


Storage Galvafroid has a shelf life of 12 months if kept in a dry store between 5°C and 20°C in the original, unopened container.

Galvafroid is a trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

146


10 CI/SfB: (18) (43) q2(D6) Jun 2008

Cemtop


Polymer modified, cement based, floor levelling compounds

Specification clauses Floor areas so designated should be covered with the Cemtop product as manufactured by Fosroc. The product should be applied in accordance with the manufacturer’s application instructions.

Uses The Cemtop range of products includes the following: Cemtop S: A self-smoothing underlayment for a wide variety of floor finishes, e.g. tiles, carpets and vinyl sheeting. Suitable for residential and commercial buildings, for new construction or refurbishment projects.

Properties See ‘Physical properties’ table on the third page of this datasheet.

Cemtop GP30: A general purpose floor levelling compound/underlayment for the preparation of floor surfaces before the application of tiles, carpet, vinyl, etc.

Application instructions Although the products have been designed for application by pump, they can also be applied by hand.

Cemtop GP12: A medium duty floor surfacing system suitable for use in areas which will be subject to foot traffic or light commercial use. Also suitable for use as a heavy duty underlayment for the preparation of floor surfaces before the application of tiles, carpet, vinyl, etc.

Installation by pump This is a specialist activity and the product must be applied by a Fosroc recommended contractor who has been fully trained in the use of the product using suitable equipment.

Cemtop XD: A heavy duty, highly abrasion resistant floor surfacing system for the reinstatement of industrial floor surfaces.

Installation by hand

See also ‘Uses’ table on page 3.

Typically, in areas of less than 100 m² it will be more practical to install Cemtop by hand.

Advantages

Surface preparation

Very fast application, enables large areas of floor to be completed in a working day

it is essential that both new and old concrete floors are correctly prepared prior to the appplication of Cemtop.

Can be applied directly onto concrete floors, eliminates traditional sand-cement screeds

New concrete floors should have been placed for at least 21 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 compound residues, loose or foreign material and laitence. Laitence should be removed by light scabbling or blasting followed by washing and vacuuming to remove dust debris. Light oil and grease staining can be removed with proprietary chemical degreaser, followed by washing with clean water.

Dimensionally stable, can be installed in large areas Rapid hardening and curing allows speedy access for foot traffic and overlaying with carpets, tiles, etc., where appropriate One-pack product eliminates on-site batching and ensures consistency of mixed product

Description Cemtop products consist of a blend of selected cements and aggregates modified with polymers and flow agents. The products are used in conjunction with Nitoprime 33.

In old concrete where deep seated contamination has occurred, mechanical methods such as blasting, grinding and scabbling should be used to provide a suitable clean surface.

The products are supplied as a grey powder which requires only the addition of water to produce self smoothing, free flowing material.

For recommendations or additional information regarding substrate preparation, please contact Fosroc. Application procedure


Thoroughly prepare the floor surface as above.

Cemtop products comply with the requirements for a Class O surface, as defined in paragraph A8 (b) of Approved Document B, ‘Fire’, to the Building Regulations 1985.

Prime the surface with Nitoprime 33 (1: 5 primer to water ratio by volume) and allow to dry. Re-prime the surface with Nitoprime 33 (1: 3 primer to water ratio by volume) and allow to dry.

BS 476, Part 6: 1989. ‘Method of Test for Fire Propagation for Products’ — Fire Propagation Index, I = 0.0.

Apply Cemtop to the required thickness onto the dry, primed surface.

BS 476, Part 7: 1987. ‘Surface Spread of Flame Test for Materials’ — Class 1 Surface Spread of Flame. 147

Page 1

10 CI/SfB: (18) (43) q2(D6) Jun 2008

Cemtop again prior to the application of Cemtop XD or Cemtop GP12 (both at 1: 3 primer to water ratio by volume).

Priming The objective of priming is to seal the substrate to prevent release of air from the substrate.

Limitations

Mixing

Concrete slabs onto which the Cemtop is to be applied must have a surface temperature of at least +5°C with air temperature maintained at +10°C or more during application. For temperatures in excess of 25°C during application refer to Fosroc Customer Services Department.

Mix 25 kg of Cemtop with the required amount of clean water (see ‘Estimating’ table on page 3). A typical batch would be 2 x 25 kg bags of the product. Pour the water into a clean mixing vessel. Add the powder slowly to the water, mixing continuously with a heavy duty drill and purpose-made paddle. Mixing should continue for at least 3 minutes until a smooth and creamy consistency is obtained.

Protect from freezing for 48 hours after placement. To prevent rapid drying protect from direct sunlight and/or drying winds during application and the initial curing period.

Ensure that sufficient labour is available to enable continuous mixing and pouring.

If the substrate onto which Cemtop is applied moves or cracks, reflective cracking may occur.

Place the Cemtop within 2 minutes of completion of mixing.

Cemtop should not be applied to asphalt substrates.

Pour the mixed material on to the dry primed surface, spread with trowel and allow to level.

Cemtop should not be applied to external surfaces or surfaces subject to wetting.

Roll surface with a spiked roller to aid air release and levelling properties. Do not over-roll.

Estimating

To reduce the formation of seam lines, freshly mixed Cemtop should be placed within 5 minutes of the previous adjacent batch being laid.

See ‘Estimating’ table overleaf.

Note: If the mix stiffens it should be discarded, do not attempt to re-mix with water.

Dual layer — Cemtop XD, Cemtop GP12 and Cemtop GP30 Thoroughly prepare the floor surface. Prime the surface with Nitoprime 33 (1: 5 primer to water ratio by volume) and allow to dry. Re-prime the surface with Nitoprime 33 (1: 3 primer to water 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 stiff bristle broom to provide a mechanical key for the next layer. 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 Cemtop GP30. If Cemtop XD or Cemtop GP12 is not applied the same day as Cemtop GP30 then the hardened Cemtop GP30 should be primed on the day of application and primed


Page 2

10 CI/SfB: (18) (43) q2(D6) Jun 2008

Cemtop Uses Cemtop S

Cemtop GP30

Cemtop GP12

Cemtop XD

General-purpose underlayment before decorative 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 FC130 and then Nitoflor FC140:

—

—

Physical properties Cemtop S

Cemtop GP30

Cemtop GP12

Cemtop XD

Compressive strength at 28 days (40 mm cubes cured at 20°C, 65% RH):

20 N/mm²

20 N/mm²

25 N/mm²

30 N/mm²

Flexural strength at 28 days (rectangular prisms cured at 20°C, 65% RH):

4.5 N/mm²

4.5 N/mm²

7.0 N/mm²

8.0 N/mm²

C + CA accelerated wear tests at 28 days* — Category:

—

—

Normal

Good

BRE impact resistance at 28 days (BS 8204, Part 1: 1987) — Category:

A†

A†

A†

A†

TRRL slip resistance test — 4S rubber slider:

N/A

N/A

TRRL rubber slider:

N/A

Dry: excellent Wet: satisfactory Dry: excellent Wet: satisfactory

Dry: excellent Wet: satisfactory Dry: excellent Wet: satisfactory

4 hours 24 hours —


Traffic time at 20°C — Foot traffic: Light traffic: Heavy traffic:


* Refer to Concrete Society Technical Report No. 34.

†

N/A

4 hours 36 hours 7 days

Category A is the highest rating.

Estimating Application thickness: Application method: Theoretical coverage: Supply:

Cemtop S

Cemtop GP30

Cemtop GP12

Cemtop XD

Featheredge to 10 mm

5 to 30 mm

6 to 12 mm*

6 to 12 mm*

Pump/hand

Pump/hand

Pump/hand

Pump/hand

1.7 kg/mm/m²

1.7 kg/mm/m²

1.7 kg/mm/m²

1.7 kg/mm/m²

25 kg bags

25 kg bags

25 kg bags

25 kg bags

5.0 litres

4.0 litres

4.5 litres

4.5 litres

Water addition per 25 kg bag: * Can be taken down to a chamfered edge. Nitoprime 33:

Supply:

5 m²/litre of concentrate per 2 priming coats 4 m²/litre of concentrate per 3 priming coats 3 m²/litre of concentrate per 4 priming coats 25 litre containers


Page 3

10 CI/SfB: (18) (43) q2(D6) Jun 2008

Cemtop Storage

Nitoflor FC140

Store in unopened bags in cool dry internal conditions.

If additional chemical resistance is required, Nitoflor FC140 can be applied over a single coat of Nitoflor FC130.

The product has a shelf life of 6 months from the date of manufacture if kept in a dry storage in the original, unopened bags. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced to less than 3 months.

It is recommended that Fosroc’s technical department should be consulted prior to the installation of a combined product system such as the systems described in this data sheet.

Nitoprime 33 has a shelf life of 12 months if stored at 20°C. Protect from frost and extreme heat.

Precautions Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Cemtop products and Nitoprime 33 are non-flammable.

Additional information Joints Expansion joints in the existing substrate must be continued through the Cemtop products and filled to the required level with Expoflex 800 or Nitoseal MS300. The Cemtop system can be laid over construction joints or day joints. 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 protect Cemtop GP12 and Cemtop XD with an epoxy floor coating such as Nitoflor FC130 or Nitoflor FC140. Nitoflor FC130 Being water vapour permeable, this product can be applied to Cemtop GP12 or Cemtop XD. The first coat must be applied within 6 hours of the Cemtop being laid. Nitoflor FC130 provides a chemical resistant pigmented sealing coat which is dustproof, easily cleaned and resistant to penetration of oils and liquids. Two coats are required. See data sheet for details.

Cemtop is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444 150 Page 4


9 CI/SfB: (43) Pr4 June 2008

®

Fosroc Nitoflor FC130 & FC140


High performance epoxy resin floor coatings

Standards compliance Nitoflor FC140 has been tested according to BS 4247, Part 1 — Nuclear Decontamination parts A and B. In both instances a ‘good’ classification was obtained.

Uses Nitoflor FC130

Nitoflor FC130 and Nitoflor FC140 comply with BS 476, Part 7 : 1971 — Class 1 spread of flame.

To provide a dust-proof easily cleaned surface which is resistant to most oils and liquids. It is suitable for use on walls and floors in warehouses, garages, light industrial and food processing areas, kitchens and other areas of pedestrian and light vehicular traffic.

Properties The values given below are average figures achieved in laboratory tests at 20°C and 35°C. Actual values obtained on site may show minor variations from those quoted.

Nitoflor FC140 To provide a hard wearing, easily cleaned, attractive floor coating in industrial areas where high resistance to chemical attack is required. It is suitable for use in production assembly areas, workshops, dairies, soft drinks production and bottling plants, breweries, kitchens, showrooms, etc. It is particularly suitable in wet working areas and where chemical spillage is likely, e.g. plating shops, processing plants, dye works, etc.

Physical properties Nitoflor FC130

@ 20°C

@ 35°C

Pot life*:

2 hours

1 hour

Time between coats: hours

6 to 24 hours 4 to 16

Initial hardness:

24 hours

16 hours

Nitoflor FC130 and Nitoflor FC140 can also be used as a coating and sealer for Cemtop industrial and commercial cementitious flooring systems. Refer to Cemtop data sheet for details.

Full cure:

7 days

7 days

Nitoflor FC140

@ 20°C

@ 35°C

Advantages

Pot life*:

4 hours

1.5 hours

Hard wearing — durable, low maintenance costs

Tack-free time:

4 to 6 hours

2 to 4 hours

High resistance to a wide range of industrial chemicals

Time between coats: hours

6 to 24 hours

4 to 16

Hygienic — impervious finish provides easily cleaned surface

Initial hardness:

24 hours

18 hours

Full cure:

7 days

5 days

Attractive — available in a range of colours to improve the working environment

Dry film thickness (2 coats): 100 microns (approximate)

Dry film thickness (2 coats): 100 microns (approximate)

* Note that after the pot life has expired, the material, although not hardened, increases in viscosity and the characteristics of the product change. Excess material should be discarded after this point.

Description Nitoflor FC130 Nitoflor FC130 is a two-component water dispersed epoxy resin coating system supplied in pre-weighed packs ready for on-site mixing and use. The cured film forms a hard, flexible, semi-matt seal to concrete and other substrates.

Chemical properties Nitoflor FC130 and Nitoflor FC140 are resistant to a wide range of chemicals. Specific data is available on request. Good housekeeping is essential in areas where chemical spillage is likely to occur. It is especially important that such spillage should not be allowed to dry since very much higher concentrations of chemicals will then result.

Nitoflor FC140 Nitoflor FC140 is a two-component solvent based, epoxy resin coating system supplied in pre-weighed packs ready for on-site mixing and use. The cured film forms a hard but flexible coating with excellent adhesion to clean concrete, sand/cement and granolithic screeds, and certain metal surfaces. It cures to a semi-gloss, impervious finish which is easily cleaned.

Application instructions All coating work to be carried out in accordance with the relevant sections of BS6150:2006, Painting of Buildings Code of Practice. Surface preparation

Nitoflor FC130 and Nitoflor FC140 are available in a range of standard colours and are also available in a clear grade.

It is essential that Nitoflor FC130 and Nitoflor FC140 are applied to sound, clean, dry substrates in order to achieve 151

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Fosroc Nitoflor FC130 & FC140

Good drying conditions are required to allow complete evaporation of the water as the resin cures. Adequate ventilation and air movement is necessary.

maximum adhesion between the floor coating and substrate. Because Nitoflor FC130 and Nitoflor FC140 are relatively thin coatings, the substrate must be fine textured. Any surface irregularities may show through causing excessive wear on high spots and changing the perceived colour of the coating.

Use with Cemtop XD Nitoflor FC130 can be used to overcoat Cemtop XD to provide a more easily cleaned, chemically resistant surface. Apply two coats of Nitoflor FC130 as described, the first of which must be applied within 6 hours after the installation of Cemtop XD.

New concrete floors Unless specially water-reduced, the floor should be at least 28 days old and give a hygrometer reading not exceeding 80% RH for Nitoflor FC 130 or 75% RH for Nitoflor FC140 when tested in accordance with BS 8203 Appendix A. Dry removal of laitance by light grit-blasting is preferable but, where this is not feasible, treat with Fosroc Acid Etch, followed by thorough rinsing with water and complete drying. Dust and other debris should then be removed by vacuum brush.

Anti-slip finish A fine textured anti-slip finish for either Nitoflor FC130 or Nitoflor FC140 may be achieved by the addition of one 0.9 kg sachet of Nitoflor FC Anti-slip Grains stirred in towards the end of the mixing process. (Note: This will reduce overall coverag e rate.) Cleaning

Old concrete floors

Nitoflor FC130 should be removed from tools and equipment with clean water immediately after use.

A sound, clean substrate is essential to achieve maximum adhesion. Light grit-blasting or acid etching should be carried out as for new concrete floors. Oil and grease penetration should be removed using a water miscible chemical cleaner.

Nitoflor FC140 should be removed from tools and equipment with Fosroc Solvent 102 immediately after use. Hardened material can only be removed mechanically. Maintenance

When using Nitoflor FC140 on very porous surfaces or surfaces which are damp prime with a single coat of Nitoprime 25.

The service life of a floor can be considerably extended by good housekeeping practices. Regular cleaning of Nitoflor FC130 and Nitoflor FC140 may be carried out using a rotary scrubbing machine with a water miscible cleaning agent or by hot water washing at temperatures up to 50oC.

Asphalt floors Nitoflor FC130 can be applied to asphalt floors provided they are at least 6 months old. Nitoflor FC140 should not be applied to asphalt floors, PVC tiles or sheet.

Estimating

Mixing

Supply

The individual components of the Nitoflor FC coatings should be thoroughly stirred before the two are mixed together. The entire contents of the small container should be poured into the large container and the two materials mixed thoroughly for at least 3 minutes. The use of a heavy-duty slow speed, flameproof or air driven drill fitted with a mixing paddle is desirable.

Nitoflor FC130:

5 kg packs

Nitoflor FC140:

5 kg packs

Nitoprime 25:

5 kg packs

Fosroc Solvent 102:

5 and 25 litre tins

Nitoflor anti-slip grains:

0.9 kg

Coating

Coverage

The mixed Nitoflor FC130 and Nitoflor FC140 should be applied to the prepared surface using a brush or lambswool roller. Ensure that the area is completely coated and that ‘ponding’ of the material does not occur.

Nitoflor FC130 and FC140:

35 to 40 m²/pack (per coat)

Nitoflor FC130 and FC140 with Anti-slip Grains:

24 to 30 m²/pack (per coat)

Nitoprime 25:

25 m²/pack

The second coat may be applied as soon as the first coat has initially dried (typically 12 to 18 hours). The time will be dependent on the type of surface and the ambient conditions.



9 CI/SfB: (43) Pr4 June 2008

Fosroc® Nitoflor FC130 & FC140 Limitations

Precautions

Nitoflor coatings should not be applied onto surfaces known to or are likely to suffer from rising damp or have a relative humidity greater than 80% (Nitoflor FC130) or 75% (Nitoflor FC140) as measured in accordance with BS 8203 Appendix A or by a Vaisala thermohygrometer type HMI 31.

Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Nitoflor FC130 is non-flammable.

The durability of Nitoflor coatings in foot traffic areas is reduced in areas of very heavy traffic such as around work benches, drinks machines, etc. It is advisable to specify additional coats in such areas.

Nitoflor FC140 is flammable. Keep away from sources of ignition. No Smoking. In the event of fire, extinguish with CO2 or foam. Do not use a water jet.

The low odour characteristics of Nitoflor FC130 is not necessarily an indication of non-tainting characteristics. Where tainting of foodstuffs during application is possible we recommend separate tests are carried out in this instance, please contact the local Fosroc office.

Flash points

Nitoflor FC130 should not be applied at temperatures below 10°C or where ambient relative humidity exceeds 85%.

Disposal

Nitoflor FC140:

23°C

Fosroc Solvent 102

33°C

Spillages of component products should be absorbed onto earth, sand or other inert material and transferred to a suitable vessel. Disposal of such spillages or empty packaging should be in accordance with local waste disposal authority regulations.

Nitoflor FC140 should not be installed at temperatures below 5°C. The manufacture of Nitoflor FC130 and FC140 coatings is a batch process and despite close manufacturing tolerances variation may occur between batches. Fosroc recommends using mateiral from one batch only as the finish topcoat.


Storage Nitoflor FC130 should be stored in dry conditions between 10°C and 30°C, away from sources of heat and naked flames in the original, unopened packs. Material from different batches shall be stored separately. Nitoflor FC130 and Nitoflor FC140 have a shelf life of 12 months if kept in the above conditions. If stored at high temperatures the shelf life may be reduced. Nitoflor FC130 should be protected from frost.

Nitoflor is the trademark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

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9 CI/SfB: (13) pq4 January 2009

®

Fosroc Nitoflor Hardtop S


‘Dry shake’ floor hardener for new concrete floors

Properties Abrasion resistance

Uses Nitoflor Hardtop S provides a highly abrasion resistant surface to fresh concrete floors by the ‘dry shake’ method which ensures that the hard wearing surface bonds monolithically to the base concrete. It is ideally suited for all industrial areas subjected to heavy traffic, e.g. power stations, heavy industry, agricultural buildings, warehouse floors, loading bays and workshops.

Nitoflor Hardtop S application rate per m2 concrete

First app. Kg/m2

Second app. Kg/m2

3Kg

2

1

ARI

5Kg

3

2

Special

BS8204 classification

Average wear of 0.02mm for special class. 20 time increase on 40N/mm2 concrete ( concrete society technical report no.34, 2nd edition)

Advantages

Hardness (Mohs scale)

Supplied ready to use — no additives required

The selected aggregates contained within Nitoflor Hardtop S have a hardness value of 7 on the Mohs original scale.

Provides a hard, abrasion resistant surface Forms monolithic bond with fresh concrete base Non-metallic aggregate — will not rust when wet Non dusting


Anti-slip

Nitoflor Hardtop S should be applied at an even application rate. It is recommended that the floor be marked off into bays of known area. Sufficient materials should then be laid out to meet the recommended spread rate.

Description Nitoflor Hardtop S surface hardening compound is a quality controlled, factory blended powder which is ready to use on site. It consists of special hard wearing aggregates selected for their physical properties of abrasion and wear resistance, Portland cement and special additives to improve workability. This combination produces a material which is easy to trowel into the surface of fresh, wet concrete. Nitoflor Hardtop S cures to provide a dense, non porous surface which is extremely hard wearing and abrasion resistant. Monolithic cure ensures that problems normally associated with thin (‘granolithic’) screeds, e.g. curling, shrinkage, cracking, etc. are completely overcome.

Base concrete The base concrete should have a minimum cement content of 300 kg/m3. The concrete mix should be designed to minimise segregation and control bleeding, although some limited bleed is desirable to ensure sufficient moisture is available to wet out the Nitoflor Hardtop S when it is first applied. The use of water reducing admixtures from the Fosroc Structuro or Conplast range is strongly recommended in order to achieve a water:cement ratio below 0.55. The base concrete should have an on-site slump of between 75 and 100 mm.

Nitoflor Hardtop S is available in natural (concrete grey) colour as standard.

The base concrete should be laid and compacted in accordance with good concrete practice, taking care to ensure accurate finished profile and minimum laitance build-up. Particular attention should be paid to bay edges and corners to ensure full compaction of the base concrete — see application instructions.

Specification clauses Floors shall be surfaced where shown with Nitoflor Hardtop S, a ‘dry shake’ floor hardener containing non-metallic, rust-free aggregates. The compound shall have the ability to improve the abrasion resistance of concrete by 225%.

Vacuum dewatering is not recommended. Application of Nitoflor Hardtop S should begin without delay when the base concrete has stiffened to the point when light foot traffic leaves an imprint of about 3 to 6 mm. Any bleed water should now have evaporated, but the concrete should have a wet sheen.

Nitoflor Hardtop S powder shall be applied to the freshlylaid concrete floor by the ‘dry shake’ method. It shall be applied at the point where light foot traffic leaves an imprint of about 3 to 6 mm. The powder shall be applied in two stages, in full accordance with the manufacturer’s instructions. Special attention shall be paid to bay edges in accordance with the manufacturer’s written requirements.

On large floors it will be necessary to work progressively behind the laying team to ensure application at the correct time.

154


Fosroc® Nitoflor Hardtop S Nitoflor Hardtop S is applied in two stages.

Cleaning

(a) The first application (see table) is broadcast at an even rate onto the concrete surface. When the material becomes uniformly dark by the absorption of moisture from the base concrete, this first application can be floated. Wooden floats or, on large areas, a power float disc may be used. It is important, however, that the surface is not overworked.

All equipment should be washed with clean water immediately after use and before the material has hardened. Curing Proper curing of concrete floors treated with Nitoflor Hardtop S is essential to the physical properties of the finished floor. The most effective method of curing is to use Concure WB which should be applied on to the finished floor 10 minutes after the power floating operation has been completed.

(b) Immediately after floating, the second application of Nitoflor Hardtop S is applied evenly over the surface at right angles to the first. Again, when moisture has been absorbed the surface can be floated in the same way as before. Final finishing of the floor using the blades of a power float can be carried out when the floor has stiffened sufficiently so that damage will not be caused.

The use of polythene sheeting, wet hessian and damp sand or ponding are not recommended. The use of salt water or brackish water should not be considered under any circumstances.

Bay edges

Surface treatments

Where bay edges are likely to suffer particularly heavy wear or impact and where saw-cut transverse control joints are to be located, it is desirable to give these areas additional protection, by one of the following methods prior to full treatment of the entire surface:

Subsequent surface treatments are not normally necessary with Nitoflor Hardtop S because of the high density, low porosity finish.

(a) Immediately after levelling the freshly placed concrete, Nitoflor Hardtop S should be sprinkled by hand at a rate of 0.5 kg/lin.m. (5 kg/m2) in a strip 100 mm wide along the bay edge and hand-trowelled into the surface.

Supply

Estimating

25 kg bags

Concure WB:

20 litre container

Coverage

(b) Immediately after levelling the freshly placed concrete, remove a wedge of the concrete 10 mm deep at the slab edge and tapered up to slab level. Replace this with a very stiff paste of Nitoflor Hardtop S, mixed thoroughly with a small amount of water. Ensure it is fully compacted on to the base concrete.

Nitoflor Hardtop S:

5 kg/m2 / 3 kg/m2

Concure WB:

3.5 to 5 m2/litre

Applications should comply with the recommended rate to obtain the published performance characteristics. Any reduction may have a detrimental effect on the finished floor’s abrasion resistance and, in the case of pigmented floors, the quality and consistency of the finish.

These reinforced areas will be further strengthened when the subsequent full treatment is applied. Timing of the application of Nitoflor Hardtop S is important and care should be taken to ensure adequate labour, machinery and material is available to complete the whole area while sufficient moisture is available to fully react with the powder to provide a good dense finish. Conversely, the full benefit will not be achieved if the material is applied too early when bleed water is still present.

Limitations Do not use Nitoflor Hardtop S in areas exposed to acids and their salts or other materials known to rapidly attack or deteriorate concrete containing ordinary Portland cement. Do not apply to concrete containing calcium chloride or concrete having greater than 3% air entrainment.

Any addition of water to wet out the surface on either the first or second application of Nitoflor Hardtop S will be detrimental to the overall quality of the floor.

Where a coloured floor is required, it is strongly recommended that a site trial is undertaken to assess possible local variations caused by aggregates and sands used in the base concrete.

It is essential that the correct recommended rate of application is achieved over the entire floor area in order to avoid possible localised variations in shading.


Nitoflor Hardtop S:


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 of manufacture if kept in a dry storage in the original, unopened bags. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced to less than 6 months.

Precautions Health and safety For further information see appropriate Product Safety Data Sheet. Fire Nitoflor Hardtop S is non-flammable.

Additional information It is strongly recommended that a heavy duty sealant such as Nitoseal MS300 be used to seal internal joints of factory and warehouse floors to take account of the increased capacity of the treated floor. For further information on these products, and others within the Fosroc range, please contact your local Fosroc office or representative.

Nitoflor is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

156


9 CI/SfB: Yu5 May 2009

Fosroc® Nitoflor Lithurin


Permanent hardening and dustproofing compound for concrete surfaces


Uses

Surfaces to be treated with Nitoflor Lithurin must be structurally sound and free from loose materials. Cracks and holes should be repaired with Nitomortar PE resin mortar (see separate data sheet).

Preparation

As a surface hardener for new and old concrete floor to prevent dusting and to increase durability. Suitable for use on concrete and granolithic surfaces. Typical applications include industrial floors, light engineering works, warehouses, animal feed and milk parlours, abattoirs, car parks, dams, reservoirs, tanks, silos and flues.

Oil and grease contamination should be treated with a suitable chemical de-greaser and washed with clean water and allowed to dry. Any laitance or existing coating must be removed prior to application as these will prevent penetration.

Advantages Highly durable, improves abrasion resistance and reduces chemical attack from oils and greases Easy to apply, no special equipment or skills required Eliminates dust formation from within the treated surface Economical and low cost method of floor protection

New concrete floors must be allowed to cure for 14 days prior to treatment. Coloured floors should be allowed to cure for 28 days prior to treatment and a small area tested with Nitoflor Lithurin to assess the effect on the colour. Nitoflor Lithurin must only be applied to dry surfaces to maximise penetration. Mixing

Description

Dissolve 15 kg of Nitoflor Lithurin with 45 litres (10 gallons) of water in plastic containers and stir until completely dissolved. Metal containers may be used provided the solution is used within 24 hours.

Nitoflor Lithurin is a white, soluble, crystalline powder based on metallic fluorosilicates and wetting agents. When Nitoflor Lithurin is mixed with water and applied to the floor, the solution penetrates the concrete reacting with lime and other soluble particles to form granite hard crystals, leaving a permanent, hard wearing and dust free surface.

Application Ensure that the surface to be treated is dry and apply the mixed Nitoflor Lithurin at a rate of approximately 1 litre to every 4.5 m² using a soft broom or brush. Ensure that the surface is thoroughly saturated with the solution and well brushed out to prevent ponding.

Properties Penetration: Specially selected wetting agents in Nitoflor Lithurin improve the depth of penetration resulting in a more durable finish better than that of other surface treatments which merely form a superficial skin Hardness: The surface hardness is achieved through a chemical reaction within the cementitious material. This gives in-depth protection against heavy traffic and other forms of abrasion Anti-dust:

The chemical elimination of free lime and other soluble particles creates a tightly bound surface resistant to dusting


The inert crystalline compounds formed by Nitoflor Lithurin application reduce the absorbency of the surface and improve resistance to solvents, greases and commonly used chemicals

Allow the solution to be absorbed into the floor for a period of up to 2 hours. Do not allow the floor to dry out and whilst the floor is still damp wash the surface thoroughly with clean water. Remove all surplus solution and water as stated in disposal instructions. Failure to do so will result in a white dusty deposit left on drying. Nitoflor Lithurin should not be discharged into drains and storm tanks. (See disposal instructions.) Two coat application is recommended for complete treatment, but very dense, well trowelled surfaces such as granolithic toppings, power floated or vacuum dewatered concrete will generally require only a single coat. If required, re-apply the solution after 24 hours ensuring that the floor is dry. All surplus solution must be removed.

Estimating Nitoflor Lithurin is supplied in 15 kg buckets. One coat applications require approximately one bucket to cover approximately 200 m² . Two coat applications require approximately one bucket per 150 m². The degree of porosity will affect the coverage rate achieved.

Consult the Fosroc Customer Service Department for details on resistance to specific chemicals

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9 CI/SfB: Yu5 May 2009

Fosroc® Nitoflor Lithurin Limitations

2 kg of lime for neutralisation. The pH of the solution must always be checked to ensure that complete neutralisation has occurred.

Nitoflor Lithurin solution is toxic and cannot be discharged into drains and storm tanks. Nitoflor Lithurin must be disposed of in accordance with the Environmental Protection Act 1990.

The reaction with the lime produces a white precipitate of calcium fluorosilicate which may be disposed of on a landfill site. The remaining liquid can be washed away down drains with excess water.

Metal, glass or paintwork must be protected against Nitoflor Lithurin. Should any splashes occur these must be removed immediately and disposed of by following the disposal instructions.

All health and safety procedures and precautions must be adhered to whilst handling and disposing of the solution.

Storage Nitoflor Lithurin has a shelf life of 12 months if stored in cool dry conditions in original, unopened buckets.

Precautions Health and safety For further information see appropriate Product Safety Data Sheet. Fire Nitoflor Lithurin is non-flammable. Disposal Due to the Environmental Protection Act 1990 soluble fluorosilicates i.e. Nitoflor Lithurin cannot be discharged into drains or storm tanks and the given guidelines should be followed. After treatment, the surplus solution and subsequent washings must be vacuumed up to remove all traces of the solution from the surface. The storage and transportation of this solution must be in polythene, plastic or stainless steel containers that can be lidded for transport. The residual liquid should be treated with builders lime i.e. calcium hydroxide, in order to neutralise the solution. The lime should be thoroughly mixed with the solution, left to stand for 24 hours and pH checked with litmus paper until a pH7 or above is achieved. Both lime and litmus paper can be obtained from any chemical laboratory equipment supplier such as BDH of Poole, Dorset. Builders lime can be obtained from any good builders merchant. As a guideline, 10 litres of solution will require

Nitoflor is the trademark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

158


9 CI/SfB: July 2009

Fosroc® Polyurea FLM


Fast setting, pure polyurea elastomeric floor coating

rapid curing pure Polyurea coating system providing high corrosion, abrasion and thermal shock resistance. It shall meet the values under the section “ Properties”.

General Information Properties Fosroc Polyurea FLM is a spray-applied, 100% solids, flexible, two-component, rapid curing pure Polyurea system, designed as a floor protective coating. It combines the advantages of seamless, waterproof coating with very long life cycles and high durability.

Typical Physical properties at 23oC

Polyurea FLM consists of Fosroc Polyurea FLM Part A ISO and Fosroc Polyurea FLM Part B AMINE and a pigmeted colour pot. The system offers excellent surface properties and overall physical properties. Uses

Solids by Volume

: 100%

Volatile organic compounds

: 0 g/litre

Viscosity

: A ISO =1000 mPas : B AMINE 16 Nmm-2

Modulus 100%/ 200%/ 300% ASTM D412

: >9/ 12/ 15 Nmm-2

Protective coating for flooring applications in a wide range of environmental conditions. Typical applications include:

Tear Resistance ASTM D624C : 85 ± 5 N/mm

Industrial floors Processing plants Food processing areas Stadia Workshops & production facilities Manufacturing plants

Elongation ASTM D412

: >300%

Shore D ASTM D2240

: 47

Abrasion (1kg,H22 wheels) ASTM D4060

: 29 mg /1000 cycles

Abrasion (1kg,CS17 wheels) DIN EN ISO 5470

: < 0.02mg /1000 cycles

Service temperature ASTM D4060

: -30oC to +135oC

Colour : RAL 7005 Grey Other colours available to order

Plant rooms Note: Anti-slip and other coating properties may be provided by the introduction of fillers or fibres by modified spray gun. Refer to the Fosroc Polyurea Method Statement, and contact Fosroc for further advice.

Chemical Resistance (ASTM D3912, 72 hours immersion) Chemical

Advantages Environment friendly - zero VOC Excellent chemical resistance, thermal stability and UV Resistance *

Result Max service temp. 50 oC

Hydraulic Oil

R

Motor Oil

R-DIS 50 oC

Diesel Fuel

R

Petrol

R-DIS 25 oC

25 oC

Very fast turn-around time. The coated substrate can be put into service within an hour

Skydrol Sodium Hydroxide (50%)

R

50 oC

Excellent impact, abrasion and puncture resistance

Ammonia (0.880) 33%

R

25 oC

Seamless and monolithic, including day joints

Sugar solution conc.

R

50 oC

Significantly enhances the durability of reinforced concrete

Bleach (5%)

R-DIS 50 oC

Butanol

R-C

25 oC

Low permeability values

Lactic Acid (20%)

R

50 oC

Phosphoric Acid (10%)

R

50 oC

Hydrochloric Acid (20%)

R-C

50 oC

Nitric Acid (30%)

R-C

25 oC

o

Designed for service temperatures from -30 C to +135 oC *See Limitations

NR

Sulphuric Acid (10%) R 50 oC R : Recommended R-DIS : Recommended – Discolouration only R-C : Recommended – Conditional; discolouration and/or slight softening or swelling – wash down within one hour to avoid effects NR : Not Recommended

Specification The protective and/or wateproofing coating shall be Fosroc Polyurea FLM, a 100% solids, flexible, two component,

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9 CI/SfB: July 2009

Fosroc® Polyurea FLM of BS EN ISO 8501-1:2007. Any laminations must be removed.

Note: The chemical resistance recommendations given above apply to spillage and secondary containment applications with up to 72 hours contact duration; for any other requirements / chemicals contact Fosroc for further advice.

Blast cleaning to Sa 2½. (ISO 8501-1:2007). Roughness: using abrasives suitable to achieve a coarse surface of Grade Medium G (50-85μm, Ry5) (BS EN ISO 85032:2001).

Clarification of property values

All welding seams must have a surface finish which ensures that the quality of the paint system will be maintained. All sharp edges must be removed or rounded off to ensure that the specified film thickness can be built-up on all surfaces. The radius of the rounding must be minimum 2 mm.

The typical physical properties given above are derived from independent testing of Fosroc Polyurea FLM spray applied in accordance with the Fosroc Polyurea Method Statement, in controlled laboratory environment. Results derived from testing field-applied samples may vary. Processing and cure parameters

Priming Block Temperature

: +70o C to +80oC

Hose Temperature

: +70o C to +80oC

Volume ratio

: 1:1

Pressure

: 120 - 150 bar

Gel Time

: 5 - 10 sec

Walkable

: 2 mins

Trafficable (light duty)

: 15 - 20 minutes

Trafficable (medium duty)

: 24 hours

Trafficable (heavy duty)

: 7 days

Following correct preparation, the substrate must be primed. Fosroc Primer 195 should be used. For concrete, suggested application rate is 2.5 - 4 m2 per litre; dependant on concrete porosity. On very porous concrete higher application rates may be required. Consult Fosroc for further recommendations. For steel substrates, a suggested rate of 6.5 m2 per litre is recommended. Add the entire content of Part B into Part A and mix with a slow speed drill and paddle for 3 minutes until homogeneous.

Instructions for use Refer to Application section below and Fosroc Polyurea Method Statement for further detail.

Apply by brush, roller or squeegee to a uniform thickness. Initial spreading may be caried out by spray but a final rolling shold be carried out to ensure full wetting and even distribution of the primer.

Surface preparation All surfaces must be clean, dry and free from contamination.

A broadcast of 0.2 - 0.5 mm kiln-dried sand onto the uncured primer should be carried out to ensure optimum adhesion properties. Excess sand shold be removed prior to application of the Fosroc Polyurea FLM.

Concrete Dry abrasive blasting, wet abrasive blasting, vacuumassisted abrasive blasting, and centrifugal shot blasting, as described in ASTM D4259, must be used to remove contaminants, laitance, and weak concrete, to expose blow holes, and to produce a sound concrete surface with adequate profile and surface porosity.

The primer shall be allowed to become touch-dry prior to application of Fosroc Polyurea FLM. Typically 1.5 hours at 20oC, 2 hours at 10oC Pot life Primer 195: 30 minutes at 25oC, 60 minutes at 15oC.

Blow holes All blow holes and minor surface imperfections shall be filled with Nitomortar FC prior to application of Primer. See separate product data sheet. Nitomortar FC should be allowed to cure for 12 - 18 hours at 20oC. Lightly abrade the surface and wipe with a cloth lightly wetted with Fosroc Equipment Cleaner and allowed to dry prior to priming.

Application Spray Equipment A high pressure spray proportioning machine/ spray gun for plural heated polyurea components such as those manufactured by GlasCraft or Graco should be used for this product.

Steel The steel must be of first class quality and must not have been allowed to rust more than corresponding to grade B

A list of appropriate equipment is provided in the Fosroc Polyurea Method Statement.


9 CI/SfB: July 2009

Fosroc® Polyurea FLM Application Method

Coverage:

Add the pigment paste, to the Part B AMINE drum and mix with a slow speed 300-400rpm bunghole mixer for 20 minutes until homogeneous.

Fosroc Polyurea FLM

: 1.5 – 3.0 ltrs per m2 (1.5 - 3.0 mm) depending on specification

Fosroc Primer 195

: Concrete : 2.5 - 4 m2 / litre : Steel : 6.5m2 / litre

If pigmented material is stored it should be mixed with a bunghole mixer for 20 minutes prior to use.

Storage

Avoid moisture contamination of bulk material, seal drums for storage. Do not add solvent. Heat the spray lines to 70 – 80 C.

Fosroc Polyurea FLM and Primer 195 have a shelf life of 12 months if kept in a dry, air conditioned store between +5°C and +30°C in the original unopened containers.

Apply the Fosroc Polyurea FLM at the specified thickness (1.5 – 3.0 mm ) to the primed substrate in a cross hatch pattern with a minimum of two alternate directional passes.

Limitations

o

Fosroc Polyurea FLM should not be applied over existing coatings.

If non slip surfaces are required consult Fosroc Polyurea Method Statement.

Fosroc Polyurea FLM is not colour stable when exposed to sunlight and UV. This will not affect the cured physical properties of the product. If longterm aesthetics regarding colour stability is of critical importance, contact Fosroc for further advice.

Day joints : when overcoating material applied for more than 12 hours. Remove any dirt / dust contamination. Wipe surface of cured coating with NEP (N-ethyl pyrrolidone). Apply Polyurea when surface is dry, typically 30 minutes with a 100mm overlap.

Application should not be undertaken by the methods described if the temperature is below 5oC or is 5oC and falling or where the prevailing relative humidity exceeds 90% or the dew point is less than 3oC above the surface temperature. Consult Fosroc if these conditions are not met for specific advice.

Due to the fast cure rate of Fosroc Polyurea FLM overspray can only be removed mechanically.

Estimating Supply: Fosroc Polyurea FLM Part A ISO component

Precautions Health and Safety

: 200 ltr drums

Fosroc Polyurea FLM Part B AMINE component : 200 ltr drums : 195 ltr drums + separate colour pack Fosroc Primer 195 Part A Base

: 12.5kg in 25 litre pail

Fosroc Primer 195 Part B Hardener


For further information refer to appropriate Product Safety Data Sheet. Flash Point Fosroc Polyurea FLM and Primer 195 are nonflammable. Flash Point Fosroc Equipment Cleaner: 44oC

Fosroc Equipment Cleaner: 5 litre



www.fosroc.com

telephone: +44 0 (1827) 262222

fax: +44 0 (1827) 262444

161


10 CI/SfB: u2 September 2008

Fosroc® Concure WB


Water based concrete curing compound

After spraying, no further application of water is necessary to ensure continued curing. The concrete surface should not be disturbed until it has sufficient strength to bear surface loads. The applied film should not be walked on before it is fully dry and care should be taken to ensure that the film is not broken.

Uses As a spray applied membrane to retain moisture in concrete for effective curing Suitable for all general concreting applications and of particular benefit for large area concrete surfaces, such as airport runways, roads and bridgeworks

Concure WB may also be applied to the surface of newly hardened concrete immediately after demoulding. In such cases the concrete surface must be damp and not dry. Dry surfaces may prevent correct film formation and cause absorption of the Concure WB which may lead to staining and difficulty in later removal.

Advantages Improved curing of concrete enhances cement hydration and provides a more durable concrete

Coverage rate

Control of moisture loss improves surface quality, reducing permeability, producing a hard wearing, dustfree surface and minimising potential for surface cracking and shrinkage

The recommended coverage rate is between 3.5 and 5.0 m²/litre (0.200 to 0.285 litres/m²). Coverage rates outside this recommended range may be used if necessary and suitable to meet specific requirements. Contact the Fosroc Customer Service Department for advice in such cases.

Fugitive colour provides visual guide during application Water based, therefore, non-flammable

Equipment

Spray application reduces labour costs and eliminates the need for alternative curing systems

Spray equipment producing a fine mist without damaging the emulsion may be used for Concure WB, such as knapsack or motorised sprayers. The suitability of equipment should be ensured by an application trial.

Standards compliance Concure WB gives 75% or greater curing efficiency when tested to BS 7542 and complies with ASTM C309 and AASHTO M148 as Type 1.

Equipment cleaning Spray equipment should be cleaned immediately after use by flushing through with water. If spray nozzles become blocked with wax particles these may be easily cleared with white spirit.

Description Concure WB is a water based concrete curing compound based on a low viscosity wax emulsion. It is supplied as a white emulsion which forms a clear film on drying.

Overcoating and removal

When first applied to a fresh cementitious surface the emulsion breaks to form a continuous, non-penetrating white coating. This dries to form a continuous clear film which provides a barrier to moisture loss, ensuring more efficient cement hydration, improved durability and reduced shrinkage.

Concure WB must be removed from a concrete surface before application of a subsequent coating to ensure a good bond of the coating material to the concrete. Concure WB will be slowly removed by physical abrasion in normal trafficking and exposure. To ensure complete removal use high pressure steam, water jet or light sand blasting.


Limitations

Minimum application temperature: 5°C

Concure WB should not be continuously re-circulated in high shear pumps in concrete train or similar applications as this may cause a breakdown of the emulsion before spraying. If continuous recirculation is necessary, the sprayer should be fitted with a low shear diaphragm pump.

Concure WB should be spray applied to the surface of fresh concrete. Application should begin immediately the concrete is free from surface water. Do not apply if bleed water is forming or present on the concrete surface. The spray nozzle should be held approximately 450 mm from the concrete surface and passed back and forth to ensure complete coverage. The fugitive white colour during application provides a guide to the area covered. Pump pressure should be maintained to give an even, fine spray.

In extreme drying conditions additional curing using polythene or wet muslin may be required.

162

10 CI/SfB: u2 September 2008

Fosroc® Concure WB Estimating

Precautions

Supply

Health and safety

Concure WB is supplied in 200 litre and 20 litre drums.


Storage

Fire

Concure WB has a minimum shelf life of 12 months provided the temperature is kept within the range of 4°C to 35°C. Freezing and prolonged exposure to heat or direct sunlight should be avoided. Should the temperature of the product fall outside this range then the Fosroc Customer Service Department should be contacted for advice.

Concure WB is water based and non-flammable.

Containers should be kept sealed and airtight to prevent loss of moisture by evaporation.

Concure is the trade mark of Fosroc International Limited



www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

163


10 CI/SfB: Yz October 2005

Fosroc® Acid Etch


Concrete remover, cleaning and etching agent

Cleaning large items of equipment (Examples are readymix trucks, concrete mixers or barrows.)

Uses

Fosroc Acid Etch should be liberally applied to the deposits by a soft broom and allowed to soak overnight if possible. If the surfaces of the deposit can be cracked by mechanical means this will speed up the operation. In severe cases more than one application may be necessary. On completion, dissolved deposits and loose material should be brushed and washed away with clean water.

For the removal of mortar and plaster runs, droppings and stains from brickwork and concrete surfaces. Also for removal of hardened concrete from tools, machinery and equipment, or rust and mill scale from steelwork. Suitable for etching of concrete floors and surfaces prior to application of resin or other surface coatings.

Advantages

Cleaning small tools

Rapid concrete etching action

Use Fosroc Acid Etch as a dip. The tools should be soaked overnight, then taken out and washed with clean water to remove all loosely adhering materials. Care should be taken to avoid prolonged contact between Fosroc Acid Etch and zinc or aluminium parts of tools, such as rivets, etc.

No corrosive action with glass, plastic and rubber Cleans hardened concrete from tools and mechanical equipment

Description

Cleaning concrete floors

Fosroc Acid Etch is a concrete remover, cleaning and etching agent. It is a combination of acid based material, corrosion inhibitors and dispersing agents and is supplied as a clear green solution.

Pre-wet the floors, then, using a stiff bristle broom, brush the affected areas with a solution of Fosroc Acid Etch and water. Strength of the solution required will vary but should be between 1 : 1 and 1 : 4 Fosroc Acid Etch to water. When the action has finished, wash down thoroughly with clean water.

Properties Specific gravity:

Typically 1.08 at 20°C

Oil or grease should be removed by treatment with a suitable chemical degreaser followed by water or steam cleaning. Where heavy contamination occurs, as in garages or workshops, pre-treatment with Fosroc Acid Etch assists in freeing oil or grease and renders the action of the degreaser used more effective.

Application instructions Cleaning brickwork and rust stains from concrete A small trial area should be cleaned first to determine the most suitable Fosroc Acid Etch dilution. Pre-wet the surface, then, using a sponge, rub the affected areas with a solution of Fosroc Acid Etch and water. Strength of the solution required will vary but should be between 1 : 1 and 1 : 4 (by volume) Fosroc Acid Etch to water. When the action has finished, wash down thoroughly with clean water. As treatment with Fosroc Acid Etch can alter the surface finish of concrete, the minimum concentration necessary for effective removal of stains should be employed. The surface should be washed down with water immediately treatment is complete.

Removal of rust and mill scale After wire brushing to remove loose material, apply a solution of Fosroc Acid Etch and water using a soft broom or brush and leave to act for 20 to 40 minutes. Strength of the solution required will normally be between 1 : 1 and 1 : 4 Fosroc Acid Etch to water. Wire brush again to remove remaining loose material and finish by thoroughly washing down with clean water. Repeat if necessary. Etching concrete floors For etching surfaces to remove laitance and give a mechanical key before applying resin or other coating, Fosroc Acid Etch should be diluted with water and applied at the rate of approximately 1 litre per 2 square metres. The dilution will depend on the condition of the floors and the degree of etching required, but normally it will be between 1 : 2 and 1 : 4. When the action has finished, wash down thoroughly with clean water.

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10 CI/SfB: Yz October 2005

Fosroc® Acid Etch Spillage Spillages should be hosed down with plenty of water. Caution Fosroc Acid Etch is acid based and should be handled with care. Acid vapours from undiluted product can damage nearby surfaces, notably causing rusting of unprotected steel. If in doubt about its effect on a material, test a small area before general application.

Estimating Supply Fosroc Acid Etch:

25 litre drum 210 litre drum

Storage Store in original unopened packaging, in cool dry conditions, away from sunlight.

Precautions Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Fosroc Acid Etch is non-flammable.

Fosroc Acid Etch is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

www.fosroc.com


165

11 CI/SfB: Yt4 February 2006

Fosroc® Nitoseal 12


Biodegradation resistant sealant

Design criteria

Uses

Example of an expansion joint in a reservoir wall is shown below

3

Nitoseal 12 is a two-part sealant designed to meet many of the requirements of the water industry in water retaining structures, sewage treatment and sea defence works. It is resistant to the bacteriological conditions associated with sewage treatment and silt accumulations in water storage. The abrasion resistance of Nitoseal 12 makes it also appropriate for use for sealing movement joints in concrete sea walls subject to tidal scour.

1 2 4 2

The principal applications for Nitoseal 12 are:

5 6

Sludge digestion tanks Filtration and aeration tanks

1 Nitoseal 12 2 Hydrocell XL* 3 Water face

Culverts Raw water reservoirs

4 Supercast Hydrofoil* 5 Thioflex 600* 6 External face

Sea walls

* Also available from Fosroc

Advantages

Properties

Resistant to aerobic and anaerobic bacteriological attack

Technical data — Nitoseal 12

Excellent adhesion under immersed conditions

Form:

Two-part compound Base: White paste Curing agent: Dark-grey paste

Storage life:

12 months in original containers in cool, dry conditions

Solids content:

100%

Density:

1.44 kg/litre

Colour:

Grey

Abrasion resistant Separate component for accelerating the initial cure

Description Nitoseal 12 is a two-part, elastomeric joint sealant based on polyurethane technology. It is supplied in packs containing base compound and curing agent in the correct proportions which, when mixed, cure to form a tough rubber-like material. Adhesion to most commonly used construction materials is excellent.

Physical/chemical change: Chemical cure Application temperature:

The use of appropriate primers is essential to ensure proper adhesion. Fosroc Primer 7 is for use on porous surfaces and Fosroc Primer 4 is for use on non-porous surfaces. In special circumstances, such as sealing sea defence works in tidal areas, a special Nitoseal 12 accelerator component is available, to be added when mixing to enhance the initial cure rate, so that work can be completed between tides. At 10°C the seal can be subjected to tidal immersion approximately 60 minutes after application, without adverse effect.

5°C to 50°C

Pot life:

2 to 3 hours at 25°C With accelerator 20 minutes at 25°C

Cure rate:

48 hours at 25°C With accelerator 24 hours at 25°C

Cure time:

48 hours at 25°C 96 hours at 10°C Permanent immersion in water should not occur until full cure has taken place

Note: The above times will be reduced by approximately 50% if the accelerator is used. In a tidal situation, the sealant should incorporate the accelerator and the sealing operation should be completed at least 1 hour at 10°C prior to immersion.

Specification clauses Joints shall be sealed, where designated, using Nitoseal 12, two-part biodegradation resistant sealant manufactured and supplied by Fosroc. The sealant shall be mixed and applied strictly in accordance with the manufacturer’s printed instructions.

Hardness shore ‘A’ at 25°C:

166

35° to 40°


Fosroc® Nitoseal 12 Flammability:

Burns but does not readily support combustion

Biological: resistance

Good resistance to both aerobic and anaerobic conditions normally occurring in sewage treatment works

Movement accommodation factor:

Mix using a slow speed drill (300 to 500 rpm) fitted with a Fosroc Sealant Mixing Paddle for not less than 4 minutes until a uniform colour is achieved with no streakiness. Application Load the mixed Nitoseal 12 into a Fosroc ‘G’ gun using a Follower Plate. Compact the Nitoseal into the primed joint. Tool off leaving a smooth finish.

20% in butt joints

Finishing

Technical data — Nitoseal 12 accelerator Flash point:

Over 65°C

Storage life:

12 months in original containers in cool, dry conditions

Pack size:

50 ml

Nitoseal 12 can be finished by tooling-off smooth using a metal or wooden spatula. A minimum amount of detergent may be used to ease this operation. Remove all masking tapes immediately after tooling. Excessive tooling can cause surface drag, this should be avoided. Cleaning Clean equipment immediately after use with Fosroc Equipment Cleaner.

Application instructions Joint preparation

Estimating

Joints to be sealed must be accurately formed. They must be dry, clean and frost free. Dust, dirt, weak laitance, old failed sealant and other foreign substances must be removed.

Packaging Nitoseal 12 accelerator is supplied in small, lever lid tins in packs of 12. One tin of accelerator is required for each 2 litre tin of Nitoseal 12.

Ensure that expansion joint fillers are tightly packed and that no voids are left at the base of the sealing slot.

Guide to Nitoseal 12 quantities

Insert a self-adhesive polyethylene bond breaking tape at the base of the joint. (Soft foam back-up material should not be used.) Priming Prime the sides of the sealing slot using the appropriate surface conditioner. Apply by brush, working well in, ensuring complete coverage. Porous surfaces: Fosroc Primer 7.

Joint size in mm (w x d)

Litres per metre run

Metre run per 2 litre

5x5 10 x 5 20 x 10 25 x 15 30 x 15 40 x 20 50 x 25

0.025 0.050 0.200 0.375 0.450 0.800 1.300

80.0 40.0 10.0 5.3 4.4 2.5 1.6

Non-porous surfaces: Fosroc Primer 4. Guide to primer quantities

NB: Avoid using too much primer resulting in pools in the base of the joint.

1 litre of Fosroc Primer 7 to 30 litres of Nitoseal 12.

Allow the primer to dry. The sealant may be applied within the time period 30 minutes to 3 hours. That is after the primer solvent has evaporated but before the film has fully reacted. Any primed surfaces left longer than 3 hours must be re-primed before applying the sealant.

1 litre of Fosroc Primer 4 to 150 litres of Nitoseal 12.

Storage Fosroc Primer 4 and Fosroc Primer 7 must be stored in accordance with the Highly Flammable Liquids and Liquefied Petroleum Gases Regulations 1972.

Mixing Add the curing agent to the base component tin. Slit the end of the curing agent sachet, place it on the top edge of the tin and press with the lid to squeeze all the contents into the tin. Note: If Nitoseal 12 accelerator is used it should be stirred well before adding to the base with the curing agent prior to mixing.


Page 2


Fosroc® Nitoseal 12 Precautions Health and safety Nitoseal 12, Nitoseal 12 accelerator, Fosroc Primer 7, Fosroc Primer 4, Fosroc Equipment Cleaner: For further information refer to appropriate Product Safety Data Sheet.

Fire Nitoseal 12 and Nitseal 12 accelerator are nonflammable. Fosroc Primer 4, Primer 7 and Fosroc Euqipment Cleaner are highly flammable. See below for more details.

Fosroc Primer 4

Fosroc Primer 7

Flash point:

14°C

23°C

Coverage:

60 m²/litre

12 to 15 m²/litre

Application temperature:

5°C to 50°C

5°C to 50°C

Drying time:

2 to 15 minutes minutes

20 to 60

Pack size:

250 ml

500 ml 5 litres

Fosroc Equipment Cleaner Flash point:

44°C

Storage life:

Indefinite

Pack size:

5 litres

Nitoseal is a trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

168


11 CI/SfB: Yt4 July 2009

Fosroc® Nitoseal MS600


One part, civil engineering sealant for immersed conditions Uses Nitoseal MS600 is suitable for sealing movement joints in buildings and civil engineering structures including joints that will be subject to intermittent or permanent immersion. Typical applications include: Reservoirs Sewage tanks Sea walls (non-tidal) Basements Subways Parapets Bridges Superstructures

Advantages

Design criteria

Approved for use in contact with potable water

Nitoseal MS600 should be applied to joints between 5 and 35mm wide. Joints which are expected to experience cyclic movements should be designed to an optimum width : depth ratio of 2:1, subject to the overriding recommended minimum sealant depths set out below: 5mm for metals, glass and other non-porous surfaces; 8mm for all porous surfaces; 20mm for joints subject to hydrostatic pressure.

Meets key international standards Resistant to aerobic and anaerobic bacteriological attack Exhibits excellent water resistance Excellent resistance to dilute acids and alkalis Cures to a tough, elastic rubber seal

To ensure that the sealant remains within its stated movement capacity (25% MAF), sealing slot widths should be designed in accordance with the recommendations of BS 6093.1993. The Movement Accommodation Factor is a figure quoted indicating the ability of a sealant to accommodate joint movement throughout the service life of that sealant, expressed as a percentage of the joint width at time of sealing.

Accommodates continuous and pronounced cyclic movement High resistance to ageing, reduces physical damage due to climatic extremes Single component yet fast rate of cure Easy to apply at low temperature Can be applied to damp substrates

To calculate the theoretical minimum joint width knowing the expected maximum working movement of the joint:

Isocyanate free technology

Description

W=

Nitoseal MS600 is a one part medium modulus sealant based on hybrid silyl modified polyether technology. It has a fast rate of cure and forms a tough, highly durable and water resistant elastomer. Conforms to the Water Supply (water quality) Regulations 2000 and 2001 Regulations 31(4b) for products having a small surface area in contact with water for public supply.

M __ + M MAF/100

W = Joint width

Standards compliance ASTM C920-94:Type S, Grade NS, Class 25 Conforms with the performance criteria of BS4254 (1991) British Standard BS 6920 : Part 1:2000 Water Regulations Advisory Service listed product. 169


Fosroc® Nitoseal MS600 M = Expected maximum working movement of joint MAF = Movement Accommodation Factor of that sealant

Form:

Smooth, non-slumping paste

The use of a bond breaker is not required in expansion joints containing cellular polyethylene joint filler such as Hydrocell XL or Expandafoam. For construction or contraction joints a bond breaker tape or back-up strip should be used.

Colour:

Grey For special colours contact Fosroc for further Information

Where a particularly neat finish is required, mask the face edges of the joint before sealing and remove immediately after tooling is completed.

Movement Accommodation factor:

25% butt joints 50% lap joints

Priming

Skinning time at 20 C / 50% RH:

30 minutes

When using primer, empty the entire contents of the hardener tin into the base tin and replace the base tin lid. Mix thoroughly by shaking for at least 2 minutes. Prime the joint face using a clean, dry brush. Avoid over application of primer causing puddles in the bottom of the joint.

Properties

Cure rate at 20 C / 50% RH:

24 hours: 48 hours: 72 hours:

Application

5°C to 50°C

Service temperature:

Dry – 30°C to +80°C Wet up to 40°C

Hardness shore ‘A’ 20°C:

32


Resistant to occasional spillage of many chemicals: see limitations

Biological resistance:

Nitoseal MS600 has been evaluated in microbiologically active situations and has been shown to have resistance to aerobic and anaerobic conditions

UV resistance:

Fosroc Primer MS2 is required for all joints.

3mm 6mm 8mm

Nitoseal MS600 should be applied between 30 minutes and 4 hours after priming. If a joint is left unsealed for more than 4 hours, the primer should be removed by grit blasting or grinding and the joint 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 for sealing the joint.

Excellent

Extrude the sealant firmly in to the joint. Tool flush within 5 minutes of application to ensure good contact between the sealant and the substrate.

Water immersion: Nitoseal MS600 must be fully cured before permanent immersion in water

Cleaning Application instructions

Clean tools immediately after use with Fosroc Equipment Cleaner.

Joint surfaces must be clean, dry and free from frost. Remove all dirt, laitance, loose material and foreign matter. Remove all rust, scale and protective lacquers from metal surfaces. Removal can be achieved by rigorous wire brushing, grinding or grit blasting.

Estimating Guide to quantities

Joints in concrete should preferably be sawn. After sawing, all saw slurry must be flushed away and the joint allowed to dry.

Joint 6 x 10 12 x 10 20 x 20 25 x 12 30 x 15

When resealing, the existing sealant should be removed from the joint and the arris cleaned back to sound clean concrete. All debris should be removed.

Litres per metre run 0.06 0.12 0.40 0.30 0.45

Metre run per 600 ml sachet 10.00 5.00 1.50 2.00 1.33

Any expansion joint filler must be checked to ensure it is tightly packed and no gaps or voids exist at the base of the sealing slot before positioning a bond breaker. Approximately 0.75 litres of Fosroc Primer MS2 will be



Fosroc® Nitoseal MS600 sufficient for 90m of joint. No allowance has been made for joint size or wastage.

Limitations Should not be applied at temperatures below 5oC Not suitable for contact with bituminous materials Not suitable for contact with solvents, oil or petrol Whilst Nitoseal MS600 has excellent adhesion to many types of residual sealant, its use should not be considered a substitute for a good standard of joint preparation 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. Shelf life 12 months. Storage outside of these conditions may reduce shelf life.

Precautions Health and safety Nitoseal MS600 is considered safe in normal use. For further information refer to appropriate Product Safety Data Sheet. Fosroc Primer MS2 is highly flammable, see material safety data sheet for details.

Important note

Nitoseal is the trade mark of Fosroc International Limited

Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

171


11 CI/SfB: Yt4 December 2005

Fosroc® Plastijoint


Hand applied flexible bituminous putty

Properties Form:

Stiff putty

Colour:

Black

Plastijoint is recommended for sealing joints, particularly vertical and inclined joints, in most types of water retaining structures.

Movement accommodation factor BS 6093:

10% for butt joints

Sewage disposal works


5°C to 50°C (Plastijoint heated to 45°C to 55°C)

Chemical resistance to occasional spillage:

Dilute acids Dilute alkalis Petroleum solvents Mineral oils Vegetable oils

Biological resistance:

Plastijoint is resistant to the aerobic and anaerobic conditions normally occurring in sewage treatment works

Solids content:

100%

Uses

Culverts Sea walls Retaining walls (brickwork and concrete) Subways and basement structures

Advantages Designed for permanent immersion in water Tough, weather resistant seal Excellent slump resistance Easily applied by hand

resistant resistant non resistant non resistant non resistant


Suitable for joints up to 40 mm wide

Preparation

Resistant to bacteriological attack

Plastijoint is applied by hand after it has been heated to 45°C to 55°C by placing in a field oven or in boiling water for approximately 1 hour. When using water, the water level should only come almost to the top of the tin (leave the lid on). Plastijoint must not be subjected to direct heating.

Description Plastijoint is a thermoplastic bitumen based putty which requires heating to make it workable. On cooling it gives a slump-free, flexible seal. Plastijoint is suitable for immersed joints including those where biological activity occurs.

Joint preparation Ensure that the joint surfaces are completely dry, clean and frost-free. Remove all dirt, dust, laitance and loose material by rigorous wire brushing. Remove all rust, scale and protective lacquers from metal surfaces. Remove any oil or grease with Fosroc Equipment Cleaner. In expansion joints, Plastijoint must always be supported by a firm backing which allows free movement. Where a particularly neat finish is required, cover face edges of joint with masking tape before priming and remove immediately after sealing work is completed.

Plastijoint is suitable for sealing joints, including low movement expansion joints, in retaining walls and basements. It is also suitable for sealing around pipe or cable entries into buildings. Plastijoint may be applied to joints between 20 and 40 mm wide. In most cases it is advisable to form a sealing slot approximately square in cross-section. Where expansion joints are subject to hydrostatic head, Plastijoint seals require support from a compressible filler such as Hydrocell.

Priming porous surfaces On concrete, stone, brickwork and timber, Fosroc Primer 3 is required. The applied primer should be touch dry before sealing. Priming non-porous surfaces Primer not normally required. Ferrous metals should be treated with an anti-corrosion primer. Application Take a convenient quantity of material from the tin and mould in gloved hand into a strip. While still hot, push this well down into the cavity to fill all crevices, ensuring good contact with the sides and base of the joint. If necessary caulk home with a piece of damp wood.

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11 CI/SfB: Yt4 December 2005

Fosroc® Plastijoint Note: If there is honeycombed concrete in the immediate vicinity of the joint, there is the risk that water under pressure may percolate behind the seal and pass into the joint. In such cases, prime the area concerned and apply additional sealant, working well into all cavities to give a ‘mushroom’ finish. Joints subject to flowing water should be finished flush or slightly concave.

Storage Shelf life 2 years stored in cool dry conditions in unopened original containers.

Precautions

Finishing

Health and safety

Heat a stripping knife and, working along the joint, cut away excess material to present a neat finish. In cold weather a gas blowtorch may be run down the seal before trimming. Plastijoint requires no special tools, but the use of a caulking iron is recommended for easy consolidation and to give a neat finish to the seal.

For further information refer to appropriate Product Safety Data Sheet. Fosroc Primer 3 is highly flammable, see material safety data sheet for details.

Cleaning Clean equipment immediately after use with Fosroc Equipment Cleaner.

Estimating Guide to Plastijoint quantities Joint size in mm

Litre per metre

Metre per 5 litre

Joint size in mm

Litre per metre

Metre per 5 litre

20 x 20 25 30 25 x 20 25 30 40 30 x 25 40

0.40 0.50 0.60 0.50 0.63 0.75 1.00 0.75 1.20

13.0 10.0 8.3 10.0 8.0 6.7 5.0 6.7 4.2

30 x 50 35 x 25 30 40 50 40 x 25 30 50

1.50 0.88 1.10 1.40 1.80 1.00 1.20 2.00

3.3 5.7 4.8 3.6 2.9 5.0 4.2 2.5

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 made for variations in joint dimensions, substrate or wastage.

Plastijoint is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

173


12 CI/SfB: Yt4 October 2005

Fosroc® Colpor 200PF


Cold applied, high performance, pitch free, pavement joint sealant


Uses Hardness shore ‘A’ at 25°C:

For the sealing and maintenance of joints in concrete roads, concrete runways and hard standings. Colpor 200PF is particularly suitable for sealing areas where fuel and oil spillage might occur such as aircraft fuelling areas, oil terminals, garage forecourts, parking and cargo areas.

Cold applied — no heating equipment required Fuel, oil and hydraulic fluid resistance

Aviation fuels Hydraulic fluids Skydrol Kerosene Petrol Diesel fuels

Solids content:

100%

Flash point:

Over 65°C

Flammability:


High durability and long service life High movement accommodation

15 ± 5


Advantages Pitch free

To avoid unacceptably prolonged cure times, do not apply at temperatures below 5°C

Synthetic oils Mineral oils White spirit Mild alkalis Dilute acids



Joint preparation

British Standard 5212 : 1990 — types N, F and FB.

Joint sealing slots in concrete should be accurately formed and must be dry, sound, clean and free from frost. Remove all dust and loose material by grit blasting or grinding. Avoid polishing the joint sides when grinding. The prepared sealing slot should be blown out with dry, oil-free compressed air.

U.S. Federal Specification SS-S-200E : 1984.

Description Colpor 200PF retains its movement accommodation of 25% on butt joints throughout the extremes of temperature, it does not harden in cold weather nor become excessively soft or pick up in hot conditions.

Ensure that any expansion joint filler is tightly packed in the joint and insert a bond breaker or cord caulked tightly into the base of the sealing groove to prevent sealant adhering to the base of the slot and provide the specified depth of sealant.

In trafficked areas the maximum expansion joint width should be limited to 30 mm. It is necessary to recess the level of the sealant 5 to 8 mm below the pavement surface dependent on the time of year and temperature prevailing at the time of sealing.

Priming Concrete joint faces should be primed with Fosroc Primer 20 or Primer 19.

The width/depth ratio of the Colpor 200PF seal should be 1 : 1 to 1½ : 1 subject to a minimum 10 mm depth of sealant (example, contraction joint: 15 mm wide x 13 mm depth; expansion joint: 25 mm wide x 20 mm depth).

Primer 20 Decant sufficient primer into a clean dry tin for the days usage. Do not return unused primer to the supply tin at the end of the day. Prime the joint faces with a thin uniform coat of primer and allow solvent to evaporate before sealing. This takes between 30 minutes and 2 hours depending on climatic conditions. If sealant is not applied within 2 hours the joint face should be reprimed.

Properties Form:

Two part compound Base compound: viscous liquid Curing agent: liquid

Colour:

Black

MAF (BS 6093):

Butt joints 25%

Physical or chemical change:

Chemical cure

Setting time:

Where concrete joints are exposed or subject to conditions of prevailing damp or where the concrete is unusually dense or porous, (e.g. in parts of Scandinavia and Northern Europe) the use of Primer 19 is recommended. Contact the local Fosroc office for further details.

After 16 to 24 hours Colpor 200PF will be tack free and accept traffic. Full cure and maximum hardness are attained in approximately 3 to 4 days at 25°C

Primer 19 Empty the entire contents of the Primer 19 hardener tin into the base tin, and replace base tin lid. Mix thoroughly

174


Fosroc® Colpor 200PF by shaking tin for 2 minutes. Prime the joint face using a clean dry brush. Avoid over application of primer causing puddles in the bottom of the joint. Colpor 200PF should be applied between 30 minutes and 4 hours after priming. If the joint is not sealed overnight the primer film should be removed by grit blasting and the joint reprimed.

Guide to Colpor 200PF quantities

The mixed Fosroc Primer 19 should be applied within one working day. Do not split packs of Fosroc Primer 19. Mixing Drain totally the contents of the curing agent tin into the large base component tin. Using a hand held, slow speed drill (300 to 500 rpm) fitted with a Fosroc paddle blade stirrer mix for 1 minute. Stop and scrape around the top of the tin to remove any remaining curing agent. Continue to mix for 3 minutes until the material is thoroughly mixed.

Joint size in mm

Litre per metre

Metre per 5.0 litre pack

10 x 10 13 x 13 15 x 15 20 x 15 20 x 20 25 x 20 25 x 25 30 x 25

0.100 0.169 0.225 0.300 0.400 0.500 0.625 0.750

50.00 29.58 22.22 16.66 12.50 10.00 8.00 6.66

1 litre of Fosroc Primer 20 or Fosroc Primer 19 will be sufficient for 25 litres of Colpor 200PF. Yields are theoretical, no allowance has been made for variations in joint dimensions or wastage.

In cold weather, Colpor 200PF mixes more easily if stored overnight at room temperature.

Limitations

Application

For the sealing of industrial floor joints, higher modulus sealants such as Thioflex 600* or Expoflex 800* (see separate data sheets) are recommended.

Pour mixed sealant into a Fosroc G Gun after removing the nozzle end cap, pulling back the plunger rod and replacing end nozzle. In joints of 25 mm and above, the mixed sealant may be poured directly from the tin by bending the side to form a pouring lip. Apply mixed sealant so that the finished level of the seal is recessed below the trafficked surface as specified.

Colpor 200PF is not compatible with bituminous surfaces. Where Colpor 200PF could come into contact with pavement asphalt, please contact the local Fosroc office for advice.

Cleaning

Storage

Clean equipment immediately after use with Fosroc Equipment Cleaner. Remove mixed material from the hands with ‘Swarfega’ or similar industrial hand cleanser.

Store Colpor 200PF in original containers in cool, dry conditions i.e. not exceeding 25°C. Storage life in these conditions is 12 months. Storage above this temperature may reduce storage life.

Estimating Precautions

Packaging

Health and safety

Colpor 200PF is supplied in cartons containing 2 x 5 litre units, comprising a tin of base and a tin of curing agent.


For machine application Colpor 200PF is available in 20 litre units. Where a fast cure machine application is required refer to Nitoseal 888 data sheet.

Colpor is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

175





Hot poured ‘N1’ polymer modified bitumen sealant

Properties Form:

Plastic solid

Uses

Colour:

Black

For the sealing and maintenance of joints in concrete roads and asphalt surfacing

Movement accommodation factor (BS 6093):

Butt joints 25%

Advantages


Over 5°C

Safe heating temperature:

185°C

Pouring temperature:

165°C to 175°C


Not resistant to petrol, diesel, lubricating oils or greases

Solids content:

100%

Density:

1.15 ± 0.05

Flash point:

Over 65°C

Complies with the Department of Transport Specification for Highway Works Clauses 1016 and 1017 Resists dirt and ingress of grit associated with trafficked pavements Good adhesion to concrete and asphalt surfaces

Description Nitoseal 333 is a hot poured, high extension polymer modified bitumen sealant complying with the requirements of BS 2499 : 1993 Type N1.

Applications instructions

Nitoseal 333 has a movement accommodation factor of 25% in butt joints. For optimum performance, consideration should be given to the possibility that the movement accommodation will not be evenly distributed between joints provided.

Joint preparation Joint sealing slots in concrete should be accurately formed 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. The prepared sealing slot should be blown out with dry, oilfree compressed air. BS 2499 : 1993 Pt 2 sets out a code of practice for the application and use of hot applied joint sealants for concrete pavements.

To ensure the sealant operates within the stated movement capacity of 25%, the width of the sealing slot should be designed in accordance with the recommendations of BS 6093. Reference should also be made to Specification for Highway Works 1991, Table 10/6.

Priming Prime concrete surfaces with Fosroc Primer B2 and allow the solvent to evaporate before sealing. Metal surfaces do not require priming but should be warmed with a gas torch immediately before sealing to promote adhesion.

Standards compliance BS 2499 : 1993 Type N1.

Application

Nitoseal 333 has been independently tested to BS 2499 : N1 in accordance with the Department of Transport Specification for Highway Works.

It is essential that the correct equipment is used for melting Nitoseal 333 to ensure that the subsequent performance is not impaired by damage through overheating or pouring at the wrong temperature. The heating apparatus must be fitted with a thermometer, an oil jacket and a means of stirring the molten compound.

Specification clauses Where so designated on the drawing, joints are to be sealed using Nitoseal 333 pavement sealant manufactured by Fosroc to BS 2499 : 1993 and independently certified to Type N1 of this specification. Joints shall be prepared and the sealant applied in accordance with the manufacturers current data sheet.

Remove Nitoseal 333 from outer cardboard packing. No cardboard should be put into the heater. Cut Nitoseal 333 and inner plastic bag into small pieces, melt a few pieces in the melting vessel, and gradually add more to the molten material, stirring occasionally. Heat until Nitoseal 333 reaches its correct pouring temperature of 165°C to 175°C.

Joint size Nitoseal 333 can normally be applied to a maximum joint size of 30 mm width and 25 mm depth. Minimum joint width and depth dimensions should not be less than 13 x 15 mm respectively except for longitudinal joints. Reference should be made to Specification for Highway Works 1991, Table 10/6 and BS 2499.

Extra care must be taken in cold weather. The cold surfaces of the joints may cause rapid chilling of the compound. To help compensate for this, Nitoseal 333 should be poured at the top limit of the pouring

176


Fosroc® Nitoseal 333 Storage

temperature range. Frost may give concrete a deceptively dry appearance.

Nitoseal 333 must be stacked flat not more than six high and covered if stored outside.

Nitoseal 333 should be poured to a level 5 to 7 mm below the traffic surface, or to the level specified.

Fosroc Primer B2 should be stored in accordance with the Highly Flammable Liquids and Liquefied Petroleum Gases Regulations 1972.

Nitoseal 333 which has been heated and then allowed to cool below 95°C must be discarded. Cleaning

Limitations

Equipment should be emptied immediately after use. Nitoseal 333 which has been heated and allowed to cool completely must be discarded.

Nitoseal 333 is not suitable for use in contact with tar or pitch based materials.

Ancillary materials

Nitoseal 333 should not be used in contact with potable water.

Fosroc Primer B2 Fosroc Fibreboard

Precautions

Fosroc Equipment Cleaner

Health and safety

Estimating


Packaging

Fire

Nitoseal 333 is supplied in 15 kg packs.

Fosroc Primer B2 is flammable. Keep away from sources of ignition. No Smoking. In the event of fire, extinguish with CO2 or foam. Do not use a water jet.

Guide to Nitoseal 333 quantities Joint size in mm

Kg per metre

Metres per 15 kg pack

0.12 0.15 0.18 0.24 0.23 0.26 0.36 0.43 0.48 0.58 0.72 0.86

120 100 83 62 65 57 40 35 31 26 21 17

10 x 10 10 x 13 10 x 15 10 x 20 13 x 15 15 x 15 15 x 20 15 x 25 20 x 20 20 x 25 25 x 25 30 x 25

Additional information Technical data — ancillary materials Fosroc Primer B2 Flash point:

0°C

Specific gravity:

0.9

Coverage:

12 m²/litre


5°C to 50°C

Pack size:

5 litre

1 litre of Fosroc Primer B2 will be sufficient for 50 kg of Nitoseal 333. These are theoretical yields. No allowance has been made for variations in joint dimensions or wastage.

Nitoseal is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

177


12 CI/SfB: March 2009



High performance, elastomeric, pavement joint sealant Uses For the sealing and maintenance of joints in concrete roads, concrete runways and hard standings. Nitoseal 878 is particularly suitable for sealing areas where fuel and oil spillage might occur such as aircraft fuelling areas, oil terminals, garage forecourts, parking and cargo areas.

Advantages


Aviation fuels Hydraulic fluids Skydrol Kerosene Petrol Diesel fuels

Synthetic oils Mineral oils White spirit Mild alkalis Dilute acids De-icing salts Urea

Solids content:

100%

Flash point:

Over 65°C

Flammability:



Fuel, oil and hydraulic fluid resistance

Joint preparation

High durability and long service life High movement accommodation

Joint sealing slots in concrete should be accurately formed and must be dry, sound, clean and free from frost.

Standards

Description

Remove all dust and laitance by grit blasting or grinding. Avoid polishing the joint sides when grinding. The prepared sealing slot should be blown out with dry, oilfree compressed air.

Nitoseal 878 is a two component product designed to retain its movement accommodation of 25% on butt joints throughout temperature extremes. It does not harden in cold weather nor become excessively soft or pick up in hot conditions.

Ensure that any expansion joint filler is tightly packed in the joint and insert a bond breaker or Expandafoam cord caulked tightly into the base of the sealing groove to prevent sealant adhering to the base of the slot and provide the specified depth of sealant.

In trafficked areas the maximum expansion joint width should be limited to 30mm. It is necessary to recess the level of the sealant 5-8 mm below the pavement surface dependent on the time of year and temperature prevailing at the time of sealing.

Priming

British Standard 5212:1990 - types N, F and FB.

Concrete joint faces should be primed with Fosroc Primer 20. Decant sufficient primer into a clean dry tin for the day’s usage. Do not return unused primer to the supply tin. Prime the joint faces with a thin uniform coat of primer and allow solvent to evaporate before sealing. This takes between 30 minutes and 2 hours depending on climatic conditions. If sealant is not applied within 2 hours the joint face should be reprimed.

The width/depth ratio of the Nitoseal 878 seal should be 1:1 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 product comprising liquid base and curative

Colour:

Grey

MAF (BS 6093):

Butt joints 25%

Cure process:

Chemical cure

Where concrete joints are exposed, or subject to conditions of prevailing damp, or where the concrete is unusually dense or porous, the use of Primer 19 is recommended. Contact the local Fosroc office for further details. Empty the entire contents of the Primer 19 hardener tin into the base tin, and replace base tin lid. Mix thoroughly by shaking tin for 2 minutes. Prime the joint face using a clean dry brush. Avoid over application of primer causing puddles in the bottom of the joint. Nitoseal 878 should be applied between 30 minutes and 4 hours after priming. If sealant is not applied within 4 hours the joint face should be reprimed.

Application temperatures:

5°C - 35°C

Setting Time:

After 6 hours @ 25o C Nitoseal 878 will be tack free and accept traffic. Full cure and maximum hardness will be achieved in 3-4 days at 25oC

The mixed Fosroc Primer 19 should be applied within one working day. Do not split packs of Fosroc Primer 19.

Shore A Hardness: 20

178

12 CI/SfB: March 2009

Fosroc® Nitoseal 878 1 litre of Fosroc Primer 19 or 20 will be sufficient for 20 litres of Nitoseal 878. Yields are theoretical, no allowance has been made for variations in joint dimensions or wastage.

Mixing Drain totally the contents of the curing agent tin into the large base component tin. Using a hand held, slow speed drill (300 to 500 rpm) fitted with a Fosroc paddle blade stirrer mix for 1 minute. Stop and scrape around the top of the tin to remove any remaining curing agent. Continue to mix for 3 minutes until the material is thoroughly mixed.

Limitations Apply at temperatures of 5°C and rising. Do not warm material above 35°C.

In cold weather, Nitoseal 878 mixes more easily if stored overnight at room temperature.

Do not apply direct heat to product. Nitoseal 878 is not compatible with bituminous surfaces. Where Nitoseal 878 could come into contact with pavement asphalt, please contact the local Fosroc Technical Department.

Application Pour mixed sealant into a Fosroc G Gun after removing the nozzle end cap, pulling back the plunger rod and replacing end nozzle. In joints of 25 mm and above, the mixed sealant may be poured directly from the tin by bending the side to form a pouring lip. Apply mixed sealant so that the finished level of the seal is recessed below the trafficked surface as specified.

For the sealing of industrial floor joints, higher modulus sealants such as Nitoseal MS300* or Expoflex 800* are recommended. *See seperate data sheet

Storage

Cleaning

Nitoseal 878: 12 months in original containers stored in cool, dry conditions i.e. not exceeding 25°C. Higher temperatures may reduce storage life.

Clean equipment immediately after use with Fosroc Equipment Cleaner. Remove mixed material from hands with ‘Swarfega’ or similar industrial hand cleanser.

Precautions

Estimating

Health and safety

Packaging


Nitoseal 878 is supplied in cartons containing 2 x 5 litre units, comprising a tin of base and a tin of curing agent. Guide to Nitoseal 878 quantities Joint size in mm

Litre per metre

Metre per 20.0 litre pack

10 x 10

0.100

200

13 x 13

0.169

118

15 x 15

0.225

89

20 x 15

0.300

67

20 x 20

0.400

50

25 x 20

0.500

40

25 x 25

0.625

32

30 x 25

0.750

26



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telephone: +44 0 (1827) 262222

fax: +44 0 (1827) 262444

179



Fosroc® Pliastic


Hot-poured rubber bitumen horizontal joint sealant

Water excluding structures All joints which extend below the high water table level should contain a waterstop in addition to the Pliastic seal.

Uses

Services and internal finishes

For sealing movement and construction joints in pavements, floor slabs, water retaining and water excluding structures

Pliastic 77 is suitable for sealing joints in factory floors other than those subjected to petrol, oils or fats. Pliastic softens when heated and should not be used in floors with under-floor heating or in areas where it would be subjected to heat from factory plant or steam cleaning operations.

Advantages An economic sealant for horizontal and inclined joints up to 1 in 20

Ensure the joint is recessed 3 to 5 mm below the traffic surface.

Resists dirt and ingress of grit associated with trafficked pavements Good adhesion to concrete and asphalt surfaces

Properties


Form:

Plastic solid

BS 2499 : 1993 — Pliastic N2.

Flash point:

Over 65°C

Solids contents: Density: Colour: Application temperature:

100% 1.02 kg/litre Black

Product pouring temperature range:

Pliastic N2: 175°C to 185°C Pliastic 77: 180°C to 190°C

Safe heating temperature:

Pliastic N2: 190°C Pliastic 77: 195°C


Dilute acids: resistant Dilute alkalis: resistant Petroleum solvents: not resistant Mineral oils: not resistant Vegetable oils: not resistant Greases: not resistant

Movement accommodation factor:

Total joint range, butt joints: Pliastic N2: 12% Pliastic 77: 10%

Description Pliastic sealants are available in a choice of two grades: Pliastic N2 Complies with BS 2499 : 1993. A low extension grade for sealing joints in concrete pavements, etc. Pliastic 77 A hard grade for sealing low movement joints in factory floors and areas where joints are closely spaced and resistance to grit and traffic is of prime importance.

Design criteria Joint size Pliastic compounds are suitable for joints up to 30 mm wide in trafficked surfaces, but joints up to 65 mm wide can be sealed with Pliastic where the joints are horizontal and are not subject to trafficking. The depth of Pliastic compounds should not exceed 50 mm and for most normal uses, 25 mm is recommended.

Over 5°C

Maintenance No special requirement, damage should be repaired if and when it occurs.

Pliastic can be used on inclined surfaces up to about 1 in 20. Extra care must be taken, however, when pouring. Vertical joints e.g. kerbs, upstands, etc, should be sealed with Plastijoint.


Road and traffic surfaces

Ensure that the joint surfaces are completely dry, clean and frost free. Remove all contamination preferably by grit blasting or by rigorous wire brushing.

When sealing joints in reinforced and unreinforced concrete roads and airfield runways ensure the joint is recessed 3 to 5 mm below the traffic surface.

Immediately prior to priming blow out all remaining loose dust with dry, oil-free compressed air.

Water retaining structures When sealing joints in water retaining structures all immersed joints should contain waterstops. All roof joints should also include a supplementary means of sealing.

Where applicable, care must be taken to ensure that compressible filler, such as Fosroc Fibreboard, will provide adequate support for the Pliastic compound.

180


Fosroc® Pliastic Priming porous surfaces

Application

Use Fosroc Primer B2 on concrete, stone and brick paving. Allow primer to become touch dry before sealing, normally 1 to 4 hours.

Joints should be filled to the surface of the concrete or to the level specified. Joint seals in carriageways are normally recessed 3 to 5 mm to avoid extrusion. A concave finish due to shrinkage on cooling is normal but in a deep or narrow joint the compound may be poured in two layers to produce a uniform finish.

Priming non-porous surfaces Metal surfaces do not require priming but should be warmed to ensure satisfactory adhesion. Ferrous metals should be treated with an anti-corrosion primer.

Cleaning Equipment should be emptied immediately after use. Compound which has been heated and allowed to cool completely must be scrapped.

Stripping of sacks Lay sack on flat surface and cut bottom seam with a sharp knife. Tear away outer layers and then strip off inner layer of paper, working from the bottom of the sack. No paper should be put into the heater.

Estimating Packaging

Heating

Pliastic N2 and Pliastic 77 are supplied in the UK in paper sacks containing 15 kg. All grades of Pliastic are supplied overseas in steel drums containing 50 kg.

The use of a heating vessel with an oil jacket and fitted with stirrer and thermometer is essential.

Fosroc Primer B2 is supplied in 5 or 25 litre cans.

Cut the compound into small pieces, melt a few pieces then gradually add more pieces to the molten material, stirring continuously. Heat until the compound reaches correct pouring temperature.

Guide to primer quantities 5 litres Fosroc Primer B2 for 250 kg of Pliastic.

Pouring temperatures: Pliastic N2: 175°C to 185°C. Pliastic 77: 180°C to 190°C.

Guide to Pliastic quantities

Do not overheat. Use as soon as possible after heating, preferably within 2 hours.

Joint size in mm

Safe heating temperatures: Pliastic N2: 190°C. Pliastic 77: 195°C.

10 x 20 25 30 40 15 x 20 25 30 40 50 20 x 20 25 30 40 30 x 25 30 40 50 40 x 25 40 50

Caution: Heating of compound should be carried out in well ventilated areas. Extra care should be taken in cold weather. The cold surfaces of the joints may cause rapid chilling of the compound. To help compensate for this, the compound should be poured at the top limit of the pouring temperature range. Frost may give concrete a deceptively dry appearance. Compound which has been heated and then allowed to cool below 95°C must be scrapped. It must not be remelted for use. In expansion joints, Pliastic should be poured to a level 3 to 5 mm below the traffic surface to allow for upward displacement when the joints close. Note: For small jobs, Pliastic 77 may be used with a small, directly heated vessel, but great care must be taken to avoid over-heating the Pliastic compound. In such cases limited quantities of the material should be cut up into small lumps and melted by gradually adding the pieces to the molten mass whilst continually stirring.


Kg per metre run

Metre per 15 kg sack

Metre per 50 kg drum

0.20 0.25 0.29 0.39 0.29 0.37 0.44 0.59 0.74 0.39 0.49 0.59 0.78 0.74 0.88 1.18 1.47 0.98 1.57 1.96

76 61 51 38 51 41 34 26 20 38 31 26 19 20 17 13 10 15 10 8

255 204 170 127 170 136 113 85 68 128 102 85 64 68 57 43 34 51 32 26


Fosroc® Pliastic Limitations

Precautions

Pliastic compounds are suitable for sealing against bituminous asphalt surfaces. Pliastic compounds do not comply with the fuel resistant requirements of BS 2499 : 1993 and should not be used in airfield hardstandings, cargo handling areas, garage forecourts or other paved areas subject to fuel and oil spillage. For these applications Colpor 200PF should be used.


Water excluding substructures Pliastic compounds are suitable for use in joints in building basements, subways, etc. All joints which extend below the high water table level should contain waterstops in addition to the Pliastic seal.

Storage Pliastic must be stacked flat not more than six high and covered if stored outside. Fosroc Primer B2 must be stored in accordance with the Highly Flammable Liquids and Liquefied Petroleum Gases Regulations 1972. Storage life is 2 years if kept in the above conditions.

Pliastic is a trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

182



Fosroc® Expoflex 800


Heavy duty epoxy urethane joint sealant


Resistant to alcohols, alkalis, mineral oil, hot detergent solution, 60% live steam, 25% mineral acids, vegetable oils and kerosene

UV resistance:

Some surface discolouration and slight surface hardening

Uses For sealing internal joints subject to, heavy loading, and abrasion or where chemical resistance is required. Can be used in factories, warehouses and distribution centres. It is, particularly effective where there is forklift truck traffic. Expoflex 800 can also be used where joints would be subject to stiletto heels, shopping centres, podium etc.

Advantages

Solids content:

100%

Density: Flash point:

1.4 g/cm³ Over 65°C


Cures to a tough seal

Joint Design

Abrasion resistant High modulus

Joints should be designed so that joint changes do not exceed the 10% MAF of Expoflex 800.

Resistant to chemical, fuel and oil spillage Easily installed to give a flush finish

We would recommend that joints in new concrete slabs are left to the final stages of construction when temperatures have stabilised and the initial shrinkage has taken place.

Description Expoflex 800 is a two-component elastomeric sealant for limited movement joints. After mixing, the resultant compound will cure to provide an exceptionally robust seal, while retaining a degree of flexibility. Expoflex 800 is abrasion resistant and withstands spillage of fuel oils, mineral acids and vegetable oils. Expoflex 800 can be used in joints between 5 mm and 50 mm wide.

Where joints are less than 25 mm and are fully supported by a solid backing, minimum depth should be 10 mm to 15 mm. Where a resilient backing, minimum depth should be 20mm. For wider joints a square section is preferable Preparation Joint surfaces shall be clean, dry and free from contamination. Any voids or gaps at the base of the sealing slot should be filled and a suitable bond breaker should be pushed into construction and contraction joint slots. Where a particularly neat finish is required mask edges of joint before priming (if required) and sealant application.

Specification clauses The joint sealant shall be Fosroc Expoflex 800, an epoxy urethane, heavy duty sealant. It shall be applied strictly in accordance with the Fosroc data sheet.

Properties Priming Expoflex 800

Colour:

Light grey

MAF (BS 6093):

10% for butt joints

Cure:

Chemical cure

Pot life:

1 hour at 25°C

Where surface shall be subject to submersion or permanently damp, joints should be primed using Fosroc Primer 13X. Decant the entire contents of primer curing agent into the primer base and stir thoroughly until mixed. Apply the primer using a clean dry paint brush working well in to ensure complete coverage. Allow to dry for 30 minutes prior to application of the sealant. If the primer coating is left for more than 2 hours, re-prime.

Trafficking time:

24 hours at 20°C: light traffic 48 hours at 20°C: heavy traffic

Mixing


To avoid prolonged cure time apply Expoflex 800 above 5°C

Hardness Shore ‘A’:

65 to 80

Form:

Two-part compound Base: White paste Curing agent: Grey paste

In cold weather Expoflex 800 mixes more easily if stored overnight at room temperature. Transfer the contents of the small tin into the base tin and mix thoroughly using a slow speed drill (300 to 500 rpm) fitted with a Fosroc Paddle Stirrer until a uniform colour is achieved throughout. Immediately after mixing load the Expoflex 183


Fosroc® Expoflex 800 800 into a “G” gun using a follower plate. Extrude the sealant firmly into joint to ensure complete contact with the joint face.

Storage Storage life of 12 months in original containers when kept in dry conditions between 5°C and 27°C.

Finishing

Precautions Expoflex should be tooled off flush with adjacent surfaces. A minimum of surface lubrication such as dilute detergent solution may be used to assist the process. Remove masking immediately after tooling.



Estimating Expoflex 800 is supplied in 2 litre tins in cartons of two. Guide to quantities Joint size w x d in mm


Metre run per 2.0 litre pack

0.075 0.100 0.200 0.500 0.625 0.750 0.900 1.000 1.600 1.250 2.500

26.67 20.00 10.00 4.00 3.20 2.67 2.22 2.00 1.25 1.60 0.80

5 x 15 5 x 20 20 x 10 20 x 25 25 x 25 30 x 25 30 x 30 40 x 25 40 x 40 50 x 25 50 x 50

200 ml tin of Fosroc Primer 13X is sufficient for 2m2 of Expoflex 800. These are theoretical yields. No allowance has been made for variations in joint width or wastage.

Expoflex is the trade mark of Fosroc International Limited



www.fosroc.com

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fax: +44 (0) 1827 262444

184



Fosroc® Hilastic LM


One-part, low modulus neutral cure silicone sealant


Uses

Joint surfaces must be clean, dry and free from frost. Remove all dirt, laitance, loose material and foreign matter. Remove all rust, scale and protective lacquers from metal surfaces. Non-porous surfaces should be degreased using Fosroc Solvent 102.

Preparation

For sealing joints in building structures, uPVC windows and door frames. Advantages

In movement joints Hilastic LM must be supported by Expandafoam cord backing which will allow free movement. If insufficient depth is available use a self adhesive bond breaking tape.

Neutral cure system — appropriate for porous and non-porous surfaces

Elastic low modulus seal Good adhesion to a variety of substrates including

Where a particularly neat finish is required, cover face edges with a masking tape and remove immediately after sealing work is completed.

uPVC

Good application properties

Application

Description

Extrude the sealant firmly into the joint to ensure complete contact with joint faces. Smooth finish if necessary with a spatula wetted with detergent solution. Joint should be tooled within 5 minutes of application.

Hilastic LM is a one-part neutral curing silicone sealant suitable for sealing around uPVC windows and movement joints in concrete, brickwork and a variety of other substrates. Hilastic LM cures on exposure to air and humidity to form a flexible seal that requires no maintenance throughout its service life.

Cleaning Clean tools immediately after use with Fosroc Equipment Cleaner. Clean hands with a proprietary hand cleaner.

Hilastic LM may be applied to joints between 5 and 25 mm wide and 5 and 12 mm deep. For joints over 10 mm wide, a width to depth ratio of 2 : 1 should be applied up to a maximum depth of 12 mm.

Limitations Not suitable for trafficked joints or for permanently immersed conditions.

Properties Form:

Thixotropic paste

Should not be used on substrates which bleed oils, plasticisers or solvents.

Colours:

White, brown, grey, buff, brick red, portland, black, dark grey

Not to be used with bitumen compounds.

Cure:

Chemically cures to a solid rubber

Skinning time @ 23°C:

Cure may be retarded in conditions of very low humidity and temperature.

30 minutes

Hilastic LM should not be overcoated or painted even when fully cured.

Cure rate @ 20°C / 65% RH: 1 mm / day Application temperature: Typical hardness shore @ 20°C / 60% RH: Movement accommodation factor (MAF):

Like most silicone sealants, Hilastic LM should not be used on natural stone.

5°C to 40°C

Estimating 30

Packaging

50%

380 ml plastic cartridges with separate screw-on nozzles, packed in cartons of 20. Total contents approximately 7.6 litres.

185


Fosroc® Hilastic LM Guide to sealant quantities Joint size in mm

Litre per metre run

Metre per 380 ml cartridge

0.025 0.050 0.100 0.150 0.200 0.300

15.20 7.60 3.80 2.53 1.90 1.27

5x5 5 x 10 10 x 10 15 x 10 20 x 10 25 x 12

These are theoretical values. No allowance has been made for variation in joint dimensions or wastage.

Storage Storage life 12 months. Store in original containers in cool, dry conditions. Storage outside these conditions may reduce shelf life.

Precautions Health and safety For further information refer to appropriate Product Safety Data Sheet.

Hilastic is the trademark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

186





One part, general purpose building sealant Uses

Joints in concrete should preferably be sawn. After sawing all saw slurry must be flushed away and the joint allowed to dry.

Nitoseal MS50 is suitable for sealing joints in Concrete, Brickwork, Blockwork, Perimeter sealing around doors and windows, Non-trafficked floor joints.

When resealing, the existing sealant should be removed from the joint and the arris cleaned back to sound clean concrete. All debris should be removed.

Advantages

Any expansion joint filler must be checked to ensure it is tightly packed and no gaps or voids exist at the base of the sealing slot before positioning a bond breaker.

Excellent adhesion to most common building materials

The use of a bond breaker is not required in expansion joints containing cellular polyethylene joint filler such as Hydrocell XL or Expandafoam. For construction or contraction joints a bond breaker tape or back-up strip must be used.

Single component with fast rate of cure Easy to apply at low temperature Can be applied to damp substrates Environmentally friendly

Where a particularly neat finish is required, mask the face edges of the joint before sealing and remove immediately after tooling is completed.

Primer-less for most applications (see “Priming”) Available in a range of colours (see “Properties”) Isocyanate free technology

Priming

Acts as an acoustic sealant

In joints where limited movement is expected, a primer is not normally required. In joints subjected to high movement or where intermittently immersed during service Fosroc Primer MS1 is recommended.

Description Nitoseal MS50 is a one part, medium modulus sealant based on hybrid silyl modified polyether technology.

Prime the joint face using a clean, dry brush. Avoid over application of primer causing puddles in the bottom of the joint.

Properties Form

Smooth, non-slumping paste

Colour

White, Grey, Black, Magnolia, Buff, Portland,Rustic Red, Brown, Anthracite

Flash point

> 65oC

Skinning time at 20 C / 50%RH

30 minutes

Cure rate at 20 C, 50% RH

24 hours 48 hours 72 hours

Application temperature

5oC to 50oC

Sachets

Typical hardness Shore “A” at 20 C

28

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 for sealing the joint.

Nitoseal MS50 should be applied between 30 minutes and 4 hours after priming. If a joint is left unsealed for more than 4 hours, the primer should be removed by grit blasting or grinding and the joint reprimed. (For further advice on priming required please contact your local Fosroc Technical Service Department.

3mm 6mm 8mm

Application and finishing

Movement accommodation 20% factor (MAF) UV resistance

Cartridges

Good Cut end off threaded stub on cartridge, Fit the nozzle and cut at 45 degrees at a suitable size for sealing the joint.

Service temperature range -30oC to 70oC

Extrude the sealant firmly in to the joint. Tool flush within 5 minutes of application to ensure good contact between the sealant and the substrate.

Application instructions Joint surfaces must be clean dry and free from frost. Remove all dirt, laitance, loose material and foreign matter. Remove all rust, scale and protective lacquers from metal surfaces.

Cleaning Clean tools immediately after use with Fosroc Equipment Cleaner.

Removal can be achieved by rigorous wire brushing, grinding or grit blasting.

187


Fosroc® Nitoseal MS50 Estimating

Storage

Guide to sealant quantities

Store in original packaging in cool, dry conditions. Shelf life 12 months. Storage outside of these conditions may reduce shelf life.

Joint size Litres/ mm metre run 6 x 10 12 x 10 20 x 10 25 x 12 30 x 15

Metres/ 380ml crtdge

0.06 0.12 0.20 0.30 0.45

Metres/ 600ml sachets

6.33 3.17 1.90 1.27 0.84

10.00 5.00 1.00 2.00 1.33

Precautions Health and safety Nitoseal MS50 is considered safe in normal use. For further information refer to appropriate Product Safety Data Sheet. Fosroc Primer MS1 is flammable, see Material Safety Data Sheet for details.

0.5 litres of Fosroc Primer MS1 will be sufficient for 60m of joint. No allowance has been made for joint size or wastage. Packaging Nitoseal MS50

10x600ml sachets per box in Grey 20x380ml cartridges per box in all colours

Fosroc Primer MS1

0.5 litre packs

Limitations Should not be applied at temperatures below 5oC Not suitable for water immersed conditions. Nitoseal MS600 should be used for this application Not suitable for contact with bituminous materials Not suitable for trafficked floor joints. Nitoseal MS300 should be used for this application May cause staining to decorative stone. For a non-staining sealant use Nitoseal MS100 Not suitable for contact with solvents, oil or petrol Nitoseal MS50 should only be over-painted with a compatible, flexible coating capable of accommodating the envisaged movement in the joint. Overcoating may reduce the MAF of the sealant.



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13 CI/SfB: Yt4 January 2006



One part, primer-less, non-staining facade sealant Uses Nitoseal MS100 has been formulated for stain-free sealing of joints in and around concrete, brick, masonry, pre-cast panels, stone cladding, windows, doors and fibre cement sheeting.

Advantages Will not stain masonry, marble or other surfaces. Excellent primer-less* adhesion to most common building materials. Can be applied to damp substrates Fast neutral cure. Highly flexible with excellent application characteristics. Low odour, environmentally friendly. Low modulus and high movement capabilities. Excellent UV and weather resistance Nitoseal MS100 may be used as a sealant to assist with sound insulation. Cured sealant:

Good adhesion to silicone, polysulphide or polyurethane contaminant.

Form:

Elastic solid

* Refer to Priming section.

Colour:

White, Grey, Black, Portland, Buff, Rustic Red

Standard compliance

Typical hardnesss Shore 'A' @ 20oC:

20

Modulus classification:

Low

U.V. resistance:

Excellent

Service temperature range:

-40oC to 70oC

MAF:

Butt joints

ISO 11600 Type F 25LM

Description Nitoseal MS100 is a tough, durable elastomeric joint sealant. It is based upon hybrid silyl modified polyether technology. It is suitable for use over a wide range of external and internal building applications and has excellent weather resistance.

Lap joints

Nitoseal MS100 has excellent primer-less adhesion to a wide range of common building substrates and does not stain concrete, marble and other masonry surfaces.

25% 50% 50% 100%

unprimed primed unprimed primed

Application Instructions

Properties

Preparation

Uncured sealant: Form:

Smooth, non slump paste

Flash point:

>65oC

Solids content:

100% approximately

Application temperature range:

5oC to 50oC

Skinning time:

25 mins, 20oC/50% RH

Cure rate:

3 mm in 24 hrs, 8mm in 7 days 20oC/50% RH

Joint surfaces must be clean and free from frost and rag dry, preferably completely dry. Remove all dirt, laitence, loose materials and foreign matter. Remove all rust, scale and protective lacquers from metal surfaces. Non porous surfaces should be degreased using Fosroc Equipment Cleaner. In all joints an Expandafoam or Hydrocell XL polyethylene foam backing should be used to prevent sealant contact with the back of the joint, and hence allow optimum performance. In shallow joints self adhesive debonding tape can be used. 189


Fosroc® Nitoseal MS100 Guide to sealant quantities

Priming Good adhesion can be gained on concrete, timber, metals, ceramics, brickwork and most coating surfaces without the use of primers. On some porous surfaces such as GRC, adhesion will be improved by the use of a primer - 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 a 45o angle. Extrude the sealant firmly into joint to ensure complete contact with joint faces. Smooth finish if necessary with a spatula wetted with a dilute detergent solution.

Joint size in mm

Litre per metre run

3x5 3 x 10 5x5 5 x 10 10 x 5 10 x 10 15 x 10 20 x 10 25 x 15

0.015 0.030 0.025 0.050 0.050 0.100 0.150 0.200 0.380

Metre per 0.38 litre cartridge 25.3 12.66 15.2 7.6 7.6 3.8 2.54 1.9 1.0

These are theoretical yields. No allowance has been made for variation in joint dimensions or wastage.

Cleaning Clean tools immediately after use with Fosroc Equipment Cleaner. Overpainting The practice of overpainting sealants which experience a high degree of movement is discouraged as it can result in premature failure of the sealant. However, Nitoseal MS100 may be overcoated with waterbased elastomeric coatings such as Dekguard Elastic and exterior emulsion paints such as Dekguard W. Tests should be carried out to confirm compatability of sealant and proposed paint systems. Nitoseal MS100 should be allowed to cure fully before the application of the coating or paint. For best results the sealant should be allowed to weather prior to overcoating.

Design criteria Movement Accommodation Factor (MAF) The Movement Accommodation Factor is a figure quoted indicating the ability of a sealant to accommodate joint movement throughout the service life of that sealant, expressed as a percentage of the joint width at time of sealing. To calculate the theoretical / minimum joint width knowing the expected maximum working movement of the joint: W=

M +M MAF/100

W = Joint width M = Expected maximum working movement of joint MAF = Movement Accommodation Factor of that sealant For further advice on joint design see BS 6093 :1993.

Estimating Nitoseal MS100 is supplied in 380 ml cartridges. To work out quantities (excluding wastage) use the following formula: S__ = Lineal metres per pack WxD S = Packaging size in millilitres W = Sealant profile width in millimetres D = Sealant profile depth in millimetres

Nitoseal MS100 may be applied to joints between 5 and 35 mm wide. To minimise stresses imposed on the joint sealant, all moving joints should be designed to an optimum width to depth ratio of 2:1. This ratio is subject to these overriding minimum sealant depths: 5 mm minimum sealant depth at any point. 5 mm minimum bonding depth against metals, glass and other non-porous surfaces, providing that joint faces are in good condition. 8 mm minimum bonding depth against masonry or other porous surfaces, or any non-porous surfaces where joint faces are in poor condition. Shear joints shall be a minimum joint width to depth ratio of 1:2 up to a maximum of 1:1. The total movement in shear should not exceed 80% of joint depth at time of sealing in these joints.



Fosroc® Nitoseal MS100 Sealants are now commonly used as weatherseals in place of flashings and scribers around window and door openings. These areas require greater attention to detail and standards of workmanship to perform successfully.

Example of sealed movement joint in external joint panels 1

Example of sealed perimeter joint of plastic or metal frame 2

1 Nitoseal MS100

2 2 Expandafoam cord

Limitations Nitoseal MS100 must not be used as follows:

Where adhesion is required to polyethylene, polypropylene, polybutylene, polycarbonate and bitumen.

Where it is subjected to permanent immersion in water.

With structural glazing or floor joints. With pipes or in other applications where it may be

1

subjected to hydrostatic or pneumatic pressures (other than wind pressure). 1 Nitoseal MS100

2 Secofoam

Where continual exposure to aggressive solvents or chemicals will occur.

Where timber or wood based products have been

Example of brickwork expansion joint

painted.

Nitoseal MS100 is a combustible material. Do not seal around chimney or flues.

Do not overpaint with oil based alkyd paint systems. Should not be considered a substitute for a good standard of joint preparation.

Joint arrises should be primed where movement in excess of 25% is expected.

Storage Cartridges: Shelf life 12 months when sealed and stored in cool, dry conditions. 1 1 Nitoseal MS 100

2

3

Health and safety

2 Hydrocell 3 DPM

No significant hazard. For additional information see appropriate Product Safety Data Sheet.

Nitoseal is the trade mark of Fosroc International Limited



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191


13


CI/SfB:Yt4 June 2008


One part, floor joint sealant

Cure rate at 20ºC, 50% RH 24 hours 3 mm 48 hours 6 mm 72 hours 8 mm

Uses Nitoseal MS300 is suitable for sealing saw-cut and movement joints in internal floors, and external joints where abrasion resistance is required.

Application temperature

5ºC to 50ºC

Typical hardness Shore "A" at 20ºC

45

Shopping centres

Trafficking time at 20ºC Light traffic Heavy traffic

24 hours 4 days

Warehouse and distribution depots

Modulus

High

Concrete hardstanding areas

UV resistance

Excellent

Factory floors Sports stadia terracing

Service temperature range -20ºC to 70ºC

Advantages Suitable for forklift truck traffic


Suitable for saw cut and perimeter joints

Preparation

Cures to a tough seal

Joints in concrete should preferably be sawn. After sawing all saw slurry must be flushed away and the joint allowed to dry.

Abrasion resistant Withstands vehicular traffic Single component

When resealing the existing sealant should be removed from the joint and the arris cleaned back to sound clean concrete. Remove all debris. The joint surfaces must be dry, clean and frost free. Remove all contaminants by rigorous wire brushing, grinding or grit blasting.

Fast rate of cure Easy to apply at low temperature Can be applied to damp substrates Primer-less for most applications (see "Priming" section)

Any expansion joint filler must be checked to ensure it is tightly packed and no gaps or voids exist at the base of the sealing slot before positioning a bond breaker.

Description

Note: The use of a bond breaker is not required in expansion joints containing Hydrocell XL cellular polyethylene expansion joint filler. For construction or contraction joints a bond breaker tape or back-up strip should be used.

Nitoseal MS300 is a one part, high modulus sealant based on hybrid silyl modified polyether technology. It has a rapid rate of cure and forms a tough elastomer capable of supporting heavy wheel loads. Nitoseal MS300 may be applied between 6mm and 20mm wide, for trafficked joints (up to 40mm nontrafficked). In most cases it is recommended to form a sealing slot with a square cross-section, subject to a minimum 10mm depth. To ensure the sealant operates within its stated movement accommodation capacity the sealing slot widths should be designed in accordance with the recommendations of BS6093.

Where a particularly neat finish is required, mask the face edges of the joint before priming/sealing and remove immediately after tooling is completed. Priming Fosroc Primer MS2 is required for joints that are to be intermittently or permanently immersed, or where the substrate is likely to be saturated (for example, externally).

Properties

When using a primer, empty the entire contents of the hardener tin into the base tin and replace the base tin lid. Mix thoroughly by shaking for at least 2 minutes. Prime the joint face using a clean, dry brush. Avoid over application of primer causing puddles in the bottom of the joint.

Nitoseal MS300 Form

Paste

Flash point

>65ºC

Colour

Grey For special colours contact Fosroc for further Information

Nitoseal MS300 should be applied between 30 minutes and 4 hours after priming.

Movement accommodation factor

Butt joints 25% Lap joints 50%

If a joint is left unsealed for more than 4 hours, the primer should be removed by grit blasting or grinding and the joint re-primed.

Skinning time at 20ºC/50% RH

25 minutes 192

13 CI/SfB:Yt4 June 2008

Fosroc® Nitoseal MS300 Do not split packs of Fosroc Primer MS2. Application and finishing

Limitations

Cut end off sachet and place in Fosroc GX Gun. Fit nozzle and cut at 45º to a suitable size. Extrude the sealant firmly into the joint. Tool flush within 5 minutes of application to ensure good contact between the sealant and the substrate.

Do not apply at temperatures below 5oC. Not suitable for contact with bituminous materials. Whilst Nitoseal MS 300 has excellent adhesion to many types of residual sealant its use should not be considered a substitute for a good standard of joint preparation.

Cleaning

In large joints ensure sealant is sufficiently cured before trafficking. In 40 mm joints this could be up to 10 days.

Clean tools immediately after use with Fosroc Equipment Cleaner.

Estimating

Storage

Guide to sealant quantities in traffic joints Joint size in mm

Litre per metre run

Metre per 600 ml sachet

6 x 10 12 x 12 20 x 20 25 x 20 30 x 20 40 x 25

0.06 0.144 0.40 0.50 0.60 1.00

10 4.17 1.50 1.2 1.00 0.60

Store in original containers in cool, dry conditions. Shelf life is 12 months if stored as above. Storage outside these conditions may reduce shelf life.

Precautions Health and safety Nitoseal MS300: This product is non-hazardous in normal use. For further infromation refer to appropriate Product Safety Data Sheet.

0.75 litres of Fosroc Primer MS2 will be sufficient for 90m of joint. No allowance has been made for joint size or wastage.

Fosroc Primer MS2 is highly flammable, see Product Safety Data Sheet for details.

Packaging Nitoseal MS300 - 600 ml sachets. 10 no. sachets per box. Fosroc Primer MS2 – 0.75 litre packs



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193



Fosroc® Plastiseal


Rubber-bitumen gun applied sealant

Example of a sealed roof perimeter joint is show below

Uses For sealing joints in flashings, guttering and sheet laps An integral part of the Proofex waterproofing system

Advantages Firm flexible weather resistant seal

1

Excellent slump resistance Excellent immersed adhesion Compatible with asphalt or bituminous surfaces Unaffected by alkalis or sulphates Easily gunned Suitable for joints up to 40 mm wide

Description Plastiseal is a flexible rubber-bitumen joint sealant with excellent slump resistance. Plastiseal stiffens to form a firm seal after application. A tack free surface will form within 1 or 2 days depending upon the conditions of exposure and ventilation, however the nature of bitumen means a slight 'sticky' feel will persist.

2

1 Plastiseal 2 Asphalt, bituminous or other roof finish

Design criteria Joint size: Joints should be of a size to permit adequate application of Plastiseal. Very narrow joints are difficult to seal effectively and for most applications 10 mm should be considered the minimum width. Maximum recommended width is 40 mm. A minimum seal depth of 15 mm must always be maintained.

Example of sealed joint in guttering is shown below 2

To ensure that the sealant operates within its stated movement capacity (MAF 10% in butt joints) the sealing slot widths should be designed in accordance with the recommendations of BS 6093.

1

The use of Fosroc Primer 3 is always recommended on porous surfaces.

1 Plastiseal 2 Gutter

194


Fosroc® Plastiseal Properties Form:

Semi-stiff paste

Colour:

Black

Priming porous surfaces


10% for butt joints, 20% for lap joints


Solvent release

Application temperature: Chemical resistance to occasional spillage:

allow free movement. Where a particularly neat finish is required, cover face edges of joint with masking tape before priming and remove immediately after sealing work is completed.

Use Fosroc Primer 3 on concrete, stone, brickwork, timber and unglazed edges of ceramic tiles. Allow primer to become touch-dry before sealing, normally 1 to 4 hours. Priming non-porous surfaces

5°C to 50°C Dilute acids Dilute alkalis Solvents Petroleum Lubricants

Not normally required. Ferrous metals should be treated with an anti-corrosion primer.

resistant resistant not resistant not resistant not resistant

Cleaning Clean up equipment immediately after use with Fosroc Equipment Cleaner.

Water immersion: Before permanent immersion in water Plastiseal must be left for a minimum period of 14 days to permit evaporation of its solvent content, this is dependent upon the ambient conditions and depth of Plastiseal Solids content:

90% minimum

Flash point:

61°C

Estimating Packaging Plastiseal is supplied in boxes of 20 x 380ml cartridges, 7.6 litres approximately. Alternatively, 180 litre drums can be supplied to special order. Primer 3 is supplied in 5 litre cans.

Maintenance

Guide to Plastiseal quantities

No special requirement, damage should be repaired if and when it occurs.

These are theoretical yields without allowance for joint size variation or wastage.

Specification clauses Joint size in mm wxd

Joints shall be sealed, where designated, using Plastiseal, a rubber-bitumen sealant, manufactured and supplied by Fosroc. The sealant shall be applied strictly in accordance with the manufacturer’s current technical data sheet.

Litre per metre run

Metre per 0.38 litre cartridge

Metre per box (7.6 litre)

0.15 0.20 0.23 0.30 0.40 0.50 0.38 0.63 0.75 0.90 0.88 1.00

2.50 1.90 1.70 1.30 1.00 0.80 1.00 0.61 0.51 0.42 0.43 0.3

51.0 38.0 33.8 25.3 19.0 15.2 20.3 12.2 10.1 8.4 8.7 7.6

10 x 15 20 15 x 15 20 20 x 20 25 25 x 15 25 30 x 25 30 35 x 25 40 x 25

Application instructions Joint preparation Ensure that the joint surfaces are completely dry, clean and frost-free. Remove all dirt, dust, laitance and loose material by rigorous wire brushing. Remove all rust, scale and protective lacquers from metal surfaces. Remove any oil or grease with Fosroc Equipment Cleaner. Gun loading

Coverage

Cut conical tip off cartridge and thread, screw on nozzle, cut at 45 degrees to required size and fit into a Fosroc ‘W’ Gun.

Fosroc Primer 3:

Expansion joints Plastiseal must always be supported by a firm backing to


12.5m2 per litre


Fosroc® Plastiseal Limitations Plastiseal should not be used in closed tanks where poor ventilation will seriously inhibit evaporation of solvent from the Plastiseal. Plastiseal is not suitable for trafficked surfaces. Wide joints are liable to mechnical damage.


Precautions Health and safety For further information refer to appropriate Product Safety Data Sheet. Fosroc Primer 3 is highly flammable, see material safety data sheet for details.

Plastiseal is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


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196



Fosroc® Silicone Sealant 33HM


One-part, high modulus, silicone acetoxy cure, sealant - specification grade

Design criteria Example of capped beading glazing system

Uses Silicone Sealant 33HM is ideal for sealing joints on glass and ceramic surfaces. Principal applications include: Glazing (not structural glazing)

2

1

1

Hygienic areas Hospitals Kitchens Showers

2

33

Baths and basins Sanitary ware In-situ draughtproofing to casement windows and doors

Advantages Silicone Sealant 33HM is a one-part sealant which cures on exposure to atmospheric moisture to form a tough, elastic seal providing excellent, long service life adhesion to glass, ceramic tiling and sanitary ware.

1 Silicone Sealant 33HM 2 Glazing Strip 3 Butyl glazing and bedding compound

Fast rate of cure Robust elastic seal

Example of sealed stress relief and expansion joint in ceramic tiled finishes

Excellent adhesion

1

1

Standards compliance BS 5889 : 1989 Type ‘B’.

2

3

Description Silicone Sealant 33HM is a moisture activated, acetoxy cure sealant having a very fast rate of cure, forming a tough elastic seal with excellent adhesion to glass, ceramics, aluminium, polycarbonate and acrylic surfaces. It is particularly recommended for use as a sealant for tiled surfaces, glass and sanitary ware.

1 Silicone Sealant 33HM 2 *Fosroc Debonding Tape 3 *Expandafoam * Also available from Fosroc. Note: Silicone Sealant 33HM can be used as a formed in place draughtproofing gasket to rectify ill-fitting casement window and door openings. For further information contact Fosroc Technical Service Department.

Technical support Fosroc offers a comprehensive range of high performance, high quality technical products. In addition, Fosroc offers a technical support package to specifiers and contractors which includes computer-aided design (CAD), standard details as well as on-site technical advice from staff with unrivalled experience in the industry.

Joint size: Silicone Sealant 33HM may be applied in joints between 3 and 25 mm wide and 5 and 10 mm deep. For optimum performance in joints with significant movement the depth of sealant should be between one-half and one-third of the joint width. The joint should also include a suitable back-up strip.

197

13

®

Fosroc Silicone Sealant 33HM

CI/SfB: Yt4 June 2008

Properties


Form:

Thixotropic paste

Colours:

White, translucent

Movement accommodation factor (BS 6093): Cure:

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 metal surfaces. Glass and metal surfaces should be degreased using Fosroc Equipment Cleaner.


In movement joints Silicone Sealant 33HM must always be supported by a firm back-up strip such as Expandafoam which will allow free movement. If insufficient depth is available use an adhesive bond breaking tape. A bond breaker is not required where Hydrocell or Expandafoam is used as the joint filler.

Chemically cures to a solid rubber

Skinning time, 20°C: 10 to 45 minutes Cure rate 20°C, 65% RH:

96 hours to 5 mm depth


5°C to 50°C

Typical hardness shore ‘A’ at 25°C:

24

100% modulus:

4.0 kg/cm²


Sulphuric acid 25% Hydrochloric acid 10% Acetic acid 10% Lactic acid 2% Caustic soda 10% Ammonia 10% Kerosene Mineral oil

Where a particularly neat finish is required, cover face edges of joint with masking tape before priming and remove immediately after sealing work is complete. Priming

resistant resistant resistant resistant not resistant resistant not resistant resistant

No priming required for glass, ceramics, aluminium, stainless steel, polycarbonate and acrylic surfaces. For plastics other than those listed above contact Fosroc Technical 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

Continuous service temperature range: –40°C to 120°C Solids content:

100%

Flash point:

Over 65°C

Extrude the sealant firmly into joint to ensure complete contact with joint faces. Smooth finish if necessary with a spatula wetted with a detergent solution.

Flammability:

Burns

Cleaning

Maintenance

Clean tools immediately after use with Fosroc Equipment Cleaner. Clean hands with a proprietary hand cleaner.

No special requirements, any damage identified during normal building inspections should be repaired or replaced as appropriate.

Limitations Silicone Sealant 33HM is not intended for use in structural glazing applications.


Not suitable for use on concrete and other alkaline surfaces. Use Hilastic LM.

Joints shall be sealed using Silicone Sealant 33HM complying with BS 5889 Type ‘B’ manufactured by Fosroc. Joints shall be prepared and the sealant applied in accordance with the manufacturer’s current data sheet.

White Silicone Sealant 33HM contains a fungicide and is unsuitable 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 6.2 litres.



Fosroc® Silicone Sealant 33HM Guide to sealant quantities Joint size in mm

Litre per metre run

Metre per 0.31 litre cartridge

0.015 0.030 0.025 0.050 0.050 0.100 0.150 0.200

20.7 10.3 12.4 6.2 6.2 3.2 2.1 1.6

3x5 3 x 10 5x5 5 x 10 10 x 5 10 x 10 15 x 10 20 x 10


Storage 12 months minimum storage life for product stored in original container kept in cool, dry conditions.

Precautions Health and safety Please refer to MSDS. As well as joint sealants and ancillary products, Fosroc also manufactures a wide range of complementary products which includes waterstops, waterproofing membranes, grouting, anchoring and specialised flooring materials. In addition, a wide range of products specifically designed for the repair and refurbishment of damaged reinforced concrete is available. This includes hand-placed and spray grade repair mortars, fluid microconcretes, chemical-resistant epoxy mortars and a comprehensive package of protective coatings.

Silicone Sealant 33HM is a trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


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199


13 CI/SfB:Yt4 February 2007

Fosroc® Thioflex 600


Multi-component, gun and pouring grade, polysulfide sealant

The use of a surface primer is always required on porous surfaces. On non-porous surfaces a primer is not normally required except where glass or glazed surfaces are to be permanently immersed in water.

Uses Sealing movement joints in building and civil engineering structures, including superstructures, floors, basements and subways.

Standards compliance British Standard BS 4254 : 1983. U.S. Federal Specification TT-S-00227E November 1969 (amended 1970).

Advantages Meets key international standards Forms a tough, elastic, rubber-like seal

DTp specification for Highway Works December 1991 series 1000 clause 1017.

Accommodates continuous and pronounced cyclic movement

ASTM C920-87: Type M, Grade NS, Class 25.

Excellent adhesion to most common substrates, including primed concrete, glass, aluminium and stainless steel

Properties

High resistance to ageing reduces physical damage due to climatic extremes

Description Thioflex 600 is available in gun and pouring grades. The gun grade is ideal for general application. It is packed in a ready to mix, 2.5 litre tin containing the base and curing agent in the correct proportions. The pouring grade for joints in horizontal surfaces is supplied in 5 litre packs with the base and curing agent in separate tins. Thioflex 600 is particularly recommended for use in high-rise buildings and other applications where access for subsequent maintenance will be difficult and the risk of early movement failure must be minimised. It is also suitable for sealing joints in brickwork, retaining walls, basements and subways. Thioflex 600 pouring grade is recommended for initial sealing of expansion joints and stress relief joints in floors and sealing other horizontal surfaces.

Form:

Multi-part, paste compound

Colours:

Gun grade: grey Pouring grade: grey




Chemical cure

Pot life:

2 hours @ 25°C

Setting time:

72 hours at 5°C 36 hours at 15°C 18 hours at 25°C

Cure time:

4 weeks at 5°C 2 weeks at 15°C 1 week at 25°C


5°C to 50°C

Operating temperature:

– 20°C to +60°C

Hardness shore Gun grade grey: 20 to 25 ‘A’ 25°C: Pouring grade: 15 to 23 Water immersion: Thioflex 600 must be fully cured before permanent immersion in water

Design criteria Thioflex 600 may be applied to joints between 5 and 50 mm wide. Joints which are expected to experience cyclic movements should be designed to an optimum width : depth ratio of 2 : 1, subject to the overriding recommended minimum sealant 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 hydrostatic pressures. To ensure that the sealant remains within its stated movement capacity (25% MAF), sealing slot widths should be designed in accordance with the recommendations of BS 6093.

200

Dilute acids Dilute alkalis Petrol Aviation fuels Diesel fuel Kerosene Lubricating oils Skydrol White spirit Chlorinated solvents Aromatic solvents Dilute oxidising acids

resistant resistant resistant resistant resistant resistant resistant resistant resistant not resistant not resistant not resistant


Fosroc® Thioflex 600 Biological resistance:

Iron and steel must be protected with an anti-corrosion primer prior to sealing.

Thioflex 600 has been evaluated in microbiologically active situations and has been shown to have resistance to aerobic conditions

Solids content:

100%

Density:

1.62 kg/litre

Flash point:

Over 65°C

Flammability:


Mixing Gun grade: The base component and curing agent are supplied ready for mixing in a single tin. Mix thoroughly using a slow speed drill (300 to 500 rpm) fitted with a Fosroc Sealant Mixing Paddle for 5 minutes. Only thorough mixing, including material right at the bottom of the tin, will result in proper curing. In cold weather Thioflex 600 mixes more easily if stored 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 two separate containers, the base in the larger tin and the curing agent in a sachet. The sachet contents should be transferred to the tin, and mixed as per the gun grade instructions. The pouring grade may be poured directly into horizontal joints or for application to horizontal joints less than 15 mm wide loaded into a Fosroc ‘G’ Gun.

The joint surfaces must be thoroughly dry, clean and frost free. Remove all dust and laitance by rigorous wire brushing, grinding or grit blasting. Remove all rust, scale and protective lacquers from metal surfaces. Remove any oil or grease with Fosroc Equipment Cleaner. Any expansion joint filler must be checked to ensure it is tightly packed and no gaps or voids exist at the base of the sealing slot before positioning a bond breaker.

Finishing Thioflex 600 should be tooled to a smooth finish. A minimum of surface lubricant such as dilute detergent solution may be used to assist the process. Any masking tape should be removed immediately after tooling.

Note: The use of a bond breaker is not required in expansion joints containing Hydrocell XL or Expandafoam cellular polyethylene expansion joint fillers. For construction or contraction joints a bond breaker tape or back-up strip should be used. Where hydrostatic pressure exists, only bond breaking tapes must be used, not foamed back-up strips.


Where a particularly neat finish is required, mask the face edges of the joint before priming and remove immediately after tooling is completed.

Contract application The designer or contractor may wish to use the services of a specialist sub-contractor for joint sealing work. Names of preferred sub-contractors are available from Fosroc.

Priming When Fosroc Primers 4 or 7 are required, these should be used as follows:

Maintenance

Fosroc Primer 4: For use on glass and ceramics which are to be permanently immersed in water. It is a one part chemically active clear liquid for brush or pad application. One thin coat should be applied and allowed to dry for 2 to 5 minutes prior to sealant application.

No special requirements, any damage identified during normal building inspections should be repaired or replaced as appropriate.

Estimating

Fosroc Primer 7: It is a one part chemically active clear liquid for brush application to concrete, stone, brickwork, timber and unglazed edges of ceramic tiles. One thin coat should be applied using a clean, dry brush, ensuring complete coverage. Avoid over priming resulting in an excess of primer in the base of the joint or application beyond faces. The mixed Thioflex 600 must be applied when the primer is tack free, that is after the evaporation of the solvent but before the primer film has completely reacted. After 3 hours the surfaces must be reprimed before applying the sealant.

Packaging Thioflex 600 gun grade is supplied in 2.5 litre tins in cartons of four. Thioflex 600 pouring grade is supplied in a 5 litre tin, curing agent included in a sachet inside the tin.



Fosroc® Thioflex 600 Limitations

Guide to quantities Joint size in mm 5x5 5 x 10 10 x 10 20 x 10 20 x 15 20 x 20 40 x 20 40 x 25 40 x 30 40 x 40 50 x 25 50 x 30 50 x 40 50 x 50



Metre run per 5 litre pack

0.025 0.050 0.100 0.200 0.300 0.400 0.800 1.000 1.200 1.600 1.250 1.500 2.000 2.500

100.00 50.00 25.00 12.50 8.33 6.25 3.12 2.50 2.00 1.56 2.00 1.67 1.25 1.00

200.00 100.00 50.00 25.00 16.67 12.50 6.25 5.00 4.00 3.12 4.00 3.33 2.25 2.00

Over-painting of sealants is not recommended because of the inability of paint films to accept movement. However, if definitely required, trials should be carried out to determine compatibility. Thioflex 600 should not be used in direct contact with materials containing pitch or bitumen. Thioflex 600 is not suitable for use in contact with potable water; Nitoseal MS600 should be used.



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 made for variation in joint width or wastage.

Thioflex is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

202


14 CI/SfB:Zt4 (K2) June 2009

®

Fosroc Flamex Fire Protection


Flexible intumescent sealants

Sealant was assessed in terms of insulation and integrity.

Uses

Insulation is defined as the ability to restrict excessive heat transfer through the joint, preventing ignition from conduction on the cold side.

For fire protection in expansion and construction joints in walls, floors and ceilings, confining smoke and fire, giving extra time for people to escape from a fire situation.

Integrity is the ability to remain intact during the test, thereby withstanding the pressures and stresses developed during 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 joints Over 4 and 5 hours insulation and longer integrity rating, depending on joint design Suitable for fire stopping of joints as defined by Approved Document B of the Building Regulations Prevents the passage of smoke through joints under fire conditions Effective as normal building sealants and allows structural movement Flamex Two is resistant to a range of chemicals

Results summary Flamex One — intumescent sealant Joint size Backing material w x d (mm)

Insulation

Integrity

Single seal in lightweight blocks: 10 x 15 Expandafoam 30 mins 20 x 15 Expandafoam > 30 mins 20 x 20 Expandafoam > 1 hr 20 x 15 Ceramic strip 2.5 hrs

3 hrs > 2.5 hrs > 2 hrs > 4 hrs

Lightweight blocks sealed both sides: 10 x 15 Expandafoam > 4 hrs 20 x 15 Expandafoam > 4 hrs 20 x 20 Expandafoam > 5 hrs

> 4 hrs > 5 hrs > 5 hrs

Wall joints

Standard complance Tested in accordance with BS 476 Pt. 20: 1987.

Description

Lightweight blocks to concrete lintel sealed both sides: 15 x 15 Expandafoam 3.5 hrs > 4 hrs

Under fire conditions Flamex One and Flamex Two intumesce, forming a foam-like structure which insulates and provides a barrier to hot gas and flame.

Lightweight blocks to hardwood frame sealed both sides: 15 x 15 Expandafoam 2 hrs 2 hrs Single seal: lightweight block to building board: 10 x 15 Expandafoam 30 mins 70 mins

Flamex One emulsion based sealant sets quickly and gives excellent adhesion to most building materials. It has a 10% movement accommodation factor for low movement joint sealing and gap filling applications such as fire door frames. Flamex One is also suitable for sealing around fire protection boards. It can be used in joints from 5 to 20 mm. The minimum depth of seal should be 15 mm. Acts as an acoustic sealant.

Conduit wall penetration 20 mm conduit in nominal 50 mm hole: 15 x 15 Expandafoam > 2.5 hrs

> 4 hrs

25 mm conduit in nominal 50 mm hole: 12 x 15 Expandafoam 3.5 hrs

> 4 hrs

Flamex Two — polysulphide intumescent sealant

Flamex Two high performance sealant forms a tough, flexible rubber-like seal with a movement accommodation factor of 25% for high movement situations. Flamex Two is suitable for expansion joints in building superstructures and may be used in both internal and external joints. Flamex Two can be used in joints from 5 mm upto 50 mm wide. The width of sealant should ideally be twice the depth, with a minimum depth of 12 mm. In trafficked joints, sealant depth should be a minimum of 20 mm. The use of a surface primer is always required.

Joint size Backing material w x d (mm)

Insulation

Integrity

Single seal in lightweight blocks: 10 x 12 Expandafoam > 15 mins 20 x 12 Ceramic strip > 2 hrs

> 1.5 hrs > 4 hrs

Wall joints

Lightweight blocks sealed both sides: 10 x 12 Expandafoam > 5 hrs > 5 hrs 25 x 12 Expandafoam > 3 hrs 3.5 hrs Lightweight blocks to concrete lintel sealed both sides: 20 x 12 Expandafoam > 5 hrs > 5 hrs 40 x 20 Expandafoam > 4 hrs > 4.5 hrs

Fire performance test data Extensive fire testing has been carried out on the Flamex range in accordance with BS 476 Pt.20: 1987 at the Technical Centre of the Loss Prevention Council (LPC).

203


Fosroc® Flamex Fire Protection Flamex Two — polysulphide intumescent sealant contd. Joint size Backing material w x d (mm)

Insulation

Integrity

Soffit joints Joints in concrete sealed both sides: 15 x 12 Expandafoam 4 hrs 20 x 12 Expandafoam > 4 hrs 25 x 12 Expandafoam > 4 hrs 30 x 15 Expandafoam 3.5 hrs 30 x 15 Ceramic strip > 5 hrs 45 x 25 Ceramic strip > 5 hrs 50 x 25 Expandafoam 2 hrs 50 x 25 Ceramic strip > 5 hrs

4 4 4 5 5 5 2 >5 > > > > >

hrs hrs hrs hrs hrs hrs hrs hrs


5°C to 30°C

Hardness Shore ‘A’ at 25°C:

20 to 30 (7 days cure at 25°C, 50% RH)

Density: Flash point:

1.61 kg/litre Over 65°C


Refer to Fosroc Technical Department for specific information

For supplies of ceramic strip please contact the Fosroc Customer Service Department.

Maintenance No special requirements, but damage identified during normal building inspections should be repaired or replaced as appropriate.

Properties Flamex One Form:

Paste


Colours: MAF: Physical change:

White and grey as standard colours Butt joints 10% Cures by loss of water

Joint preparation

Skinning time:

20 to 40 minutes, but will depend on temperature and relative humidity As a guide a 20 x 15 mm joint is fully cured in 28 days at 25°C, 50% RH. Smaller joints will cure more quickly. A fairly advanced state of cure is reached at 7 days

Cure time (typical rates):

Application temperature: Hardness Shore ‘A’ at 25°C: Solids content:

5°C to 40°C 30 to 50, typical 45 (28 days cure at 25°C, 50% RH) 85%

Density:

1.48 kg/litre

The joint surfaces must be thoroughly dry, clean and frost free. Remove all contamination by rigorous wire brushing, grinding or grit blasting. Remove all rust, scale and protective lacquers from metal surfaces. Remove any oil or grease with Fosroc Joint Cleaner. The Flamex sealant shall be backed or supported with Expandafoam* cord, Hydrocell XL*, a ceramic strip or a bond breaker tape. The choice will be dependent upon the performance level required and the type of joint being sealed. In open joints where Expandafoam is to be used ensure that an appropriate diameter cord is selected to give sufficient compression and support to the sealant. In construction or contraction joints, a bond breaker tape should be applied to the base of the sealing slot to prevent adhesion of the Flamex sealant.

Flamex Two Form:

Where the ceramic strip is required it should be installed before priming, by folding and inserting into the joint using two thin metal plates to compress the strip and push it into the joint at the same time. Expandafoam is then placed over the ceramic strip before joint sealing takes place.

Multi-component paste in one tin; requires mixing Mid grey

Colour: MAF:



When gunning the sealant ensure good contact is made with the joint sides. For very wide joints it may be necessary to apply the sealant in two or more passes.

Chemical cure

Pot life: Setting time (typical rates):

2 hours at 25°C 96 hours at 5°C 48 hours at 15°C 24 hours at 25°C

Full cure (typical rates):

4 weeks at 5°C 2 weeks at 15°C 1 week at 25°C

Where an especially neat finish is required, mask the face edges of the joint with masking tape before priming and remove after tooling is complete. Priming Flamex One In many cases priming is not required. On very porous surfaces such as lightweight blocks, priming with a dilute solution of Flamex One 1: 3 with water is recommended.


204


®

Fosroc Flamex Fire Protection

Uncured Flamex Two should be cleaned from equipment using Fosroc Equipment Cleaner.

Flamex Two Fosroc Primer 4 and Fosroc Primer 7 are required and should be used as follows:

Contract application The designer or contractor may wish to use the services of a specialist sub-contractor for joint sealing work. Names of preferred sub-contractors are available from Fosroc.

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.

Limitations

Iron and steel must be treated with an anti-corrosion primer prior to sealing.

The fire rating of Flamex sealants is specific to the tests quoted on this data sheet. Users should satisfy themselves that the test results are applicable to their own installations.

Fosroc Primer 7: For all porous surfaces such as concrete, stone, brickwork, blockwork and timber.

Over-painting of Flamex sealants is not recommended.

Apply by brush, working in well, ensuring complete coverage. Avoid over priming resulting in an excess of primer in the base of the joint or beyond the joint faces.

The chemical resistance of Flamex One is limited. Refer to Fosroc Technical Department for chemical resistance of Flamex Two. Spillages must be cleaned from the sealants as soon as is practical.

The mixed Flamex Two should be applied when Fosroc Primer 7 is tack free, normally within 20 minutes to 1 hour — that is after the evaporation of the solvent but before the primer film has completely reacted. After 3 hours the surfaces must be re-primed before applying the sealant.

Flamex sealants should not be used in direct contact with materials containing pitch or bitumen or in situations where water cannot freely drain away. Flamex One is not suitable for any joints subject to trafficking.

Excessively porous surfaces may need a second coat, applied over the first coat which must be thoroughly dry.

Estimating

Mixing

Packaging

Flamex Two base component and curing agent are supplied ready for mixing in a single tin. Mix thoroughly using a slow speed drill (300 to 500 rpm) fitted with a Fosroc Sealant Mixing Paddle for 5 minutes. Only thorough mixing will result in proper curing. In cold weather Flamex mixes more easily if stored overnight at room temperature. Immediately after mixing, load the sealant into a Fosroc ‘G’ Gun using a follower plate and apply to the joint.

Flamex One is supplied in 380ml cartridges packed in cartons of 20. Flamex Two is supplied in 2.5 litre tins in cartons of 4. Guide to Flamex One quantities Joint size in mm 10 x 15 15 x 15 20 x 15

Finishing Flamex One is applied using a Fosroc ‘W’ Gun and should be tooled off within 15 minutes of sealing using clean water. The use of dilute detergent solution is not recommended.


Metre run per 380 ml cartridge

0.150 0.225 0.300

2.5 1.7 1.2

Guide to Flamex Two quantities Joint size in mm

Flamex Two should be tooled to a smooth finish. A minimum of surface lubricant such as dilute detergent solution may be used to assist the process.

10 x 12 15 x 12 20 x 12 25 x 12 30 x 15 40 x 20 50 x 25

Any masking tape should be removed immediately after tooling. Normally joints in Flamex will be flush finished and left unpainted. Cleaning equipment Uncured Flamex One may be cleaned from tools and neighbouring surfaces using a damp cloth and water.



0.12 0.18 0.24 0.30 0.45 0.80 1.25

20.80 13.80 10.40 8.3 5.5 3.10 2.00



205


Fosroc® Flamex Fire Protection

Guide to primer quantities 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 other factors.

Storage Flamex sealants have a storage life of 12 months in original containers when kept in dry conditions between 5°C and 25°C.

Precautions Health and safety For further information refer to appropriate Product Safety Data Sheet. * See separate data sheet.



telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

www.fosroc.com


206

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October 2005

Fosroc® Flamex S


One-part low modulus neutral cure fire rated silicone sealant

Movement accommodation factor (MAF):

Uses

Physical or chemical cure:

Chemical cure

Skinning time (23°C at 50% RH):

2 hours

Cure rate (23°C at 50% RH):

2 mm per day


5°C to 30°C

For fire protection of curtain walling, building façades, expansion joints and penetration seals, where pipes and cables 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 and penetration configurations


Typical Shore ‘A’ hardness: 20

Excellent adhesion 50% MAF allowing structural movement

Fire ratings

Meets BS 5889 Type A

The fire rating tables give times for insulation and integrity ratings, These are defined as:

Prevents the passage of smoke through joints in fire conditions

Insulation: The ability to restrict excessive heat transfer through the joint, preventing ignition from conduction on the cold side.

Acts as an acoustic sealant


Integrity: The ability to remain intact during the test, thereby withstanding the pressures and stresses developed during a fire situation.

Flamex S has been tested to the following standards: BS 476 Part 22 : 1987 (ISO 834) in expansion joints achieving up to a 4 hour fire rating (fire rating table A).

Fire rating table A Method: BS 476 Part 22 : 1987

BS 476 Part 22 : 1987 (ISO 834) in pipe and cable penetration systems achieving up to a 4 hour fire rating (fire rating table B).

Joint size width x depth

ISO 834 achieving over 1 hour (A - 60) fire resistance in joints, pipe and power cable penetrations (fire rating table C).

10 x 10 mm 15 x 10 mm 20 x 10 mm 25 x 20 mm

Description

10 x 10 mm 15 x 15 mm 20 x 20 mm 25 x 25 mm

Attainment of a specific fire rating is dependent on the joint configuration. For detailed information see fire rating table A.

10 x 10 mm 15 x 10 mm 25 x 20 mm

Properties

White/Grey

A A A A

120 90 60 120

n/a 30 30 60

A A A A

240 240 240 240

240 240 240 240

240 240 240

240 240 240

Polyethylene backed seal double sided

Attainment of a specific fire rating is dependent on penetration configurations. For detailed information see fire rating tables B, C and D.

Thixotropic paste

Insulation mins

Polyethylene backed seal single sided - on non-fire side of test furnace

Flamex S is a fire rated silicone sealant which cures quickly and gives excellent adhesion to most building materials. The minimum width for joints when using Flamex S should be 6 mm. For joints between 6 and 12 mm wide a seal depth of 10 mm is recommended.

Colour:

Integrity mins

Polyethylene backed seal single sided - on fire side of test furnace

Centre Scientifique que du Bâtiment (CSTB) Test achieving 1 hour fire rating in pipe and power cable penetrations (fire rating table D).

Form:

Joint configuration

207

B B B

14 CI/SfB: (18) (4-) (D6)

October 2005

Fosroc® Flamex S 20 mm Flamex S and 25 mm mineral wool 50 mm penetration 25 mm cable 4 hrs None 4 hrs

Rock fibre backed seal single sided - on fire side of test furnace 25 x 10 mm A 120 Rock fibre backed seal single sided - on non-fire side of test furnace

30

25 x 10 mm

240

A

240

Fire rating table C Method: ISO 834

Rock fibre backed seal double sided 25 x 10 mm

A

240

Penetration size

240

Joint type A

Joint type B

1

Depth

Sleeve 160 mm 2 cables EKKJ diameter galvanised 3 x 10 x 10 mm² steel 0.8 mm thick 1KV Cu Core

Ventilation duct 98 mm 400 mm diameter galvanised steel 0.8 mm thick

Penetration size

Penetrant

Width 2

1

Fire rating table B Method: BS 476 Part 22 : 1987

4 4 4 4

20 mm Flamex S and 25 mm mineral wool 150 x 150 mm penetration 25 mm diameter cable 1 hr

2 hrs

20 mm Flamex S and 75 mm mineral wool 150 x 150 mm penetration 25 mm diameter steel pipe 4 hrs 1 x 25 mm cable; 4 x 12.5 mm cable 4 hrs

4 hrs 4 hrs

1.5 hrs

Backing Fire material rating

Concrete floor: Flamex S depth of 12 mm, ceramic fibre backing Tested non-fireside of test furnace

hrs hrs hrs hrs

400 x 400 mm

20 mm Flamex S and 50 mm mineral wool 150 x 150 mm penetration None

60 mins

Gypsum board to concrete: Flamex S depth of 12 mm, ceramic fibre backing Tested fireside or non-fireside of test furnace 30 mm wide joint None 110 mm 60 mins

Insulation Integrity rating rating

10 mm Flamex S and 75 mm mineral wool 150 x 150 mm penetration 100 mm diameter steel pipe 1 hr 25 mm diameter cable 2.5 hrs 1 x 25 mm cable; 4 x 12.5 mm cable 1.5 hrs None 1.5 hrs

102 mm 60 mins

450 mm diameter 2

Services

Backing Fire material rating

Gypsum board, lightweight wall: Flamex S depth of 2 x 12 mm, ceramic fibre backing Tested fireside and non-fireside of test furnace

1 Flamex S 2 Backing material

Penetrant

Gypsum board, lightweight wall: Flamex S depth of 12 mm, ceramic fibre backing Tested non-fireside of test furnace Sleeve 160 mm 2 cables EKKJ 114 mm 60 mins diameter galvanised 3 x 10 x 10 mm² steel 0.8 mm thick 1KV Cu Core

Example of test joint configurations

4 hrs 4 hrs

4 hrs


208

48.3 mm o.d. mild steel pipe 2.6 mm thick

138 mm 60 mins

14 CI/SfB: (18) (4-) (D6)

October 2005

Fosroc® Flamex S Mask the face edges of the joint with masking tape before sealing to prevent contamination of the substrate and remove the masking tape immediately after tooling.

Fire rating table D Method: Centre Scientifique que du Bâtiment Penetration size

Penetrant

Insulation Integrity rating rating

Priming On cement and concrete, priming with Flamex S Primer is recommended.

Concrete substrate: Flamex S depth of 12 mm, 110 mm ceramic fibre backing Tested non-fireside of test furnace 333 x 200 mm

Cables — 2 x type 88-448/88 Cu 1 x type 88-224/4 Cu 330 x 200 mm Cables — 1 x type 88-448/88 Cu 1 x type 88-224/4 Cu 200 mm diameter NB80 mild steel pipe 60 mm o.d.

60 mins

> 120 mins

60 mins

> 120 mins

60 mins

> 120 mins

Sufficient primer should be transferred to the working container. Do not decant more primer than can be used in 1 hour. Apply by brush to give a thin uniform layer. Flamex S should be applied after 30 minutes. The maximum sealant application time is 3 hours. Application temperatures for the primer are 5°C to 30°C. Any unused decanted primer should not be returned to the original container but disposed of in the appropriate manner. Any brushes and containers should be cleaned with Fosroc Equipment Cleaner. Finishing Flamex S should be tooled within 5 minutes of sealing to ensure good contact between the sealant and the substrate. Cleaning

The fire ratings given are specific to the conditions of the test and provide a good indication of the expected performance of the sealant in a fire situation. Users should satisfy themselves that the test results are applicable to their own installations. Testing of a particular system may be required. To achieve any specific fire rating, all substrates being used must have at least an equivalent fire rating.

Uncured Flamex S can be removed from tools and nonporous surfaces using Fosroc Equipment Cleaner. Sealant adhering to porous surfaces should be left to cure and then removed by abrasion.

Limitations Flamex S should not be applied to surfaces that are below 5°C.


Flamex S should not be used against substrates that bleed oils, plasticisers or solvent.

Joint preparation Joint surfaces must be thoroughly dry, clean, and free from frost and contamination. Remove all laitance by rigorous wire brushing, grinding or grit blasting. Remove all rust, scale and protective lacquers. Any oil or grease should be removed with Fosroc Equipment Cleaner.

Flamex S is not intended for use as the structural seal in any application.

Estimating

Application

Guide to Flamex S quantities

Flamex S should be backed or supported with a closed cell polyethylene foam of nominal density 35 kg/m³, a ceramic fibre blanket of nominal density 128 kg/m³, or mineral wool of nominal density 100 kg/m³. The choice is dependent upon the performance level required and the type of joint being sealed. Contact the local Fosroc office for details.

Joint size in mm 10 x 15 15 x 15 20 x 15

Where using a closed cell polyethylene foam ensure the diameter cord selected will give sufficient compression and support to the sealant. In construction or contraction joints a bond breaker tape should be used.


Metre run per 380 ml cartridge

0.150 0.225 0.300

2.5 1.7 1.3

Packaging Flamex S is supplied in 380 ml plastic cartridges packed in cartons of 20.

Extrude sealant firmly into the joint ensuring complete contact with joint faces.


209

14 CI/SfB: (18) (4-) (D6)

October 2005

Fosroc® Flamex S Storage Flamex S has a storage life of 9 months if kept in a dry store in the original, unopened container, at between 5°C and 25°C. Flamex S Primer should be stored in accordance with the UK Highly Flammable Liquids and Liquefied Petroleum Gases Regulations 1972.

Precautions Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Flamex S is non-flammable. Flamex S Primer: Highly flammable liquid. Keep away from all sources of ignition — No Smoking. Avoid contact with skin and eyes and inhalation of vapours. Wear suitable gloves and eye/face protection. Use only in wellventilated areas.

Flamex is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

www.fosroc.com


210

15 CI/SfB: Hn7:Rn7 September 2008

Fosroc® Expandafoam


Closed-cell polyethylene joint filler, back-up strips and cord

Colour: Temperature stability:

–40°C to +60°C

Uses

Density:

30 +/- 5 kg/m³

Expandafoam is a closed-cell polyethylene joint filler for use as an expansion joint filler in brick and blockwork, isolation joints and hinge joints where a readily compressible low load transfer joint filler is required.


Grey

The joint filler / back-up strips as detailed shall be Expandafoam supplied by Fosroc. Whether in sheet form or in strip or cord form, Expandafoam shall be installed strictly in accordance with the relevant Fosroc technical data sheet.

Strip and cord sections are also available. These are used as back-up strips for elastomeric sealants. Back-up / bond breaker strip to support sealants Bridge decks, abutments, pier hinge joints


Brick and blockwork in building superstructures

Joint sealing slots

Advantages

When used as an expansion or isolation joint filler in brickwork, Expandafoam should be positioned to provide for a surface sealing slot of the required dimensions ensuring that the sealing slot is free from mortar droppings or slurry bridging.

Readily compressible Low load transfer Excellent recovery after compression Non-absorbent

Expandafoam sheets may be fixed into position using a suitable adhesive. Care should be taken not to contaminate the surfaces of the sealing slot with adhesive.

Rot-proof CFC-free

Where Expandafoam is used as the joint filler no additional bond breaker is necessary.

Standards compliance BS 5628 Part 3 ‘Use of Masonry’ paragraph 20.4.

Used as a back-up / bond breaker strip Expandafoam serves both to regulate the depth of the sealing slot required and ensures that the movement of the joint sealant is not restricted by three-sided adhesion.

DTp Specification for Highway Works, December 1991 series 1000. Clause 1015.

Description

The size of the back-up strip should be approximately 20% greater than the joint width and depressed sufficiently to provide the required sealing slot dimensions. Circular cord sections provide a convex face giving an optimum seal configuration, they also overcome any problem of twisting which can occur with square or rectangular sections.

Expandafoam is a flexible, readily compressible, closedcell polyethylene joint filler supplied in sheet form and as rectangular strips or circular section cords.

Properties

Estimating

Technical data — (sheets and strips) Form:

Cross-linked, compressible, closedcell foamed sections and sheet

Weathering test:

No disintegration

Recovery:

Greater than 70%

Water absorption:

Negligible

Effects of fire:

Being a thermoplastic material, Expandafoam will melt. It is combustible but rate of flame spread will be reduced when confined within a joint

Sheet size:

Technical data — (cord) Form:

Compressible closed-cell foam circular cords

Storage life:

Indefinite

Water absorption:

Negligible

1.0 x 2 metres

Sheet thickness:

10, 12, 15, 20 and 25 mm

Strip sizes:

15 metres long

Strip dimensions:

10 x 10 x 10 x 12 x 12 x 20 x 20 x

75 mm 100 mm 150 mm 75 mm* 100 mm 150 mm 200 mm

Note: sizes marked with * are supplied to order. All 10 and 12 mm strips have a 10 mm deep tear-out section and all 20 strips have a 20 mm tear-out section to ensure uniform depth of sealant cover.

211

15 CI/SfB: Hn7:Rn7 September 2008

Fosroc® Expandafoam Guide to cord quantities Cord diameter in mm 10 12 15 20 25 30 40 50

Linear metres per carton 1150† 750 550, 100† 350,100 200 160 270† 180

Note: size marked with † supplied to order


Precautions Health and safety There are no known health hazards associated with Expandafoam in normal use.

Expandafoam is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

212


15 CI/SfB: Rj3 October 2005

Fosroc® Fibreboard


Impregnated fibreboard filler

Design criteria

Uses

Typical sealed expansion joints in roads, runways and other trafficked surfaces

Fosroc Fibreboard is a compressible, non-extruding, bitumen impregnated, fibreboard expansion joint filler suitable for forming joints between in-situ and pre-cast concrete components.

4

1 2

Forming structural expansion and separation joints in:

3

Concrete pavements and floors Roads, ramps and runways Pedestrian areas

1 Pliastic* or Colpor 200PF* 3 Fosroc Fibreboard 2 Bond breaker tape 4 Recessed seal

Concrete retaining walls Concrete basement structures and subways

* Also available from Fosroc.

Advantages

Example of a sealed subway expansion joint is shown below.

Easy to handle, cut and tamp

1

Resilient Will not extrude under compression

2

Description Fosroc Fibreboard is a compressible joint filler manufactured from bitumen impregnated wood fibres. It is supplied in sheet form and is used to form and fill expansion joints in in-situ and pre-cast concrete construction.

6

5

Standards compliance DTp Specification for Highway Works, May 2005 series 1000 Clause 1015 (joint filler boards).

1 Thioflex 600* 2 Bond breaking tape 3 Supercast Rearguard ‘S’ waterstop*

American Association of State Highway Officials, Standard Specification M 153-54. US Federal Specification HH-F-341a: Type 1, Class B.


Specification clauses The expansion joint filler as detailed shall be genuine Fosroc Fibreboard supplied by Fosroc and installed strictly in accordance with the relevant Fosroc data sheet.

Properties Form:

Compressible sheet

Solids content:

100%

Recovery:

Greater than 70%

Weathering test:

No disintegration

4

213

3

4 Blinding concrete 5 Proofex Engage* 6 Fosroc Fibreboard

15 CI/SfB: Rj3 October 2005

Fosroc® Fibreboard Application instructions

Estimating

Slabs

Nominal sheet thicknesses: 10mm

Where used to form an expansion joint in in-situ concrete, Fosroc Fibreboard shall be placed against the shuttering on the concreting side before the pour begins. Copper nails may be used to prevent displacement in joints in suspended slabs.

Sheet sizes:

12.5 mm

20 mm

25 mm

1200 x 2440 mm

Fibreboard Strips 12.5mm thick

Alternatively, Fosroc Fibreboard may be bonded to the existing slab or previous pour using a suitable adhesive such as Plastiseal. Care should be taken not to contaminate surfaces of the sealing slot with the adhesive.

20mm thick

Pack of 10

100mm x 2.44m

Pack of 10

150mm x 2.44m

Pack of 5

200mm x 2.44m

Pack of 10

150mm x 2.44m

Storage 1

As with all organic materials there is a very slight risk of spontaneous combustion if stored long term in wet conditions. Store under cover, in the dry.

2 3

Precautions There are no known health hazards associated with Fosroc Fibreboard in normal use.

1 Shuttering 3 Copper nails 2 Fosroc Fibreboard Joint sealing A joint sealing slot can be formed by placing a removable timber former on top of the Fosroc Fibreboard. Alternatively, Fosroc Fibreboard can be installed to the full depth of the slab and cut back to the required depth subsequently using a power brush machine. This latter method is generally used for housing estate roads which cannot be cleaned and sealed until all building has finished. Fosroc Fibreboard should be tamped down to ensure that it fills the joint completely and provides continuous support for the joint sealant.

Fosroc Fibreboard is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

214


15 CI/SfB: Rn6 June 2008

Fosroc® Hydrocell XL


Cross linked, non-absorbent, closed cell, polyethylene joint filler

Specification clauses The joint filler shall be cross linked, non-absorbent, semirigid, cellular polyethylene. It shall have a recovery of 98% after 50% compression and a compressive strength of 0.15 N/mm² when tested in accordance with ASTM D3575. It shall have a water absorption of less than 0.05% by volume when tested in accordance with ASTM D3575 and be resistant to weathering and chemical attack.

Uses Hydrocell XL is a cross linked, non-absorbent, semi-rigid, cellular polyethylene joint filler used for forming expansion joints in concrete, brickwork and blockwork. The product provides excellent support to sealants subject to hydrostatic pressure and is particularly recommended for water retaining or water excluding structures.

Properties

Potable water reservoirs

Property

Test method

Typical values

Culverts and canals

Recovery:

ASTM D3575

98% after 50% compression

Compressive strength:

ASTM D3575

0.15 N/mm²

Water absorption:

ASTM D3575

Cross linked to resist lateral and hydrostatic pressure

Weathering test:

DTp Clause 1015 No disintegration

High density support of sealant to prevent adhesion failure


Sewage tanks Roadways and hardstandings Retaining walls Basement structures and subways Runways, taxiways and aprons

Advantages

Less than 0.05% by volume

Excellent resistance to acids, alkalis, oxidising agents and biological degradation

Non-absorbent closed cell structure High compression recovery Non-extruding Low load transfer to joint edges Non-tainting and rot proof

Compression loading

Chemically resistant

The load compression curve shown below gives typical compression values achieved in accordance with ASTM D3575.

Bitumen free Natural bond breaker

Typical load/compression curve

Description 0.3

Load N/mm²

Hydrocell XL is a cross linked, semi-rigid, closed cell polyethylene sheet material used for forming or filling expansion joints between adjacent in-situ or precast components. Hydrocell XL provides excellent support backing to elastomeric sealants and is especially recommended for use in expansion joints in brickwork and in the construction of water retaining and water excluding structures.

0.2

0.1

Standards compliance DTp Specification for Highway Works, December 1991, Series 1000, Clause 1015.

0 0

BS 5628, Part 3: Code of Practice for the Use of Masonry.

10

20

30

% compression

The compressive strength of Hydrocell XL prevents the transfer of load across movement joints. Each cell is cross linked thereby preventing breakdown under hydrostatic pressure. The closed cell formation prevents the absorption of water. 215

40

50

60

15 CI/SfB: Rn6 June 2008

Fosroc® Hydrocell XL Application instructions

Storage

Joint sealing slots

Hydrocell XL should be stored in original unopened packaging, in cool dry conditions, away from sunlight.

When forming expansion joints with Hydrocell XL in in-situ concrete, joint sealing slots can be readily formed in the following manner.


Before installing, simply cut off a strip to the required depth. Pin the strip back by using 50 mm nails at approximately 100 mm intervals. Then install the filler flush with the finished surface.

There are no known health hazards associated with Hydrocell XL in normal use.

Prior to sealing, the top strip can then be pulled easily from the joint to provide an uncontaminated sealing slot ready for preparation and sealing. As elastomeric sealants will not bond to Hydrocell XL the additional need for bond breaker strips is eliminated.

Estimating Hydrocell XL is supplied in the following sheet sizes and can be easily cut to the required size with a Stanley knife or saw. 10 15 20 25

mm mm mm mm

x x x x

1000 1000 1000 1000

mm mm mm mm

x x x x

2000 2000 2000 2000

mm mm mm mm

Limitations Hydrocell XL should not be used when the operational temperature is continuously below -70°C or above 100°C.

Hydrocell is the trademark of Fosroc International Limited

Important note



www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

216


15 CI/SfB: Yn7 January 2006

Fosroc® Secofoam


Multi purpose expanding polyurethane foam gap filler

Properties Form:

P.U. foam

One-part foam gap filler, insulant and fixative, supplied in a disposable aerosol canister for easy application.

Storage:

Cool place out of sunlight

Shelf life:

9 months

Density:

20 to 25 kg/m³

Tensile strength: (BS 5241)

9 N/cm²

Uses Secofoam is used for fixing and filling gaps around the following:

Compressive strength at 10% compression: (BS 4370)

New and replacement windows and door frames Pipe and duct work entries Thresholds and sills Wall chases Roof eaves and ridges Foam insulation slabs

Advantages

Water absorption by volume:

0.3% on cured foam

Foam structure:

Fine homogeneous cells

Colour:

Pale green


Highly flowable — fills irregular gaps Provides a barrier to draughts and water penetration

Thermal conductivity: (ASTM C518.76)

High thermal insulation properties prevents heat loss through gaps Easy and quick to apply


Fast curing Good adhesion

3 N/cm²

Chemical cure by reaction with moisture 0.023 W/m/°K

+5°C to +35°C

Ozone friendly — contains no CFC’s

Service temperature:

–40°C to +90°C

Non shrinking

Tack free time:

6 to 10 minutes at 20°C

Flammability:

Class B3 DIN 4102

Toxicity:

Toxic when wet, non toxic cured

Description Secofoam is a one component moisture cured rigid polyurethane foam which are available in pressurised disposable aerosol canisters.


The major use of Secofoam is in the installation of new and replacement window and door frames as an easy and quick method of filling gaps and clearances between the surrounding structures. The strong bond obtained and the high density cellular structure of Secofoam assists in the strength of the frame fixing and reduces the number of mechanical fixing points required. Door frames can be fixed by Secofoam alone without the need for mechanical fixings.

Window frame installation (replacement windows or re-sealing) Secofoam is suitable for use with most types of window or sub frames. Ensure the opening is free from dust and loose material before installing the frame. Secofoam reacts with moisture and it is advisable to lightly spray the surface to be foamed prior to commencement. This is especially important during warm/hot weather. Secofoam will adhere to the damp surface. Position the frame and make the specified number of mechanical fixings. Because of the strength and adhesive qualities of Secofoam, fewer fixings are required. The foam is injected into the gap remaining around the frame to fill slightly less than half the gap. The foam will then expand to fill the remaining depth. Secofoam is tack free within 10 to 30 minutes and excess can normally be cut off after 2 hours. The rate of cure is dependent upon prevailing temperature and humidity conditions. Full cure normally takes place within 12 to 24 hours. 217


Fosroc® Secofoam Pipe and duct entries Secofoam does not shrink and is suitable for sealing around pipes and ductwork where they pass through walls. Minor vibrations will not affect the bond. Secofoam will dampen noise transmission and will prevent the ingress of insects. When cured Secofoam may be cut or sanded and then plastered, rendered or finished with emulsion paint.

4 2

3

1

6 7

3 7 5

1 2 3 4 5 6 7

Secofoam Frame Glass Brick Putty Window Sealant 1

Door frame installation Brace or wedge the frame into position as required. Seal and fix by filling the gap between the frame and the surrounding structure with Secofoam. By tightly covering the frame gap opening internally with polythene, it is possible to direct Secofoam expansion outwards. Fill gap to slightly less than half the known depth and finish off as previously described under ‘Window frame installation’.

1 2 3 4

4

2

Secofoam Brick Pipe Nitoseal MS50

Insulation Because of its acoustic and thermal insulation properties, Secofoam is recommended for filling irregular voids and gaps between insulation and cellular slabstock in caravans and refrigerated container construction, etc.

3

1

5

2

2

4

1

1 2 3 4 5

Secofoam Frame Brick Door Sealant

3

1 Secofoam 2 Concrete 3 Insulation board


Page 2


Fosroc® Secofoam It is recommended that, for any large areas, Secofoam should be in layers of approximately 25 mm, allowing an initial cure to take place before the next application, otherwise sufficient pressure may be generated during expansion of the foam to cause deformation or damage the structure insulated.

3. When the foam has hardened trim off excess with a sharp knife and protect any exposed edges from UV attack by application of suitable Fosroc sealant, plaster or paint.

Others

Cleaning

4. Contents should always be fluid enough to shake, if not stand in warm water for a few minutes prior to use.

Once cured Secofoam can only be removed mechanically.

Secofoam may be used to fill wall chases over pipes and electrical conduit and should be finished as previously described. It may also be used as an eaves or ridge filler on industrial roof details providing it is top sealed to prevent UV degradation of the foam.

Estimating Pack size:

750 ml x 12

Operating instructions

Foam, free expansion:

45 times initial volume

1. Shake aerosol canister vigorously. Check that the contents of the canister are fluid enough to shake, if not stand in warm water for a few minutes prior to use.

Limitations Secofoam is subject to discoloration and deterioration by UV light. The foam must be cut back and protected by pointing with a suitable sealant, plaster or paint. A range of appropriate sealants are available from Fosroc.

2. Fix applicator mechanism to canister. 3. When required, insert canister, insert flexible tube and press applicator sideways allowing the foam to exude as required.

Precautions

4. Control of the rate of application may require some initial practice. It is recommended that trials are carried out excluding beads onto waste paper or similar until a degree of competence is attained. Always press adaptor trigger slowly first. All trial material must be disposed of carefully. Any overhead work should be done first as the propellant is more powerful when canister is full.

Health and safety Secofoam contains isocyanates. For further information please consult product Safety Data Sheet.

5. When work is completed, stand canister upright for 5 minutes slowly release a small quantity of propellant to 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 and lightly dampen or spray with clean water. 2. Inject the foam to fill half the gap depth and allow to rise. After each section is injected re-shake the canister and wipe nozzle regularly. Do not overfill since the foam expands many times its original volume and will continue to expand, whilst curing.

Secofoam is a trade mark of Fosroc International Limited



www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

219


16 CI/SfB: (52)t4 December 2005

Fosroc® Supercast Butyl-Nek


Flexible sealing compound for Precast Concrete Units

Properties Physical Properties

Uses

ASTM

Provides a permanent watertight joint for precast concrete units regardless of their shape or size.

Specific Gravity @ 25oC

D 4-801.331

Ductility @ 25oC

D 113-85

6.0cm

D 36-86

325 min

Penetration @ 25 C

D 217-82

75

Flash Point

D 92-85

62 oC

Application Temp Range

5oC min

50oC max

-20oC min

50oC max

Softening Point @ 25oC

Easily compressible and designed to completely seal and fill the annular space between pre-cast units.

o

Advantages

Not affected by rainwater, allowing for delays between application and jacking

Service Temp Range

Resistant to chemicals

Cost-effective installation

Chemical Properties Immersed for 30 days, FS SS-S-2120A section 4.5/ASTM C 990

Description The Supercast Butyl-Nek range consists of preformed rubber/bitumen sealing strips of varying sizes designed to form watertight seals between precast concrete elements such as pipes, box culverts and manhole rings.

5% Solution of Caustic Potash

Complies

5% solution of Hydrochloric Acid

Complies

5% solution of Sulphuric Acid

Complies

Saturated Hydrogen Sulphide Solution

Complies

Standard Compliance Supercast Butyl-Nek meets the requirements of:

Sag or Flow Resistance

Civil Engineering Specification for the Water Industry, 5th edition, WRc 1998 DOT Specification for Highway Works, HMSO 1998 BS EN1917 (supersedes BS8005) sewerage BS 8301 (Building Drainage) 1985 Federal Specification SS-S-210(210A0) Federal Specification AASHTO M-198B Federal Specification ASTM C-990-91

Tested to FS SS-S-210A section 4.5.3/ASTM C990, held in a vertical position for 5 days @ 57C - no visible change.

Application Instructions Preparation Wire brush all loose dirt and particles from the joint surface. Joint surfaces should be free from dirt, dust, oils, release agents and curing compounds.

Specification clauses Flexible rubber/bitumen sealing compound, where shown on the drawings, shall be Fosroc Supercast ButylNek obtained from Fosroc Limited, Coleshill Road, Tamworth, Staffs, B78 3TL.

Priming Brush or spray apply Supercast Butyl-Nek Primer around entire joint circumference and allow to dry thoroughly. Supercast Butyl-Nek Primer may be applied at the precast manufacturing plant or on site. Supercast ButylNek will not adhere to wet primer, the primer will take 1-3 hours to dry in good weather conditions. Drying can take up to 24 hours depending on coating thickness, temperature and condition of substrate. The primer will need protecting from rain and frost until fully dried.

The flexible rubber/bitumen sealing compound, shall contain 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 shall have a specific gravity of 1.331 at 25 deg. C to ASTM D 71-84. It shall be used in accordance with the Fosroc’s current application instructions.

Vertical Application Unroll Supercast Butyl-Nek coil whilst pressing firmly to the dry, clean, primed joint surface. Leave plastic film in place to protect Supercast Butyl-Nek from contaminants until ready to join units. Form a continuous joint, attaching Supercast Butyl-Nek end to end. Do not stretch 220

16 CI/SfB: (52)t4 December 2005

Fosroc® Supercast Butyl-Nek the product. Remove plastic film from Supercast ButylNek and align next unit. Each unit is homed by its own weight, compressing Supercast Butyl-Nek to tightly pack and immediately seal the joint. After the last section is set and fully homed the installation is complete. Backfilling and compaction can commence immediately.

Storage

Horizontal Application

Precautions

Ensure that unit jointing can be accomplished without getting mud, silt, gravel or other foreign material into the joint. Generally the trench should be de-watered and have a firm base. Unroll Supercast Butyl-Nek coil whilst pressing firmly to the dry, clean joint primed surface. Leave plastic film in place to protect Supercast Butyl-Nek from contaminants until ready to join units. Form a continuous joint, attaching Supercast Butyl-Nek end to end. Do not stretch the product. Remove plastic film from Supercast Butyl-Nek and align next unit. The unit should be partially supported to maintain concentricity until the Supercast Butyl-Nek is fully compressed within the annular joint space. Backfilling and compaction can begin immediately after jointing is complete.

Health and Safety

Supercast Butyl-Nek has a shelf life of 12 months. Store in original boxes in cool, dry conditions, away from sunlight.


Estimating Pack sizes for Supercast Butyl-Nek Supercast Butyl-Nek 12mm x 60mm

Box of 4 x 6mm rolls

Supercast Butyl-Nek 12mm x 80mm

Box of 3 x 6m rolls


Box of 2 x 6m rolls


Box of 8 x 4.5m rolls


Box of 8 x 4.5m rolls


Box of 4 x 4m rolls

Supercast Butyl-Nek Primer:

5 litre can



www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

221


16 CI/SfB: Hn6 October 2009

Fosroc® Supercast PVC waterstops range


Centrally and externally placed PVC waterstops

All centrally placed Supercast waterstops incorporate an eyeletted, reinforced edge flange. This enables them to be easily positioned by wiring to surrounding reinforcement.

Uses

Hydrofoil sections 16

The Supercast range of PVC waterstops is designed to provide an integral sealing system for movement and construction joints in concrete cast in-situ. These joints typically occur in the following types of structure:

24 250mm

Water retaining

12 20

Reservoirs, water towers and sewage tanks 200mm

Dams, culverts, canals and spillways Swimming pools

Heavy duty sections

Bunded areas surrounding liquid retaining tanks

Basements and underground car parks

Increased web thickness gives a much stiffer section. The stiffened profile is used where large volumes of concrete are being placed. They are used where concrete is being placed from a great height such as deep wall shutters.

Tunnels and subways

XHD Hydrofoil section

Water excluding

Abutments and retaining walls 17

Roof decks and podium areas 30

Advantages 250mm

Range of profiles to suit every need Fully continuous 4 bulb network

All dimensions are approximate and subject to Fosroc manufacturing tolerances.

Reinforced eyeletted edge flanges for positive fixing Simple on-site jointing

Supercast Rearguard S

Full range of moulded and fabricated intersection pieces

Sections incorporate a flat top centre box which allows movement to be accommodated in expansion joints. The centre box also provides a seating to support joint fillers.

WRc approval for use in contact with potable water

Supercast Rearguard S can also be used in contraction and construction joints.

The range consists of centrally placed profiles; Supercast Hydrofoil and Supercast XHD Hydrofoil; and externally placed profiles; Supercast Rearguard S.

All Rearguard sections incorporate a nailing flange with a reinforced edge to provide a secure fixing that will resist tearing. 25

Description

22

Supercast waterstops are extruded from a high grade PVC compound which has been formulated to give excellent flexibility and longevity characteristics. They are available as straight lengths and factory produced intersections or as a factory prefabricated segment of a network to minimise site jointing.

250mm 22 20 200mm

Supercast Hydrofoil sections

Rearguard S sections

Centre bulb sections are used in expansion, contraction and construction joints. The centre bulb allows for movements in a structure to be accommodated whilst its hexagonal design provides a flat surface. This allows shuttering and joint fillers to fit snugly.

22

20 All dimensions are approximate and subject to Fosroc manufacturing tolerances. 150mm

222


Fosroc® Supercast PVC waterstops range Design criteria

specification CRD-C 572-74. It shall have a tensile strength in excess of 14 MN/m² and an elongation at break in excess of 300%

The choice of the width and thickness of waterstop is largely governed by concrete thickness, the position of the reinforcement, aggregate size and complexity of the pour.

Properties

In general the 250mm width of waterstop is suited to wall thicknesses of 250mm and over. For concrete between 200mm and 250mm thick, the use of the 200mm waterstop will be appropriate and below 200mm, 150mm waterstop should be used.

Profiles

Centrally placed waterstop These waterstops are positioned within the thickness of the concrete components and as a result are supported by concrete on both sides. They are therefore able to withstand water pressure from either side. This makes them suitable for use in water retaining structures. They will prevent loss of water from within the tank and will prevent ingress of ground water when the tank is drained down.

Form:

Extruded thermoplastic sections

Colour:

Blue

Hydrostatic head:

Up to 10 m

Joint movement:

Up to 10 mm

Compound Typical figures:

To BS 2782 at 25°C

Tensile strength:

Minimum 14 MN/m²

Elongation at break: Minimum 300% Hardness:

Shore ‘A’ 80-90

Installation instructions

Externally placed waterstop

Supercast Hydrofoil These waterstops are designed for use in basement, foundation and floor slab construction in vertical and horizontal joints in both water retaining and water excluding structures.

Waterstops must be installed so that they are securely held in their correct position while the concrete is being placed. Concrete must be fully compacted around the waterstops to ensure that no voids or porous areas remain. Where reinforcement is present, an adequate clearance must be left to permit proper compaction.

When used in walls, externally placed waterstops will only resist water pressure from the face to which they are fixed. When used below floor slabs, where the waterstop is supported by the blinding concrete or when placed in vertical situations against permanent concrete shuttering, externally placed waterstops will resist water pressure from either face.

The brass eyelets used in securing the waterstop are located outside the edge bulbs so as not to create water paths around the profile. Supercast Rearguard When used on ground slabs where the waterstop is supported on blinding, Rearguard profiles usually require no fixing. Lay the waterstop centrally over the line of the joint to be formed.

Standards compliance Supercast PVC waterstops are suitable for use in contact with potable water. Water Regulations Advisory Service approved product. Drinking Water Inspectorate Regulation 25(1)b of the Water Supply (Water Quality) Regulations 1989.

Fixing to vertical shuttering is done by nailing through the outer nailing flanges leaving the head of the nail proud so that it is held in the cured concrete. This prevents the waterstop being displaced when the shuttering is struck.


Fixing to vertical shutter

1.

Supplier specification

Where indicated on the drawings, PVC waterstops shall be Supercast Waterstops obtained from Fosroc. All wall/ floor waterstop connections shall be made using Supercast intersection pieces to ensure continuity of the four bulb profiles. 2.

Performance specification

Where indicated on the drawings, PVC waterstops shall be made from extruded plasticised PVC compound. The compound used shall meet the US Corps of Engineers



Fosroc® Supercast PVC waterstops range Site jointing instructions

Factory welded Supercast Rearguard S to Hydrofoil and Rearguard S XHD Hydrofoil

Jointing of Supercast waterstops is carried out using Fosroc Heat Welding Equipment. The ends to be joined are cut square and held in alignment in a special jig. The ends are then pressed either side of a special heated blade, until an even, molten bead of PVC appears around the section. The heated blade is then removed and the molten ends pressed fully together. The PVC cools to form a strong fusion welded joint. Full instructions are available from Fosroc. Intersection pieces

T-piece on edge on edge (T-PCE)

Standard intersection pieces are available for each Supercast waterstop profile. The standard on-flat intersection leg length is 230 mm from centre line. Onedge intersections have a standard 75 mm leg length.

90° mitre (M-O-E INT)

Factory welded intersections for Supercast Rearguard S

Factory welded intersections for Supercast Hydrofoil and Supercast XHD Hydrofoil.

Flat mitre (M-O-F) Flat mitre (M-O-F)

3 way on flat 3 way on flat

4 way on flat

4 way on flat

90° mitre on edge (M-O-E) 90° mitre on edge (M-O-E INT) T-piece on edge (T-PCE)

270° mitre on edge (M-O-E EXT)



Fosroc® Supercast PVC waterstops range Estimating

Supercast

Section Wt/roll Minimum radii Roll width in in on flat on edge length mm kg m m m

Hydrofoil

250 200 150

27.1 27.3 21.3

15 14 12

0.15 0.15 0.075

12 15 15

Rearguard S

250 200

33.4 24.0

10 9

5.0 5.0

12 12

250

42.9

15

0.23

10

XHD Hydrofoil

Precautions Health and safety Hot weld site jointing of PVC waterstops liberates hydrogen chloride mist and vapour. Ensure adequate ventilation. If working in still air or confined spaces, provide forced ventilation or suitable respiratory protective equipment. For further information refer to appropriate Product Safety Data Sheet.


Storage

Application at low temperatures

Store in original unopened packaging, in cool dry conditions, away from sunlight.

Care in the handling and installation of Supercast PVC waterstops is necessary at low ambient temperatures. Such temperatures will also require special precautions to be taken with the placing and curing of concrete.

Equipment Jointing jigs 200 mm Supercast Rearguard S 250 mm Supercast Rearguard S 200 mm Supercast Hydrofoil 250 mm Supercast Hydrofoil 250 mm Supercast XHD Hydrofoil Heater blades 110 v and 220v, 350w blades are available. Warning: Ensure that heater blades are earthed by the green/yellow wire, and that the wiring operation is carried out by a competent electrician. Warning: Hot blade Do not immerse blade in water/liquids.

Supercast is a trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

225


16 CI/SfB: n5 November 2008

Fosroc® Supercast SW


Swellable waterstops for in-situ concrete

Supercast SWX also enables Supercast SW sections to be linked into conventional Supercast PVC waterstop networks. This allows the use of Supercast PVC for expansion joints and Supercast SW for construction joints whilst maintaining an integrated waterproofing network.

Uses Integral sealing for construction joints in concrete cast in-situ.

Design criteria

Convenient and problem solving in situations where a conventional waterstop would require complex shuttering.

Supercast SW should be used to prevent the passage of water through non-movement joints in both new in-situ concrete and between new and existing concrete. Supercast SW increases in volume up to 300% and gives resistance to hydraulic pressure.

Typical uses include secant piled and diaphragm walled basements, pile caps and casting against old concrete. The Supercast SW range can provide simple solutions to detailing pipe entries, construction joints in the vertical plane and to kicker joints.

Swelling of Supercast SW in fresh concrete is minimal therefore maximising the positive pressure seal provided by the hydrophilic to the protected joint.

They can be linked to Supercast PVC waterstops to give an appropriate effective combination of waterstops which maintain network continuity.

Supercast SW20 has a larger section and so offers a greater surface area of contact to the concrete in areas of higher risk, such as when waterproofing Grade 3 and Grade 4 basements.

Advantages Easy to install by adhesive bonding, or casting into joint faces

Both Supercast SW10 and SW20 have a delayed swell action which helps prevent pre-swell during wet site conditions (see limitations).

Supercast SWX enables full integration of Supercast SW and Supercast PVC networks Supercast SW Adhesive can be applied to damp substrates Solves detailing problems in conjunction with Supercast PVC waterstops

The minimum thickness of concrete cover required to accommodate pressure developed during the swelling process is 75 mm for Supercast SW10 and 80mm for SW20.

Swelling properties unaffected by long term wet/dry cycling

Standard compliance

Tolerant of salts in concrete and groundwater

Supercast SW10 and Supercast SW20 are suitable for use in contact with potable water and are Water Regulations Advisory Service approved products.

Sustains effective seal in wet conditions Highly adaptable to accommodate complex joint shapes

Drinking Water Inspectorate Regulation 25(1)b of the Water Supply (Water Quality) Regulations 1989.

Description


The Supercast SW range consists of swellable waterstops; Supercast SW formed sections, Supercast SWX gun-applied paste and Supercast SW adhesive.

Supercast SW Water swellable polymeric hydrophilic waterstops (and attachments) where shown on the drawings, shall be Fosroc Supercast SW10 (or SW20) obtained from Fosroc Limited, Drayton Manor Business Park, Coleshill Road, Tamworth, Staffs. B78 3TL. It shall be used in accordance with the manufacturer’s current application instructions.

Supercast SW sections are made from high performance synthetic elastomer strips. The swelling action of the Supercast SW range is the result of contact between water and hydrophilic groups which are an intimate part of the Supercast SW polymeric structure. These hydrophilic groups are not subject to extraction and loss of swelling performance by prolonged or repeated wetting. Expansion of the waterstop creates a positive pressure against the faces of the concrete joint, thus preventing water passing through the joint. Supercast SWX is a grey, elastomeric water-swellable gun applied paste. Supercast SWX can be used as a swellable adhesive to adhere Supercast SW waterstop to concrete. It has the capability to fill undulations and surface holes in the concrete beneath the waterstop and swell into these when required. 226


Fosroc® Supercast SW Water swellable polymeric hydrophilic waterstop, where shown on the drawings, shall be made from a preformed elastomeric strip which can integrate into existing waterstop networks. It shall be free from rubber, bentonite or other inclusions. The waterstop shall have an unrestrained volumetric expansion of up to 300%. It must not deteriorate under prolonged wet/dry cycling. It must be able to withstand a hydrostatic head of up to 50 metres (refer SW grade). It shall be used in accordance with the methods given in the manufacturer’s current data sheet.

Supercast SW waterstop

Properties Form:

Rectangular section elastomeric strips

Size: Supercast SW10: Supercast SW20:

5 mm x 20 mm 10 mm x 20 mm

Solids content:

100%

Colour: Supercast SW10: Supercast SW20:

Black Red

Unrestrained volumetric expansion ratio:

Up to 300%

Application temperature range:

–5°C to 50°C

Service temperature range:

–30°C to 70°C

Hydrostatic pressure resistance*:

SW10: 30 metres SW20: 50 metres

Pile cap detail using Supercast SW waterstop

Secant piled wall Supercast SW waterstop

Supercast Rearguard waterstop

*(In concrete construction joint with no movement) Unrestrained volume swell

Supercast SWX gunned between bulbs to form seal

Swollen

Supercast SW, Supercast SWX and Supercast Rearguard waterstops at secant pile wall and floor slab junction

Dry 0

Number of wet/dry cycles 10 20

30

Graphic showing reproducibility of volume swell with wet/dry cycling

Application instructions Supercast SW may be positioned by bonding with Supercast SWX or Supercast SW Adhesive. The waterstop may be installed either into a suitable groove cast in the concrete or directly onto the concrete surface.



Fosroc® Supercast SW Estimating

SW Details with 2 cages of reinforcement

Pack sizes Supercast SW10: Supercast SW20 : Supercast SWX:

5 mm x 20 mm x 15 metre rolls 10 mm x 20 mm x 5 metre rolls 310 ml cartridge packed in cartons of 20, or as a single tube

Minimum wall height above kicker is 1m

Supercast SW Adhesive: 380 ml cartridge packed in cartons of 20

Minimum wall thickness

Coverage

Minimum concrete cover to SW

190mm with SW 10 200mm with SW20

75mm with SW10 80mm with SW20

Supercast SW10 /SW20: Usually single run of strip per joint Supercast SWX: (per cartridge)

Note: assuming 20mm diameter rebar.

SW Details with 1 cage of reinforcement placed centrally

6 mm diameter bead - 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 no allowances for wastage.

Limitations Supercast SW should not be used for expansion joints or those subject to movements in excess of 2mm. Supercast SW should not be used in locations which allow free unrestrained swelling or for free standing walls, such as bund or dwarf walls, where the swell pressure is sufficient to lift the wall from its foundations. Contact Fosroc for product/method recommendations in this case. Supercast SW may be fixed with SWX Adhesive on smooth surfaces, but SWX Adhesive should be used where concrete is rough. In both instances the bead diameter of the adhesive should be a minimum of 12mm. Supercast SW must not be immersed in water prior to concrete placement, however, Supercast SW20 can tolerate upto 3 days exposure to damp conditions on site.

Storage Supercast SW Shelf life:

12 months Store in original unopened cartons or bags in cool, dry conditions, away from sunlight.

Supercast SWX Shelf life:

See diagram opposite.

9 months Store in original unopened cartridges or cartons in cool, dry conditions, away from

Supercast SW Adhesive Shelf life:


12 months Store in original unopened cartridges or cartons in cool, dry conditions, away from sunlight


Fosroc® Supercast SW Additional information


Ancillary materials

Supercast SW

Supercast SWX Form:

Elastomeric water swellable paste

There are no known health hazards associated with Supercast SW10 and SW20 in normal use.

Colour:

Grey

Supercast SWX

Tack-free time:

Approximately 1 hour (20°C / 50% RH)

Cure rate:

3mm in 24 hours

Volume swell ratio:

200%

Concrete pour:

2 to 8 hours

Supercast SWX may cause sensitisation by skin contact. Avoid contact with skin and eyes. Wear suitable gloves and eye/face protection. Use only in well ventilated areas. Supercast SW Adhesive No significant hazard. For additional information see relevant product safety data sheet.

Supercast SW Adhesive Form:

Grey paste


5°C to 30°C

Maximum open time:

30 minutes

Concrete pour:

2 to 8 hours

Adhesion: Can be used on damp concrete provided it is rag dry. The above data represents typical values and should not be considered as a purchase specification.



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16

Fosroc® Supercast Synkoflex and Synkoflex FR General purpose non swelling preformed plastic adhesive waterstops for concrete joints

CI/SfB:(1-)Zt4 May 2008


be applied in accordance with Fosroc’s current data sheet Supercast Synkoflex FR

Uses Non-swelling plastic adhesive waterstop, where shown on the drawings, shall be Fosroc Supercast Synkoflex FR. It shall be capable of being applied to freshly poured concrete and be unaffected by fuels or by infiltration of groundwater up to a hydrostatic head of 30m. It shall be applied in accordance with Fosroc’s current data sheet.

Supercast Synkoflex and Supercast Synkoflex FR waterstops provide watertight integrity for construction joints in concrete structures where swellable waterstops are not best suited i.e. bund walls, thin section walls and where concrete placement is delayed to allow steel reinforcement fixing.

Properties Advantages Supercast Synkoflex Can be applied onto freshly poured concrete Can be applied onto existing concrete which is primed with Supercast Synkoflex Primer or Supastik E10 Adhesive (for Supercast Synkoflex FR) Fuses with fresh concrete, allowing it to be applied with a minimum cover of 25mm Not affected by rainwater, allowing prolonged delays between application and concrete pour Can be easily joined to Fosroc Supercast PVC waterstops at expansion joints Highly adaptable to accommodate complex joint shapes

Form

: Square section flexible waterstop

Nominal size

: 25mm x 25mm x 4m roll

Colour

: Black

Specific gravity

: 1.20 to 1.35

Resistance to Hydrostatic head

: 50m of water

Application Temp. Range

: 5oC min

Service Temp. Range

: -20oC min

50oC max 50oC max

Resistant to chemicals Fuel resistant (Supercast Synkoflex FR only) Supercast Synkoflex FR

Cost – effective installation.

Form

: Rectangular section flexible waterstop

Nominal size

: 30mm x 12mm x 5m strips

Colour

: Blue

Specific gravity

: 1.60

Resistance to hydrostatic head

: 30m of water

Description Supercast Synkoflex is a non-swelling preformed plastic adhesive waterstop of dimensions 25mm x 25mm. It can be laid onto fresh concrete, or applied to existing concrete when used in conjunction with Supercast Synkoflex Primer. Supercast Synkoflex FR is a fuel-resistant, non-swelling preformed plastic adhesive waterstop of dimensions 12mm x 30mm. It can be laid onto fresh concrete, or applied to existing concrete when used in conjunction with Supastik E10 Adhesive.

Application Temp. Range : 5oC min Service Temp. Range

: -20oC min

50oC max 50oC max

Specification Clauses


Supercast Synkoflex

Supercast Synkoflex

Non-swelling plastic adhesive waterstop, where shown on the drawings, shall be Fosroc Supercast Synkoflex (or Supercast Synkoflex FR for fuel-resistant applications) obtained from Fosroc Limited, Coleshill Road, Tamworth, Staffs, B78 3TL.

Existing concrete surfaces Ensure all debris is removed and surfaces are clean and dry. Brush on a 50mm wide strip of Supercast Synkoflex Primer and allow primer to dry (usually 2-3 hours). Hand press the Supercast Synkoflex onto the primed area. Individual strips must be overlapped by 25mm.

It shall be capable of being applied to freshly poured concrete and be unaffected by rainwater or by infiltration of groundwater up to a hydrostatic head of 50m. It shall

Freshly poured concrete Lay the Supercast Synkoflex onto the fresh concrete and overlap strips by 25mm. 230

16

®

Fosroc Supercast Synkoflex & Synkoflex FR

CI/SfB:(1-)Zt4 May 2008

Supercast Synkoflex FR

Health & Safety

Existing concrete surfaces Ensure all debris is removed and surfaces are clean and dry. Trowel on a 75mm wide strip of Supastik E10 Adhesive. Hand press the Supercast Synkoflex FR onto the primed area. Individual strips must be overlapped by 25mm.

There are no known health hazards associated with Supercast Synkoflex or Supercast Synkoflex FR in normal use. For further information refer to appropriate Product Safety Data Sheet. Supastik E10: Contains resins which may cause sensitisation by skin contact, avoid contact with skin and eyes. Wear suitable protective clothing, gloves and eye/ face protection. Barrier creams provide additional skin protection. Should accidental skin contact occur, remove immediately with a resin removing cream, followed by soap and water. Do not use solvent. In case of contact with eyes, rinse immediately with plenty of clean water and seek medical advice. If swallowed seek medical attention immediately — do not induce vomiting.eyes. Wear suitable protective clothing, gloves and eye/face protection. Barrier creams provide additional skin

Freshly poured concrete Lay the Supercast Synkoflex FR onto the fresh concrete and overlap strips by 25mm. Estimating Supercast Synkoflex

:

Box of 6 x 4m rolls

:

Box of 6 x 5m rolls

25mm x 25mm Supercast Synkoflex FR 12mm 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 concrete cover (for Supercast Synkoflex FR). Supercast Synkoflex should not be used for fuel storage areas - Supercast Synkoflex FR (fuel-resistant) should be used.

Storage Supercast Synkoflex and Supercast Synkoflex FR have a shelf life of 12. Store in original boxes in cool, dry conditions, away from sunlight.

Supercast is the trade mark of Fosroc International Limited



www.fosroc.com

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fax: +44 (0) 1827 262444

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16 CI/SfB: Hn6 February 2006

Fosroc® Supercast Twinstop


Composite PVC and hydrophilic waterstop system for dual watertight security

excellent flexibility and longevity characteristics. Profiles are available as straight lengths and factory produced intersections or as a factory produced prefabricated segment of a network to minimise site jointing.

Uses Supercast Twinstop has been specially designed to provide significant advantages over co-extruded hydrophilic waterstops. This enables the PVC waterstop to be fixed on site in the usual way and provides the additional benefit of two hydrophilic elements treated with a retarded swell coating, thus avoiding the common problem of hydrophilic pre-swell on site.

Technical support

Advantages

Design criteria

Hydrophilic elements are treated with a delay swell coating to avoid problems associatd with hydrophilic pre-swell

Supercast Rearguard TS 250 mm

Fosroc offers a comprehensive range of high performance, high quality construction products. In addition, Fosroc offers a technical support service to specifiers, end-users and contractors, as well as on-site technical assistance in locations all over the world.

WRc approval for use in contact with potable water

Fully continuous four-bulbed network Complete integration with existing PVC Patented, reinforced eyelet edge flanges for positive fixing

1 2

Cost-effective alternative to co-extruded waterstops Range of fabricated intersection pieces

1 Supercast SW TS hydrophilic elements 2 Supercast PVC waterstop

Hydrophilic elements have been designed into the system in the optimum position

Supercast Hydrofoil TS 250 mm

Can be used in situations where salt water, sewage, agricultural silage, oil, diesel and petrol are prevalent Tolerant of site conditions — if damage does occur to hydrophilic elements, they can simply be removed and replacements slotted in


1

Supercast Twinstop is suitable for use in contact with potable water and is a Water Regulations Advisory Service approved product.

2

1 Supercast SW TS hydrophilic elements 2 Supercast PVC waterstop

Supercast PVC waterstops are made from extruded plasticised PVC compound which meets the US Corps of Engineers specification CRD-C 572-74. When tested to BS 2782 at 25°C, it has a tensile strength in excess of 14 MN/m² and an elongation at break in excess of 300%.

Properties Form:

Description Supercast Twinstop has been designed to combine the latest developments in hydrophilic technology with the traditional 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 250 mm Supercast PVC waterstops are extruded from a highgrade PVC compound which has been formulated to give

232

Colour:

Composite PVC hydrophilic waterstop Blue/red

Tensile strength at 25°C: BS 2782

Minimum 14 MN/m²

Elongation at break at 25°C: BS 2782

Minimum 300%

16 CI/SfB: Hn6 February 2006

Fosroc® Supercast Twinstop Example of Supercast Twinstop System

Application instructions Installation

1

Waterstops must be installed so that they are securely held in their correct position while the concrete is being placed.Concrete must be fully compacted around the waterstops to ensure that no voids or porous areas remain. Where reinforcement is present, an adequate clearance must be left to permit proper compaction.

3

2

Supercast Rearguard TS 250 mm

4

When used on ground slabs where the waterstop is supported on blinding, the Rearguard profile usually requires no fixing. Lay the waterstop centrally over the line of the joint to be formed. Fixing to vertical shuttering is done by nailing through the outer nailing flanges leaving the head of the nail proud so that it is held in the cured concrete. This prevents the waterstop being displaced when the shuttering is struck.

5

1 Supercast Twinstop waterstop 2 Supercast SW TS hydrophilic insert on side facing water 3 *Thioflex 600 joint sealant 4 *Hydrocell XL filler board 5 Water face * Also available from Fosroc.

Supercast Hydrofoil TS 250 mm The brass eyelets used for securing the waterstop are located outside the edge bulbs so as not to create waterpaths around the profile. The Hydrofoil profile should be positioned with the hydrophilic inserts on the water facing side.


Notes Care should be taken to ensure that the hydrophilic inserts are not exposed to excessive rain or puddling before the concrete pour. If this does happen and damage does occur to the hydrophilic element, the damaged hydrophilic can simply be removed and a replacement tooled in.

Precautions Health and safety Hot weld site jointing of PVC waterstops liberates hydrogen chloride mist and vapour. If welding is carried out after the hydrophilic insert has been positioned, some rubber fume may be evolved. Ensure adequate ventilation. If working in still air or confined spaces, provide forced ventilation or suitable respiratory protective equipment.

Concrete should never be poured onto a pre-activated hydrophilic strip.

Supercast Twinstop is the trade mark of Fosroc International Limited

Important not



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fax: +44 (0) 1827 262444

www.fosroc.com


233

234

235

236

17 CI/SfB: Y9 October 2005

Fosroc® Integra


Crystalline capillary waterproofing system for concrete substrates

Mortar consistency Add Integra to clean potable water. Mix 1 part water to 4.5 to 5 parts of powder by volume, or 3.7 to 4.2 litres of water per 25kg bag. Mix thoroughly with a slow speed drill and paddle until a mortar consistency is achieved.

Uses Integra is an economical cementitious coating system for waterproofing concrete against positive and negative hydrostatic heads of water.

Do not mix more material than can be applied in 20 minutes. If material thickens re-stir to reduce consistency. Do not add extra water.

Its uses include: sewage treatment and water treatment tanks, pipes, tunnels, manholes and below grade basements including retaining walls.

Application Dry shake for newly poured concrete Use Integra as is directly from container. Wearing rubber gloves, distribute the powder evenly by hand, over freshly poured concrete at 1.2 to 1.3 kg/m² before final floating operation. It is best to distribute the powder at half the recommended rate in one direction and the other half at a right angle to the first application. Keep hands as close as possible to the surface to prevent material from blowing away. For large areas, a rotary type spreader may be used. Float slab and trowel to final finish.

Advantages Penetrates concrete, seals capillary tracts and hairline cracks Cost effective Effective waterproofing treatment for hydrostatic conditions Contains no chlorides Easy to apply

Slurry coat for existing concrete Integra slurry coat may be applied with a brush (synthetic bristle), broom, or plaster sprayer. Be sure to work slurry well into openings, rough surfaces, joints and routed out areas. Apply second coat, when required, when first coat has taken an initial set (usually within one hour). If first coat has dried out, moisten surface before applying second coat.

Exterior and interior applications Can be applied onto new and old concrete surfaces Can be used above or below ground

Description Integra is a crystalline capillary concrete waterproofing system containing proprietary blends of Portland cement, quartz aggregate and special chemicals. In the presence of moisture, the active chemical additives in Integra penetrate concrete and react chemically with free lime to produce insoluble crystals. This crystalline growth reduces concrete porosity by blocking capillaries and filling hairline non-structural cracks.

During the application of Integra no water should be allowed to seep through the substrate. Water leakages should be presealed by means of the quick set plugging mortar, Renderoc Plug 1 (see separate data sheet). Curing and protecting All Integra applications must be kept moist for a minimum of 48 hours. After initial set, moist curing, using water spray is recommended. Treated surfaces shall be fog sprayed 3 to 4 times daily for the 48 hour period. For warmer climates, more frequent spraying may be required. It is important to keep Integra moist to allow the crystal formation to occur. Call your Fosroc representative for specific recommendations on the use of curing compounds. Protect surfaces from traffic for 48 hours and heavy traffic for 7 days. Freshly applied Integra must be protected from extreme weather conditions such as rain, strong winds, high temperatures and freezing for a period of not less than 48 hours after application.

Application instructions Surface preparation Surfaces must be clean and sound. Remove all oils, dust and laitance ideally by water blasting. Note that all surfaces must be damp prior to the application of Integra. Mixing Slurry consistency Add Integra to clean potable water. Mix 1 part water to 2.5 to 3 parts powder by volume, or 7.0 to 7.5 litres of water per 25kg bag. Mix thoroughly with a slow speed drill and paddle until a creamy consistency is achieved.

Cleaning Prior to curing, Integra may be cleaned from tools and other surfaces with water.

237

17 CI/SfB: Y9 October 2005

Fosroc® Integra Estimating Supply

25kg bags. Coverage Two coat application By brush: By trowel:

1-1.5kg/m² per coat 2-2.5kg/m² per coat

Actual coverage rates will depend on the profile and porosity of the substrate.

Limitations Not recommended for application temperatures below 5ºC. Full activation and effectiveness may occur 2-3 weeks after application.

Storage Store in unopened bags in cool dry internal conditions. The product has a shelf life of 12 months from the date of manufacture if kept in a dry storage in the original, unopened bags. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced to less than 6 months.


Integra is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 0 (1827) 262222

fax: +44 0 (1827) 262444

238


17 CI/SfB: Vs1 March 2006

Fosroc® Mulseal DP


Bitumen / rubber latex waterproofing emulsion

Coverage:

Typically 1.1 - 1.4 m²/litre per coat, but will depend upon the nature of the surface being treated

Uses


Mulseal DP is a bitumen rubber / latex compound designed for use in waterproofing applications. Mulseal is suitable for uses such as waterproof membrane to retaining walls, as a vapour barrier to panels and repairing fine cracks in asphalt surfaces.

Preparation Surfaces shall be clean and free from dust, dirt, oil, grease, moss and loose material. Mulseal DP may be used on damp surfaces such as green concrete, brick or block work but there must be no standing water. Metal and timber surfaces should be dry and primed with one coat of Fosroc Primer 3. All other surfaces should be primed with a coat of a 1:1 mixture of Mulseal DP and water.

Advantages Excellent adhesion to most common building materials Low water vapour permeability

Application

Can be applied to “green” concrete

Mulseal DP may be applied by brush or squeegee. For most purposes two full coats should be considered a minimum requirement. Where required Mulseal DP may be reinforced by a bedding layer of bitumen saturated glass fibre into the first full coat prior to application of subsequent coats. When used as a sandwich damp course to ground slabs, the final coat should be blinded with clean sharp sand passing through a 3 mm sieve to provide a key for the second concrete pour.

Resistant to sulphates and ground salts Dries to a flexible film Simple to apply by brush

Description Mulseal DP single part bitumen latex emulsion is applied by brush or squeegee. The incorporation of rubber latex imparts elasticity to the dried coating. Mulseal DP is suitable for use on most building materials such as concrete, brickwork, metals and stone. It is easily applied and may be used on damp surfaces, provided that no free water is present. It can also be applied to “green” concrete immediately shuttering has been struck. Where it is used as a sandwich membrane in floors, Mulseal DP should have continuity with the damp courses.

Limestone should not be used. Mulseal DP is water based and remains soluble until thoroughly dry. Do not apply during rain or when rain is expected. Priming Porous surfaces such as concrete or block work must be treated with a priming coat made up of a solution of Mulseal DP and clean cold water mixed in equal parts.


Metal and timber surfaces must be primed with a coat of Primer 3 before applying. Mulseal DP can be applied by brush or squeegee. It must be thoroughly stirred before use. For efficient waterproofing, a minimum of two full coats must be used.

DTp Specification for Highway Works May 2005 series 2000 clause 2004.

Specification clauses Where shown on the drawings, the waterproofing/vapour barrier membrane shall be Mulseal DP from Fosroc. Surfaces shall be prepared and the product applied in accordance with the manufacturers current data sheet.

For horizontal surfaces, a squeegee or a cheap, soft bristle broom is satisfactory. For vertical surfaces, use a cheap expendable brush. A useful technique that may be employed to keep brushes clean when using Mulseal DP is as follows:

Properties

Mix a strong solution of detergent and water, minimum 5 litres. Soak the brush in the solution and shake out before use. As work progresses, rinse the brush at intervals to prevent it clogging and shake out surplus detergent solution before resuming. Mulseal DP should be laid on to the surface using the brush in one direction and not brushed out. During a break in work or when it is completed, clean the brush in a strong detergent solution and then in running water. Clean off any remaining Mulseal DP with white spirit, allowing the spirit to evaporate before re-using the brush. Brushes should be of an inexpensive type and considered as expendable. Paint brushes are not suitable. On the larger job, it is preferable to maintain several brushes in use.

Form:

Thixotropic liquid

Solids content:

60%

Density:

1.00 kg/litre

Application temperature: Drying time:

5 to 50°C 4 to 6 hours. 24 hours should be left between coatings. Mulseal should not be applied in enclosed spaces unless there is adequate circulation of air to allow for evaporation of water 239

17 CI/SfB: Vs1 March 2006

Fosroc® Mulseal DP Precautions

Mulseal is supplied ready for use. If, however, after thorough agitation the product appears unduly thick it can, as an exception, be thinned with not more than 0.25 litre of clean water per 5 litres of Mulseal DP.


Cleaning

Fire

Splashes of Mulseal DP on paintwork, etc, should be wiped off at once with a damp cloth.

Fosroc Primer 3 is highly flammable. Keep away from sources of ignition. No smoking. In the event of a fire, extinguish with CO2 or foam. Do not use water.

Ancillary materials Fosroc Primer 3.

Flash points

Estimating

Fosroc Primer 3

-7oC

Supply Mulseal DP: Fosroc Primer 3:

5 litre tins, 25 and 200 litre drums 5 litre tins

Yield Mulseal DP 1.1 to 1.4 m²/litre per coat Mulseal in 1.1 priming coat 2.0 to 2.5 m²/litre. Fosroc Primer 3 12 to 15 m²/litre.

Limitations Protect from frost during storage. Mulseal is damaged by freezing. Mulseal DP should not be used if rain or frost is expected, but frost will not affect the dried film.

Storage Store in original unopened packaging, in cool dry conditions, away from sunlight. Mulseal DP should be protected from frost.

Mulseal is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

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17 CI/SfB: Vr4 December 2006

Fosroc® Nitocote CM210


Flexible cementitious waterproof coating

Properties of cured coating (21 days cure at 23ºC followed by 28 days immersion at 23ºC). The values obtained are for Nitocote CM210 when applied in two coats each of 1mm wet film thickness:

Uses Nitocote CM210 is a flexible cementitious coating, used for waterproofing water retaining structures and water excluding structures.

Resistance to positive water pressure (DIN 1048): Resistance to negative water pressure (DIN 1048):

Nitocote CM210 provides a flexible waterproof coating suitable for use in potable water tanks, reservoirs, canals and culverts.

7 bar (70m head of water) 3 bar (30m head of water)

Static crack accommodation:

>1.0mm

Abrasion resistance:

Wear Index 1 (ASTM D 4060) equivalent to 40 N/mm2 concrete

The material can be used on concrete, brick and blockwork substrates.

Chloride ion diffusion No penetration after resistance (Taywood method): 12 months continuous testing

Advantages Approved by Drinking Water Inspectorate (DWI) Withstands high positive and negative hydrostatic pressures Excellent bond to concrete and masonry Long working life Easy application by brush, roller, trowel or spray Bonds to green or damp concrete Effective barrier to sulphates and chlorides

CO2 diffusion resistance (Taywood method) after 5000 hours QUV* :

>50m

* Note QUV test required coating to be exposed to 4 hours condensation at 50oC followed by 4 hours ultraviolet light at 50oC. Total exposure time was 5000 hours.




BS 6920: 2000 Effect on Water Quality. Water Regulations Advisory Scheme approved.

Surface preparation

DWI Regulation 31 approved.

All surfaces which are to receive the coating must be free from oil, grease, wax, dirt or any other form of foreign matter that might affect adhesion. Typically, concrete surfaces can be cleaned using a high pressure water jet and detergent. Poor quality, friable, or contaminated surfaces require grit-blasting or scabbling

Fire Tested to BS 476: 1987 Parts 6 and 7.

Description Nitocote CM210 two-component polymer modified cementitious coating is supplied in a pre-packaged form. The product has been designed to be easily mixed on-site using a slow speed drill and paddle and then applied to the substrate using a brush, roller, trowel or by spray application. Nitocote CM210, available in grey and white, cures to form a flexible impermeable membrane.

Spalled surfaces or those containing large blow-holes and other such defects should be repaired using Nitocote CM210 or a Fosroc approved repair mortar or render. Care must be taken when choosing the repair mortar to ensure that it has all necessary approvals for contact with potable water. Contact local Fosroc office for advice on suitable materials.


If the surface contains small blow-holes, typically less than 1mm wide, the coating can be applied directly on to the substrate without the need for a treatment.

The waterproofing coating shall be Nitocote CM210, a flexible cementitious coating approved under the DWI Regulation 31 (WRc Listed). The cured coating shall have the capability to resist a positive water pressure of 7 bar and a negative water pressure of 3 bar when tested to DIN 1048.

Cracks which are greater than 0.2mm in width should be chased-out to 4mm in width and approximately 15mm in depth. This should be filled with Nitocote CM210 (applied using a Fosroc ‘G’ Gun). When the material in the crack has hardened the coating should be applied over the crack and reinforced with polypropylene mesh (see later section).

Properties Typical properties of mixed material: Pot life at 20ºC:

1 hour

Colour:

Grey or white

Mixed density:

1850 kg/m³

Minimum application temperature:

5ºC 241


Fosroc® Nitocote CM210

All the mixed material should be used within 1 hour of mixing.

Mixing The liquid component should be poured into a plastic or metal drum having a volume of at least 25 litres.

Allow first coat to cure for a minimum of 4 hours at 20oC/ 50% RH and longer at lower temperatures or higher humidities. The exact drying time will depend on surface temperature, relative humidity and air movement. High temperatures and/or low humidity will reduce the drying time. This can vary from 1 to 16 hours. The maximum ambient temperature for application is 40oC.

This should be placed onto a plastic sheet to avoid contamination. The powder component is gradually added to the liquid whilst mixing with a Conbextra Mixing Paddle or other approved spiral paddle attachment on a variable speed drill. Mixing is continued, constantly moving the paddle around the drum, until a lump-free slurry is obtained. This should take a minimum of 3 minutes and a maximum of 5 minutes.

The first coat should be left to dry until firm and unmarkable to the touch. There is no maximum time between coats, however the surface may need cleaning with water prior to application of the second coat to remove potential contamination.

Note: The preferred drill speed is between 250 and 750 rpm. Mixing warning

The second coat should also be applied at a wet film thickness of 1mm. Pre-dampening of the surface is not necessary when applying the second coat.

Nitocote CM210 may exhibit satisfactory handling characteristics even though inadequately mixed. This will result in a significantly lower level of performance or possible failure. It is therefore essential that mixing instructions are strictly adhered to with particular emphasis on the time of the mixing operation.

No curing membrane is necessary, however the freshly applied coating should be protected from rain and strong wind or until firm to the touch to prevent damage to the wet coating.

Pre-wetting of substrate

Brush application

Thoroughly dampen the substrate surface with water using a brush, roller or spray. High porosity substrates will require more dampening that dense substrates. Do not apply the coating when the substrate is wet, but allow the water to soak in until the substrate is just visibly damp before proceeding.

The most suitable type of brush is a soft bristled wallpaper paste brush (120 to 220mm wide). Where larger areas are to be applied it is advisable to use a brush with a handle. Load the brush up well and spread the material to the required thickness. If the brush begins to drag during application, do not add water to the material but dampen the surface again. Finish in one direction for a neat appearance.

Any excess water should be removed using a sponge. Any running water should be stopped with a suitably approved plugging mortar such as Renderoc Plug 20. Contact the local Fosroc office for further advice on suitable materials.

For floor application, a soft bristled broom is recommended. Pour the material on to the substrate and then spread to the required thickness.

General For optimum use of the product, Nitocote CM210 white should be applied as the first coat, with Nitocote CM210 grey as the second coat. This gives a visual indication of coverage.

Roller application Application by roller has the benefit of speed over brush application, particularly on smooth substrates. A good quality medium hair roller is recommended. The roller should be well loaded for ease of application. A heavy roller pattern will be left, therefore it is important to use a finishing tool to produce a smooth coating, with a uniform 1mm wet film thickness.

The first coat should be applied at a wet film thickness of 1mm (coverage per coat is 1.8kg/m2 or 1 litre/m2). To ensure the correct thickness is achieved, measure out an area (for example 200m2), then calculate how much material will be needed to cover this area. Monitor the coating thickness during application at regular intervals using a wet film gauge. Care must be taken to fill all imperfections such as blow-holes during application. Blow-holes can be filled while the coating is still fluid by using a dry sponge. If the coating has dried before these imperfections are found they can be filled using fresh material.

Trowel application Application with a steel plastering trowel also has the benefit of speed over brush application, as well as producing a superior finish. It is recommended that a scratch coat of Nitcote CM210 be applied prior to the first coating to fill blow-holes, which should be allowed to cure for the equivalent of 2 hours at 20oC.



Fosroc® Nitocote CM210 Finishing tools

Apply debonding tape over the sealant. After application of the Nitocote CM210 remove the tape and overlaying coating.

A finishing tool may be required to produce a smooth finish or to repair film defects. Examples of suitable tools include a steel plastering trowel, a caulking tool and a hard sponge. All of these must be used immediately after coating application, otherwise the coating may drag or tear. When using a hard sponge it should be dry or very slightly damp. A wet sponge should not be used as this will cause polymer to come to the surface of the coating which causes an unsightly white streaky effect.

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 be dry cured. This is to ensure the full physical properties are developed. UK potable water approvals

Spray application

In the case of contracts requiring DWI and Water Byelaws Scheme certification, Nitocote CM210 white should be applied as the first coat followed by a second coat of Nitocote CM210 grey. The product must be allowed to cure for a minimum of 7 days at 7oC or greater.

Spray application should be carried out using a suitable wet spray technique. This is the preferred method for applications over 150m2. In smaller tanks with restricted access it may be beneficial to spray. This means the material will be pumped into the restricted area rather than having to be physically carried.

Tanks with a surface area less than 250m2 should be flushed with water prior to filling.

Mixing should be carried out as previously described, and particular care should be taken to ensure that no lumps remain in the mix. The mixing container should be placed on plastic sheeting to stop gravel and stones from contaminating the mix. Material should be scraped off the mixing bucket above the wet line after every mix. The paddle should also be cleaned at this stage. All of these precautions are important to stop dried material or gravel from causing blockages in the pump.

The tank should be disinfected in accordance with local regulations before re-connection to the public water supply. Cleaning and disposal Immediately after application is completed, clean all tools and equipment with clean water. Hardened material can be removed by mechanical means and by use of Fosroc Solvent 102. Waste material should be allowed to harden overnight then disposed of as non-hazardous waste.

Pour the material into the hopper. Scrape the sides of the hopper down regularly to stop material from hardening and then dropping into the mix. Place a cover over the hopper to prevent product skinning caused by water loss.

Estimating Supply

The mixed material is pumped through the hose to the spray gun. Substrate preparation and coverage rates described above should be adhered to. Wet film thickness should be measured using a wet film thickness gauge every 2 to 3 metres initially until the sprayer has judged the ideal application speed and distance from the wall. Any areas less than 1mm thick should be sprayed over again. For the rest of the application, thickness measurements should be carried out every 10m2.

Powder component (grey or white):

18.2kg bag

Liquid polymer component: 5.0kg plastic container Proofex LM mesh:

100mm x 50m

Coverage Coverage rate at 1mm wet film thickness:

12.5m2 per pack 0.54m2 /kg

Reinforcement with polypropylene mesh Proofex LM mesh may be used to reinforce Nitocote CM210 at joints and cracks. The mesh should be bedded into the first coat while still wet. Immediately after placing apply a further thin coat of Nitocote CM210 to ‘wet’ out the mesh. Allow to set before applying the second coat.

The coverage figure given is theoretical - due to wastage factors and the variety and nature of possible substrates, practical coverage figures will be reduced. A minimum coverage of 3.6kg/m2 applied in not less than two coats is recommended.

Sealed joints

Limitations

Sealant joints should be filled with a suitable joint sealant before application of Nitocote CM210. If potable water contact is expected, the sealant should be approved. Contact your local Fosroc office for recommendations.

Nitocote CM210 should not be used when the temperature is below 5oC. The product should not be exposed to rainfall or moving water during application or within 4 hours at 20oC. The maximum ambient temperature for application is 40oC.



Fosroc® Nitocote CM210 Nitocote CM210 should not be used on external surfaces where an aesthetic appearance is critical because differences in environmental conditions during cure may cause colour differences in the final surface. If any doubts arise concerning temperature or substrate conditions, consult the local Fosroc office. Nitocote CM210 should not be used on structures subject to high movement, i.e. elevated water retaining tanks. If any 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 of manufacture if kept in a dry storage in the original, unopened bags. Material from different batches shall be stored separately. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced to less than 6 months.




www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

244


17 CI/SfB: July 2009

Fosroc® Polyurea WPE


Fast setting, pure polyurea elastomeric waterproof coating

Properties Typical Physical properties at 23oC

General Information

Solids by Volume

Fosroc Polyurea WPE is a spray-applied, 100% solids, flexible, two-component, rapid curing pure Polyurea system, designed as a waterproofing and protective coating. It combines the advantages of seamless coating with very long life cycles and high durability. Fosroc Polyurea WPE consists of Fosroc Polyurea WPE Part A ISO, Fosroc Polyurea WPE Part B AMINE and a pigmented colour pot. The system offers excellent surface properties and overall physical properties.

: 100%

Volatile organic compounds

: 0 g/litre

Viscosity

: A ISO =1000 mPas : B AMINE 19 N mm-2

Modulus 100%/ 200%/ 300% ASTM D412

: > 9/ 13/ 16 N mm-2

Tear Resistance ASTM D624C : 85 N/mm

Uses Anti-corrosion, waterproof and protective coating for concrete and steel in a wide range of environmental conditions. Typical applications include: Below ground waterproofing Pipe/ Pipeline coating

Elongation ASTM D412

: >300%

Shore D ASTM D2240

: 46

Abrasion (1kg,H22 wheels) ASTM D4060

: 36 mg /1000 cycles

Service temperature

: -30oC to +135oC

Colour (Others colours available to order)

: RAL 7005 Grey : Unpigmented

Tank coating Chemical Resistance (ASTM D3912, 72 hours immersion)

Waste water tank lining Roof waterproofing Aquarium lining

Chemical

Stadia

Hydraulic Oil

R

Landscape & water containment

Motor Oil

R-DIS 50 oC

Advantages

Diesel Fuel

R

Petrol

R-DIS 25 oC

Environment friendly - zero VOC

Skydrol

NR

Excellent chemical resistance, thermal stability and UV Resistance *

Sodium hydroxide (50%)

R

50 oC

Ammonia (0.880) 33%

R

25oC

Very fast turn-around time. The coated substrate can be put into service within an hour

Sugar solution conc.

R

50 oC

Bleach (5%)

R-DIS 50 oC

Butanol

R-C

25 oC

Lactic Acid (20%)

R

50 oC

Phosphoric Acid (10%)

R

50 oC

Low permeability values

Hydrochloric acid (20%)

R-C

50 oC

Designed for service temperatures from -30oC to +135 oC

Nitric acid (30%)

R-C

25 oC

Sulphuric Acid (10%)

R

50oC

Excellent impact, abrasion and puncture resistance Seamless and monolithic, including day joints Significantly enhances the durability of reinforced concrete

Non slip finish easily achievable *

Result Max service temp. 50 oC 25 oC

R : Recommended R-DIS : Recommended – Discolouration only R-C : Recommended – Conditional; discolouration and/or slight softening or swelling – wash down within one hour to avoid effects NR : Not Recommended

See Limitations

Specification The protective and / or waterproofing coating shall be Fosroc Polyurea WPE, a 100% solid, flexible, two component, rapid curing pure Polyurea coating system providing high corrosion, abrasion and thermal shock resistance. It shall meet the values under the section “Properties”.

Note: The chemical resistance recommendations given above apply to spillage and secondary containment applications up to 72 hours contact duration; for any 245


Fosroc® Polyurea WPE Blast clean to Sa 2½. (BS EN ISO 8501-1:2007). Roughness: using abrasives suitable to achieve a coarse surface of Grade Medium G (50-85μm, Ry5) (BS EN ISO 8503-2:2001).

other requirements/chemicals contact Fosroc for further advice. Clarification of property values

All welding seams must have a surface finish which ensures that the quality of the paint system will be maintained. All sharp edges must be removed or rounded off to ensure that the specified film thickness can be built-up on all surfaces. The radius of the rounding must be minimum 2 mm.

The typical physical properties given above are derived from independent testing of Fosroc Polyurea WPE spray applied in accordance with the Fosroc Polyurea Method Statement, in controlled laboratory environment. Results derived from testing field-applied samples may vary. Spray application parameters

Priming Block Temperature

: +70oC to +80oC

Hose Temperature

: +70oC to +80oC

Volume ratio

: 1:1

Pressure

: 120 - 150 bar

Gel Time

: 5 - 10 sec

Walkable

: 2 minutes

Trafficable (light duty)

: 15 - 20 minutes

Fully Serviceable

: 24 hours

Following correct preparation, the substrate must be primed. Fosroc Primer 195 should be used. For concrete, suggested application rate is 2.5 - 4 m2 per litre dependant on concrete porosity. On very porous concrete higher application rates may be required. Consult Fosroc for further recommendations. For steel substrates, a rate of 6.5 m2 per litre is recommended.


Add the entire content of Part B into Part A and mix with a slow speed drill and paddle for 3 minutes until homogeneous.

Refer to Application section below and Fosroc Polyurea Method Statement for further detail.

Apply by brush, roller or squeegee to a uniform thickness. Initial spreading may be carried out by spray but a final rolling should be carried out to ensure full wetting and even distribution of the primer.

Surface preparation All surfaces must be clean, dry and free from contamination.

A broadcast of 0.2 – 0.5 mm kiln-dried sand onto the uncured primer is recommended for optimum adhesion properties. Excess sand should be removed prior to application of the Fosroc Polyurea WPE.

Concrete Dry abrasive blasting, wet abrasive blasting, vacuumassisted abrasive blasting, and centrifugal shot blasting, as described in ASTM D4259, may be used to remove contaminants, laitance, and weak concrete, to expose blow holes, and to produce a sound concrete surface with adequate profile and surface porosity.

The primer shall be allowed to become touch-dry prior to application of Fosroc Polyurea WPE. Typically 1.5 hours at 20oC 2 hours at 10oC. Pot life Primer 195 : 30 minutes at 25oC, 60 minutes at 15oC.

Blow holes All blow holes and minor surface imperfections shall be filled with Nitomortar FC prior to application of Primer. See separate product data sheet. Nitomortar FC should be allowed to cure for 12 –18 hours at 20oC. Lightly abrade the surface and wipe with a cloth lightly wetted with Fosroc Equipment Cleaner and allow to dry prior to priming.

If primer is unsanded the Fosroc Polyurea WPE should be applied within 24 hours. After this time the primer should be removed by shot blasting and the area reprimed. Application Spray Equipment

Steel The steel must be of first class quality and must not have been allowed to rust more than corresponding to grade B of BS EN ISO 8501-1:2007. Any laminations must be removed.

A high pressure spray proportioning machine/ spray gun for plural heated polyurea components such as those manufactured by GlasCraft or Graco should be used for this product. A list of appropriate equipment is provided in the Fosroc Polyurea Method Statement.



Fosroc® Polyurea WPE Application Method

Coverage:

Add the pigment paste, to the Part B AMINE drum and mix with a slow speed 300-400rpm bunghole mixer for 20 minutes until homogeneous.

Fosroc Polyurea WPE

: 1.5 – 3.0 ltrs per m2 (1.5 - 3.0 mm) depending on specification

If pigmented material is stored it should be mixed with a bunghole mixer for 20 minutes prior to use.

Fosroc Primer 195

: Concrete : 2.5 - 4 m2 /litre : Steel : 6.5 m2 /litre

Avoid moisture contamination of bulk material, seal drums for storage. Do not add solvent.

Storage Fosroc Polyurea WPE and Primer 195 have a shelf life of 12 months if kept in a dry, air conditioned store between +5oC and +30oC in the original unopened containers.

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 hatch pattern with a minimum of two alternate directional passes.

Limitations

If non slip surfaces are required consult Fosroc Polyurea Method Statement.

Fosroc Polyurea WPE should not be applied over existing coatings.

Day joints : when overcoating material applied more than 12 hours previously. Remove any dirt / dust contamination. Wipe surface of cured coating with NEP (N-ethyl pyrrolidone). Apply Polyurea when surface is dry, typically 30 minutes with a 100 mm overlap.

Fosroc Polyurea WPE is not colour stable when exposed to sunlight and UV. This will not affect the cured physical properties of the product. Application should not be undertaken by the methods described if the temperature is below 5oC or is 5oC and falling or where the prevailing relative humidity exceeds 90% or the dew point is less than 3oC above the surface temperature. Consult Fosroc if these conditions are not met for specific advice.

Due to the fast cure rate of Fosroc Polyurea WPE overspray can only be removed mechanically.

Estimating

Precautions

Supply:

Health and Safety Fosroc Polyurea WPE Part A ISO component

: 200 ltr drums


Fosroc Polyurea WPE Part B AMINE component : 200 ltr drums or : 195 ltr drums (Note : separate 5 litre Colour Pack required) Fosroc Primer 195 Part A Base


Fosroc Primer 195 Part B Hardener


Flash Point Fosroc Polyurea WPE and Primer 195 are nonflammable. Flash Point Fosroc Equipment Cleaner: 44oC

Fosroc Equipment Cleaner : 5litre



www.fosroc.com

telephone: +44 0 (1827) 262222

fax: +44 0 (1827) 262444

247


17 CI/SfB: Ln2 July 2009

Fosroc® Proofex 3000


High performance waterproofing membrane for basements and structures


Uses

All concrete surfaces must be a wood float or shutter finish and free from cavities or projections.

Surface preparation

A high performance self adhesive membrane for a range of waterproofing applications including basements and substructures. Proofex 3000 provides a vapour and waterproof membrane to water excluding structures and protects concrete from attack by aggressive ground salts.

Masonry surfaces must be flush pointed. All surfaces must be clean, dry and free from contamination, ice and frost. Priming

Advantages

Vertical and suspended slab surfaces shall be primed with Proofex Primer. Ensure complete coverage and allow to dry. Only prime an area to which the Proofex 3000 can be applied the same day. Very porous surfaces may require more than one coat of primer.

Cross-laminated HDPE film for protection against damage Dimensionally stable Combines toughness with flexibility for detailing around corners

Angle and corner details

Self adhesive layer system makes installation quick, simple and reliable

Where possible, a 25mm chamfer should be provided to all external angles prior to application of the reinforcing strip.

Resistant to ground water, soluble sulphates and chlorides

Suitable for waterproofing basements grades 2, 3 and

Use Proofex Angle Fillet strips fixed using 6 mm beads of Plastiseal at all wall to floor junctions.

4 as defined in BS 8102 : 1990, ‘Protection Of Structures Against Water From The Ground’

Description

All internal and external angles should be reinforced with Proofex Engage Detail Strip or a 300 mm wide strip of Proofex 3000.

Proofex 3000 is a cold applied, flexible, waterproof, high performance membrane incorporating a cross laminated HDPE carrier film with a polymer modified bitumen compound.

Application Application temperature range 5°C to 35°C.

Proofex 3000 should be laid in accordance with the provisions of BS 8102 : 1990.

Vertical application: Cut the Proofex 3000 to length allowing 150 mm for the end laps and position by peeling back the release paper and applying the self adhesive face to the prepared surface.

Where Proofex 3000 is being used as a floor DPM there, should be continuity with wall DPCs and other DPMs used in the structure. If methane presence is suspected, a comprehensive site survey needs to be carried out. Refer to Proofex 3000MR datasheet for further information.

Start at the top of the wall and work down by progressively removing the release paper in stages. Proofex 3000 should be applied to ensure that all end laps are weathered.

Typical properties Membrane thickness:

1.5 mm

Adhesion to primed concrete (ASTM D1000):

4.9 N/mm

In cold weather temporary batten support of the Proofex 3000 membrane is recommended. Horizontal application: Completely unroll the Proofex 3000 membrane and place against a chalk line. One half of the roll should then be rolled up to the mid point, the release paper carefully cut, without damaging the Proofex 3000 membrane and progressively removed from the mid point out to the end of the roll.

Tensile strength (BS EN 12311-1) Longitudinal:

215 N/50mm

Transverse:

220 N/50mm

Elongation (BS EN 12311-1) Longitudinal: Transverse Water vapour permeability (BS EN 1931): Hydrostatic test (BS EN 1928):

This process should be repeated on the other half of the roll. The Proofex 3000 membrane should be brushed onto the surface to ensure good bonding.

324% 238%

Impermeable to ISO 12572 >60 kPa

248


Fosroc® Proofex 3000 The next roll or length is aligned against the previously applied piece allowing for the 50 mm minimum (or as specified) edge laps and 150 mm end laps and applied as stated previously. The edge and end laps should be rolled to ensure complete adhesion and continuity between the layers. Penetrations Penetrations e.g. pipe entries through the Proofex 3000 membrane require special attention to detail. Use of Proofex Top Hats is recommended and should be stuck to membrane using Proofex Total Tape and sealed to pipe with Nitoseal MS50

Roll area:

20 m²

Edge laps:

50 mm minimum

End laps:

150 mm minimum

Weight:

32kg

Proofex Primer Coverage:

6 to 8 m²/litre

Minimum installation temperature:

+5°C rising

o

Protection

Drying time @ 20 C:

1 to 2 hours

Pack size:

5 ltr and 25 ltr drums

Proofex Engage Detail Strip

Proofex 3000 membrane should be protected from physical damage and weathering as soon as possible after application. Surfaces should be protected from damage by Proofex Protection Board.

Thickness:

1.5 mm

Roll size:

200 mm x 10 m

Proofex Protection Board

Proofex 3000 can also be covered with Proofex Sheetdrain to give both protection and a drainage layer.

3 mm Thickness:

1000 mm x 2000 mm

Coverage:

2.0 m2

Ancillary Products Storage Proofex Protection Board Bitumen impregnated board, designed to protect membranes from damage through backfilling and trafficking.

Proofex 3000 has a shelf life of 12 months and must be stored in an upright position at a temperature between 5°C and 40°C.

Proofex Engage Detail Strip A reinforced, double sided waterproof adhesive tape for use as reinforcing at all floor and wall junctions. It consists of a strong synthetic fibre fabric impregnated and coated both sides with a butyl adhesive, which is protected by a removable siliconised paper.

Proofex Primer has a shelf life of 2 years.

Precautions Health and safety Each Proofex 3000 roll should be lifted by a minimum of two site operatives.

Proofex Top Hat MDPE sheathing, which encapsulates an aluminium foil layer. For use at service penetrations through Proofex 3000.

For information on Proofex Primer refer to Product Safety Data Sheet. Proofex Primer is flammable. Keep away from soruces of ignition. No smoking. In the event of fire, extinguish with CO2 or foam. Do not use a water jet.

Proofex Angle Fillet Strips fixed at all floor and wall junctions with a 6mm bead of Plastiseal.

Flash Point

Estimating

Proofex Primer:

>39oC

Proofex 3000 Roll size:

1 m x 20 m Proofex is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

249


17 CI/SfB:(16.9)Ln6 October 2009

Fosroc® Proofex Cavitydrain


High density polyethylene drained cavity former for waterpoofing of sub-structures


Uses

Check floor slab is laid to adequate falls and all channel and outlet grills are fixed. Make good any defects to concrete surfaces that would prevent adequate fixing of Proofex Cavitydrain.

Ensure drainage system is free from obstructions.

Proofex Cavitydrain is used where sub-structures are constructed in concrete designed to minimise water entry in accordance with BS 8102, 1990 ‘Protection of structures against water from the ground’, Type C.

Cut Proofex Cavitydrain to length allowing for the connection detail at the drained wall cavity. Ensure the bases of the conical voids always face the substrate.

Any water ingress through the structural concrete will not enter the internal environment because Proofex Cavitydrain provides a continuous water and damp proof drainage former to connect with drainage channels or outlets cast into floor slabs.

Fix along the opening jointed edge by mechanical fixing with Steel Hammer-in Anchors (6mm diameter x 30mm overall length) at 1000 mm centres. If shot fired fixing is preferred use Hilti XSW 30 fasteners or similar. In both cases apply a small quantity of Plastiseal into the conical void before mechanical fixing to ensure continuity of the damp proof barrier.

Water leakage problems which show up in the construction stage can be remedied before the drainage layer is put in place, adding to the security of the waterproofing system.

Edge laps between adjacent sheets of Proofex Cavitydrain should be formed by bonding with selfadhesive foam strip or a bead of Plastiseal. The minimum overlap should be 25 mm and fixed firmly together using 10 mm long self tapping screws at 300 mm centres.

Advantages Internal application in a controlled environment increases security against waterproofing failure Provides a continuous drainage former and damp proof barrier

Use fixings at 1000 mm centres in the conical voids adjacent to the formed edge lap.

High compressive strength Conical voids enable high load transfer to structural elements

Description

Where projections through the floorslab occur trim Proofex Cavitydrain to butt against the projection. Fill three rows of conical voids around the perimeter of the projection with mortar or concrete and allow to dry. Prime the face of the projection and the area of filled conical voids with Proofex Primer and allow to dry.

Proofex Cavitydrain is a profiled HDPE with ribbed conical voids spaced to permit high water flow through a permanent void against the sub-structure face.

Flash around pipes and column bases using Proofex 3000 membrane to provide continuity of water proofing (see detail).

Mortar is poured into the conical voids on the internal face of the drainage former allowing high load transfer to structural elements.

Example of Proofex Cavitydrain at floor slab /column base joint

Chemically resistant Easily fixed and installed using mechanical fixings

3

5

4

Properties Void height:

20 mm

Vertical drainage capacity (H.G. = 1.0): *

12 l/s/m

Horizontal drainage capacity (H.G. = 0.01): *

0.34 l/s/m

Compressive load at 10% compression: †

2

1 Proofex Cavitydrain 4 Floor screed 2 *Proofex Angle Fillet 5 *Proofex 3000 membrane 3 Insulation if required * Also available from Fosroc

90 kN/m²

Mass/unit area: Chemical resistance:

1

1.0 kg/m² Resistant to most acids, alkalis, oils and fuels

Where a joint occurs between horizontally and vertically applied Proofex Cavitydrain it may be formed by first fixing the wall cavity former terminated 20 to 30 mm above floor slab level.

* BS 6906, Part 7. † ASTM D1621.

The floor cavity former is then bent through 90 degrees up the wall, interlocking the first two rows of conical voids into the wall cavity former (see detail). 250

17 CI/SfB:(16.9)Ln6 October 2009

Fosroc® Proofex Cavitydrain Example of Proofex Cavitydrain at joint between wall and floor

4 Floor screed 5 Butt joint 6 Supercast Rearguard S Waterstop*

1

* Also available from Fosroc. Fill the first three rows of conical voids in the horizontal Proofex Cavitydrain with mortar or concrete and allow to dry. Prime surface with Proofex Primer. Apply Proofex Angle Fillet and a 300 mm strip of Proofex 3000 membrane as a closure strip between the horizontal and vertical Proofex Cavitydrain.

2

3 4 1

Estimating Proofex Cavitydrain HC comes in rolls: 0.97 m x 50 m. Approximately 60 fixings are required per roll of Proofex Cavitydrain.

1 Proofex Cavitydrain 2 Floor screed 3 Supercast Rearguard S Waterstop* 4 Channel connected to site drainage system

Limitations If it is not possible to cast floor screeds immediately following the application of Proofex Cavitydrain, temporary protection must be provided to prevent physical damage from site operations.

* Also available from Fosroc. Where this detail is not possible butt the horizontal sheet against the vertical sheet ensuring both drainage planes drain freely into the drainage channel (see alternative detail).

Avoid point loads of Proofex Cavitydrain from floor screed reinforcement by using spreaders or pre-filling the conical voids with concrete or mortar.

Example of Proofex Cavitydrain at joint between wall and floor (alternative detail)


1

2

3

Precautions

4

Health and safety

6

Each Proofex Cavitydrain roll should be lifted by a minimum of two site operatives.

5 1

For Proofex Primer refer to Product Safety Data Sheet.

1 Proofex Cavitydrain 2 Proofex 3000 membrane flashing* 3 Proofex Angle Fillet* Proofex is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 0 (1827) 262222

fax: +44 0 (1827) 262444

251


17 CI/SfB: 19Ln6 January 2009

Fosroc® Proofex Engage


Pre-applied waterproofing membrane which mechanically bonds to poured concrete, remaining in place if settlement of substrate occurs

Typical properties

Uses A unique patented waterproofing membrane for a range of waterproofing applications including basements and substructures. Proofex Engage provides a water, water vapour and gas protection to water excluding structures and protects concrete from aggressive ground salts and chemicals.

Advantages Unique mesh system bonds permanently to concrete, remaining in place even if settlement takes place

Membrane properties

Typical value

Peel adhesion to concrete: BS4254 mod*

74N per 50mm

Shear strength of joints: MOAT 27:5.2.2 Selvedge: Proofex Engage Detail Strip:

377N 506N

Puncture resistance: ASTM E154

600N

Methane permeability: BS903 Part A30:1996

1.33E-17m2/sec/Pa

CO2 permeability: Rilem Report 12

360N/m

Unique impermeable lap joints derived from surface bentonite impregnation of the non-woven geotextile layer during manufacture

Montmorillonite Content (Sodium Bentonite) XRD

Approx. 90%

Full surface contact between the bentoniteimpregnated cover layer and the concrete ensures that small cracks and surface imperfections are sealed


Quick and easy installation in almost all weather conditions

Forms a tenacious mechanical bond to poured concrete when cast in situ, remaining in place if settlement of the substrate occurs

No requirement for priming systems, joint taping or protection systems

One product can be used in both pre-applied and post-applied construction situations

BBA accredited, certificate no. 06/4310

Substrate preparation Horizontal application – the membrane must be applied to a smooth prepared substrate. Standing water should be removed before the membrane is unrolled. Concrete blinding is preferred but a well-rolled granular fill with a compacted sand blinding is acceptable. The substrate shall be free from loose aggregate or other sharp protrusions. Vertical application – the membrane is applied to as-cast concrete, formwork or adjoining retaining structures. The surface of the concrete or retaining structure should be as smooth a prepared finish as possible.

Description

Installation below floor slabs

Proofex Hydromat consists of two elements –

Natural sodium bentonite as the sealing material.

Two layers of geotextile to encapsulate and contain the bentonite.

Roll out the product and trim to fit. A watertight seal is achieved by overlapping adjacent panels by minimum 100mm for 1.2 x 2.42m and 150mm for 2.42 x 15m at side and end laps, ensuring that the lap area is free of debris. Care must be taken to ensure that the product is installed without wrinkles or folds, and that the non-woven geotextile is facing upwards such that it will be in contact with the concrete when it is poured.

A continuous layer of natural sodium bentonite is sandwiched between a needle-punched polypropylene geotextile (the cover layer) and a slit film woven geotextile (the carrier layer). The components are needle-punched together uniformly across the membrane to hold the bentonite sealing material in a stable position.

The overlaps should run in a uniform direction, and concrete must be placed on top of the membrane, following the direction of the overlaps to remove the possibility of concrete folding back the panel and interrupting the waterproofing continuity. A minimum 150mm concrete floor slab can then be cast.

The surface of the cover layer is filled during manufacture with the same bentonite as in the centre of the membrane to facilitate continuity of bentonite across the membrane and the creation of impermeable overlap joints.

At day joints, the remaining exposed sections of Proofex Hydromat should be covered with a suitable weather resistant cover to protect it from rain, and accidental damage and trafficking of this area should be minimised. In the event that equipment and materials must be stored on the applied membrane, a 50mm concrete screed 254

17 CI/SfB: (1-)Lg9 May 2009

Fosroc® Proofex Hydromat

Nail or staple the product in place within the lap area between adjacent panels, nailing at 300mm centres along the line of the lap. It is important that the membrane panels are installed evenly, without folds or wrinkles, and ensuring that any vertical laps involve the uppermost panel coming down over the lower panel.

should be cast over the membrane as protection. Upon continuation, care should be taken to conform with the lapping requirements detailed above. Installation against shuttering At the transition between the horizontal and the vertical, Proofex Hydromat is simply turned up through 90 degrees and stapled or nailed to the shuttering. Remove nail heads before casting concrete if flat head nails are used, such that the nails can be removed with the shuttering without damaging the membrane. Staples or nails should only be located in the lap area between adjacent panels, at c. 300mm centres along the line of the lap.

Care and Detailing Double layers should be used at all corners. Outside edges of installed membrane should be protected by plastic sheeting at the end of work to ensure they remain clean and dry to form the overlap the following day. Plant or equipment should not be permitted to travel on the unprotected surface of the membrane.

Installation on cast vertical walls

Any repair patches should overlap the repair area and extend beyond the extremity of the damage by a minimum of 200mm. The area to be patched should be free of debris and swept clean. If this causes loss of the bentonite in the cover geotextile then extra Proofex Hydromat Powder (either in dry form or as a paste for sloping or vertical surfaces) at a minimum of 0.5kg/sq.m should be placed around the perimeter of the area and then the patch placed in position.

Following completion of the wall, Proofex Hydromat should be fixed to the wall face by nailing with soft washer fixings, such as Hilti X-SW 30-ZF. The nail length is determined by substrate type and condition: if in doubt, contact Fosroc Technical Department. Care must be taken to ensure that the product is installed without wrinkles or folds, and that the bentonite-impregnated non-woven geotextile is placed facing the concrete and on the backfill side of the wall. Overlaps must be a minimum of 100mm for 1.2 x 2.42m and 150mm for 2.42 x 15m and be nailed every 300mm along the top edge and within the lap area. The remaining area of the membrane within the laps should not be nailed. The overlap of the membrane between the kicker and the wall must be a minimum of 350mm, lapped to ensure that the panel coming down the wall laps over the panel coming up from the slab. This area must be nailed tightly. An additional membrane sealing strip with a width of 400mm may be placed directly over the kicker joint and running parallel to it and directly over the overlap area between the vertical and returning horizontal panels.

Sealing around penetrations must be carried out in accordance with Fosroc’s instructions and technical guidance. Tie bolt holes should be filled with Renderoc Plug 20 and then covered with a ‘mushroom’ of Proofex Hydromat Powder in paste form. This should be done before fixing of the Proofex Hydromat for post-fixed membrane installations, or prior to backfilling for pre-fix applications. In applications where the membrane is shutter-fixed, patches of Proofex Hydromat extending a minimum 150mm beyond the bolt locations are also required, lapping with the surrounding membrane.

Backfill must be free from any angular material or debris which could damage the membrane and should not contain rocks larger than 50mm.

Normally Proofex Hydromat does not need to be artificially hydrated. However, if the membrane could come into contact with liquids such as salt water, before it hydrates the membrane must be artificially hydrated. Consult Fosroc for technical guidance.

To prevent intrusion of backfill materials between the Proofex Hydromat and the concrete wall, a protective termination bar may be installed. Thus is commonly made of non-degradable boards, fixed to the structure through the membrane at 100-150mm below the top of the tanking line around the whole structure.

Ancillary products Proofex Hydromat Powder

Installation for sealing vertical walls against retaining structures

To ensure watertight continuity during detailing work and for sealing around awkward geometrical shapes, it may be necessary to cover an area with loose natural sodium bentonite powder. This can be done using Proofex

Before constructing the structural wall, fix the Proofex Hydromat directly onto the retaining wall. The bentonite impregnated non-woven geotextile side of the membrane must be installed facing the structural wall which is yet to be cast.


17 CI/SfB: (1-)Lg9 May 2009

Fosroc® Proofex Hydromat Precautions

Hydromat Powder, either in dry condition or mixed 1 part powder:4 parts water in the form of a paste.

Health & Safety A typical area of use is around piles. See Fosroc standard details.

Proofex Hydromat 2.42m x 15m weighs approximately 210kg in the dry state and should be lifted by mechanical equipment.

Estimating

Proofex Hydromat Powder weighs 25kg and should be lifted by two operatives.

Proofex Hydromat Thickness:

7mm (dry)

Roll sizes:

1.2 m x 2.42 m 2.42 m x 15 m

Weights:

18 kg, 210 kg


Proofex Hydromat Powder Bag size:

25kg

Limitations Proofex Hydromat should only be hydrated with normal groundwater. The hydration of Proofex Hydromat is adversely affected by the presence of salts e.g sea water and may also be affected by the presence of soluble materials such as those found in chalk or lime soils. Consult Fosroc Technical for advice in these circumstances

Proofex is a trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

256


17 CI/SfB: November 2005

Fosroc® Proofex LM


Two component bituminous liquid membrane for waterproofing of underground structures and intricate details in conjunction with Proofex waterproofing systems

Application instructions Substrate preparation All surfaces to be sealed must be clean and free from all loose particles and all other adhesion inhibiting substances. Mortar residues, laitance, etc., should be removed.

Uses and advantages For the waterproofing of intricate details e.g. pipe entries, covings etc

The substrate to be waterproofed may be dry or damp (not shining wet). There should be no standing water on horizontal areas. If the surface is dry, it is recommended that the substrate is dampened by spraying water beforehand. All substrates to be waterproofed with Proofex LM must be primed prior to applying the waterproofing layer. The primer is prepared by diluting one part Proofex LM (premixed product) with ten parts of clean water and applied by brush. Once priming is complete, the first coat of Proofex LM can be applied straight away.

For external waterproofing of underground structures Can be applied to damp surfaces Resists hydrostatic head of up to 70 metres Seamless - flexible with crack-bridging capabilities Simple trowel application Solvent-free - environmentally friendly and harmless to ground water Resistant to aggressive ground water

Macro-porous substrates with cavities require a scratchcoat of Proofex LM to avoid bubble formation or risk of blistering. The scratch-coat should be left to dry for 1 to 2 hours before applying the next layer.

Compatible with Proofex waterproofing systems Standard compliance Materialprüfanstalt Nordrhein-Westfalen; tested in accordance with DIN 18195, parts 4 to 6. General test certificate No. P-22 1356 8 96-1, MPA Dortmund

It is recommended that, where required, each full first coat of Proofex LM is left to dry overnight before applying a second coat. Mixing

Description

Proofex LM kits consist of exact quantities of two components contained within the same pack. The powder component is carefully mixed into the liquid component by means of a slow speed drill with paddle until it forms a homogeneous, paste-like compound of uniform colour.

Two component bituminous rubber emulsion with special hydraulically hardening fillers.

Properties Consistency:

Paste-like (mixture)

Density:

Approximately 1.2 g/cm³ (mixture) while fresh

Pot life:

Approximately 90 minutes at +20ºC


Approximately: minimum +5ºC up to +35ºC ambient temperature

Primer:

Mixed material diluted with water 1:10

Curing:

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, is approximately 24 hours. Resistant to rain after 3 hours at +20ºC/65% relative humidity

Resistance:

Application by trowel Proofex LM is applied by steel float in one or two even layers depending on the maximum loading. To avoid crack formation the applied material must not be worked on, once the coating starts to dry. In areas with extreme loadings (covings, edges and pipe penetrations) the material has to be applied twice. Fosroc recommend the use of a Proofex LM mesh allowing 10mm overlaps between the first and the second coat. Application temperatures The pot life of Proofex LM is at least 90 minutes at +20ºC and normal humidity. Higher temperatures shorten while lower temperatures lengthen the pot life.

To numerous salt solutions, weak acids and aggressive substances normally existing in soil

Protection of the waterproofing The structure may only be backfilled after complete curing of the waterproofing layers has taken place. Sharp objects should not come in contact with the membrane.

257

17 CI/SfB: November 2005

Fosroc® Proofex LM Fire

Estimating

The completed installation may be protected as required with Proofex Protection Board.

Supply 28 kg pack.

Proofex LM should not be exposed for prolonged periods. The cured membrane should therefore be protected from the elements (including sunlight) if the product will be left exposed for several weeks.

Coverage and yield Proofex LM: Approximately 4 to 6 kg/m² at normal loadings. Approximately 8 kg/m² where standing water and pressurised water occur.

Suitable noise, heat and mechanical insulation materials such as styrene and mineral foam may be glued to Proofex LM.

Coverage per m²/mm dry film thickness equals approximately 1.65 kg Proofex LM.

Normal application

Proofex LM primer: Approximately 50 to 80 g/m² unthinned material, depending on the porosity of the substrate.

Proofex LM primer: Dilute Proofex LM with water in a mixing ratio of 1:10.

Storage

Damp conditions with no water pressure present Waterproofing (one layer) Layer thickness (wet):

Approximately 3.3 mm

Coverage:

Approximately 4 kg/m²

The product has a shelf life of 12 months from the date of manufacture if kept in a dry storage in the original, unopened bags. Store in unopened bags in cool dry internal conditions. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced to less than 6 months.

Positive water pressure: Up to 1 bar (10 metre head of water) Waterproofing (one or two layers) Layer thickness (wet):


Coverage:

Approximately 5 kg/m². Incorporate reinforcement mesh at all sharp corners

Precautions Health and Safety For further information, refer to appropriate Product Safety Data Sheet.

Up to 7 bar (70 metre head of water) Waterproofing (two layers) Layer thickness (wet):


Coverage:

Approximately 8 kg/m². With or without incorporating reinforcement mesh

Proofex is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

258


17 CI/SfB: (1-)Lng September 2008

Fosroc® Proofex Sheetdrain


Geocomposite HDPE drainage sheet with thermobonded polypropylene filter

Example of external tanking with drained protection is shown below

Uses Proofex Sheetdrain is a double cuspated drainage sheet, available in 2 sizes: 8mm for depths up to 6m and 16mm for depths up to 20m. It is fixed to walls and roofs of structures to provide a filtered, drainage plane that will route ground water and gases away from the structure, utilising subsoil drains to link with the site drainage system. Proofex Sheetdrain reduces water pressure on structures and the possibility of water ingress and can be effectively used in conjunction with other waterproofing systems. 4

Proofex Sheetdrain can also be used as protection to a sheet membrane against physical damage from backfill operations. 1

It is an effective alternative to traditional stone ‘French’ drains providing improved drainage performance. Where directly cast concrete sub-structure walls need to be drained, Proofex Sheetdrain may be used as a lost shuttering liner. Proofex Sheetdrain is effective in constructing basements, retaining walls, service ducts, lift pits and subways with and without Proofex sheet membrane, allowing construction to BS 8102 : 1990.

7

5

Proofex Sheetdrain provides filtered drainage and enhanced protection when used with Proofex waterproof membranes on reservoirs, podia and elevated slabs.

Advantages

3

Maintains high rate of flow (water and gas) while under stress thanks to its symmetrical, impervious structure

2

6

Maintains an air layer along walls High impact resistant, high density polyethylene core with a crush strength of up to 450 kPa/m² provides drainage void around structures under backfill and long term loadings

1 2 3 4 5 6 7

Cost effective alternative to ‘French’ drains Easily fixed on site

*Proofex 3000/3000MR/4000R *Proofex Engage Detail Strip *Proofex Angle Fillet *Proofex Sheetdrain *Supercast Rearguard Waterstop Sub-soil drainage pipe Drainage stone


Description The Proofex Sheetdrain range are geocomposite drainage sheets with either 8mm or 16mm thick high density polyethylene cores and polypropylene geotextiles, recommended for most building and civil engineering drainage applications. Supplied in 1.1m x 25m rolls.

259


Fosroc® Proofex Sheetdrain Properties 8mm

16mm

Geospacer: Raw material Profile Crush resistance (NF EN 964-1)

100% virgin HDPE 100% virgin HDPE Double cuspated symmetrical and watertight >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 Length per roll Flow capacity (EN ISO 12958) I = 1 / between two foams Tensile strength/elongation at break (ISO EN 10319) Durability Maximum long term load

1.1m 25m 0.85 l/m/s (under 20 kPa) 0.7 l/m/s (under 50 kPa)

15 KN / m / 40% 21 KN / m / 70% predicted to be durable for a minimum of 25 years in all natural soils 60 kPa 150 kPa 150 KN/m2

Compression strength:

1.1m 25m 2.3 l/m/s (under 20 kPa) 1.6 l/m/s (under 100 kPa)

450 KN/m2

Mechanical Resistance: For an anticipated duration of 100,000 hours (11 years) Proofex Sheetdrain 8 distortion is in the order of 0.72mm under a 60 kPa load, corresponding to a burial depth of 6m (water-saturated clay soil, laid vertically)

Example of Proofex Sheetdrain at joint between service reservoir roof and wall

Specification clauses 3 Specification – depth up to 6m 4

The geocomposite sheet drain shall be Fosroc, 8mm Proofex Sheet drain. It shall be a double cuspated HDPE core, with a polypropylene non-woven geotextile bonded to one side. It shall have a thickness of 8mm under a pressure of 50kPA and a crush resistance 150 kPa.The geocomposite drainage sheet shall be installed strictly in accordance with the manufacturer’s technical data sheet.

1

5

2

Specification – depth up to 20m 6 1 2 3 4 5 6

*Proofex Sheetdrain *Proofex 3000/3000MR/4000R/SM waterproof membrane Geotextile reinforcing strip *Supercast Rearguard waterstop *Fosroc Slip Membrane Water flow to subsoil drain at base of wall * Also available from Fosroc.

The geocomposite sheet drain shall be Fosroc, 16mm Proofex Sheet drain. It shall be a double cuspated HDPE core, with a polypropylene non-woven geotextile bonded to one side. It shall have a thickness of 16mm under a pressure of 100kPA and a crush resistance 450 kPa. The geocomposite drainage sheet shall be installed strictly in accordance with the manufacturer’s technical data sheet.



Fosroc® Proofex Sheetdrain Application instructions

Limitations

Fixing

Proofex Sheetdrain should not normally be used in saturated clays at depths greater than 20m for 16mm size and 6m for 8mm size to allow for the effects of long term loadings.

Proofex Sheetdrain should be fixed using Hilti IZ 8x70 fixings at a rate of 1 per metre 2 or when applied to a membrane with Proofex Engage Detail Strip.

Proofex Sheetdrain should not be used in soil containing high concentrations of iron oxides or hydroxides or in extremely fine uniformly graded silts or peat. Please contact Fosroc Technical Department for advice when in doubt.

Joints Pull back the geotextile fabric 100mm from one side of joint, and overlap the HDPE cores. Over lap the geotextile fabric. Geotextile should be laid in direction of flow to prevent ingress of fine material.

Proofex Sheetdrain is resistant to chemicals found in normal soil conditions, some chemicals in certain concentrations could have an adverse effect on the drains performance. Please contact Fosroc Technical Department for advice when in doubt.

Drainage connection Pull back sufficient geotextile fabric to wrap around the drain. Cut back the HDPE core to an appropriate length and wrap geotextile fabric around drain.

Estimating Product

Packaging

Proofex Sheetdrain:

1.1 m x 25 m roll

Quantity 1

Top closure

Storage Pull back the geotextile fabric 100mm. Cut back the HDPE core by 50mm and wrap the geotextile fabric over the exposed end to prevent ingress of backfill.

The product is supplied in a roll and must not be exposed directly to UV radiation for over two months.

Backfilling

Precautions

Backfilling must be free from any sharp objects or debris, which could damage the Sheetdrain. It should not contain rocks or boulder larger than 50mm. This must be placed against the Sheetdrain in 300mm layers compacting to 85% modified Proctor. Backfilling should be in direction of laying of strips.

There are no known health hazards associated with Proofex Sheetdrain in normal use. Health and safety Proofex Sheetdrain 8 weighs approximately 17kg. Proofex Sheetdrain 16 weighs approximately 38kg. Each roll should be lifted by a minimum of two site operatives.

Ancillary materials *Proofex Detail Strip Hilti IZ 8x70 fixings * Available from Fosroc.

Proofex is the trademark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

261


17 CI/SfB: 19n6 October 2005

Fosroc® Proofex WG


High performance Epoxy resin waterproof grout

Properties The following results are typical for the hardened grout at 20°C.

Uses

Test method for Density:

Free-flow epoxy grout for use in waterproofing pile-caps to ensure complete integrity of the waterproofing system. Also for applications where the building is being constructed on gas – contaminated land.

Typical results 2025 kg/m³

Compressive strength (B 6319, Part 2: 1983) 6 hours (24°C): 1 day: 3 days: 7 days:

36 N/mm² 89 N/mm² 93 N/mm² 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

Proofex WG is a three-component system consisting of base resin, liquid hardener and specially graded inert fillers. It is suitable for thicknesses from 20-100 mm.

Secant modulus (BS 6319, Part 6: 1984)

13 kN/mm²

Design criteria

Proofex WG is resistant to oil, grease, fats, most chemicals, mild acids and alkalis, fresh and sea water. Consult Fosroc’s Customer Service Department when exposure to solvents or concentrated chemicals is anticipated.

Advantages Non-shrink and hence ensures complete surface contact and bond Fully waterproof and compatible with Proofex membranes High compressive, tensile and flexural strengths Fast, convenient installation with rapid strength gain

Description

Chemical resistance

Example of Proofex WG applied to circular pile-caps

1

Pot life 2

Ambient temperature affects the time for which bulk material will remain fluid.

3

Typical values in minutes are: 10°C 20°C 30°C Proofex WG:

60

30

15

Exotherm

1 2 3

All epoxy systems will develop a temperature rise on mixing. Its extent will be a function of the volume to surface ratio, the ambient temperature as well as the mass and thermal conductivity of the surrounding materials. Contact Fosroc for specific data on each product.

Proofex WG *Proofex Engage *Proofex LM *Also available from Fosroc.


Where methane is present, the building needs to be constructed in accordance with Building Research Establishment Report 212.


Fosroc offers a comprehensive range of high performance, high quality construction products.

All epoxy resin grouting where shown on the drawings, must be carried out using Proofex WG as manufactured by Fosroc and used in accordance with the manufacturer’s data sheet.

Technical support


Fosroc offers a technical support package to specifiers and contractors as well as technical advice from staff with unrivalled experience in the industry.

All epoxy resin grouting where shown on the drawings, must be carried out with a factory packed product manufactured by a registered firm. The grout must be compatible with the chosen waterproof membrane. The 262

17 CI/SfB: 19n6 October 2005

Fosroc® Proofex WG hardened grout must have a compressive strength which exceeds

Cleaning

99 N/mm² at 7 days, a tensile strength which exceeds 13 N/mm² at 7 days and a flexural strength which exceeds 31 N/mm² at 7 days.

All tools and equipment should be cleaned immediately after use with Fosroc Solvent 102. Spillages should be absorbed with sand or sawdust and disposed in accordance with local regulations.

The storage, handling and placement of the grout must be in strict accordance with the manufacturer’s instructions.

Limitations Temperature


During application

Preparation

The cure rate will be slower near 5°C, and application should not be attempted when the temperature is 5°C and falling. Where application temperature exceeds 20°C note the pot life given previously.

Concrete surfaces All surfaces must be free from oil, grease, free-standing water or any loosely adherent material. Concrete surfaces should be cut back to a sound base. All dust must be removed and bolt holes or fixing pockets blown clean of any dirt or debris.

In service The cured grout, which is completely resistant to frost and sub-zero temperatures, is suitable for use up to 45°C.

Steel surfaces All steel surfaces should be shot blasted free of rust and flaky mill scale. Cleaned surfaces may be protected by the application of Nitoprime 28.

Estimating Supply

Formwork The formwork should be constructed to be leakproof as Proofex WG is a free-flowing grout.

Proofex WG: 16 litre packs containing liquid base and hardener

Mixing

Storage

Pour all the contents of the hardener pack into the base container. Mix using a slow speed power drill and paddle until homogeneous.

Proofex WG has a shelf life of 12 months if kept in dry conditions at 20°C.

Pour all the resultant liquid into a container with a capacity of 15 to 25 litres. Add all the filler provided for each product. Mix using a slow speed power drill and paddle for 2 minutes or until a uniform colour is achieved in the grout.

Precautions Health and safety Fire Fosroc Solvent 102 is flammable. In the event of fire extinguish with CO2 or foam.

Placing

Flash point

The mixed grout should be poured steadily from one side only to eliminate the entrapment of air.

Fosroc Solvent 102:

33°C

Continuous grout flow is essential. For additional information see relevant Product Safety Data Sheet.

Sufficient grout must be available prior to starting. The time taken to pour a batch should be regulated to the time taken to prepare the next batch.

Proofex is the trademark of Fosroc International Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

263


20

®

CI/SfB: Ly June 2008

Fosroc Expoband H45


Flexible expansion joint membrane Example of Reservoir Wall

Uses

(sealed internally with Expoband H45)

Expoband H45 is a Hypalon membrane system which is designed to be bonded over movement joints or cracks in structures to prevent the passage of water. It is bonded in position using Supastik E10 two-part epoxy adhesive. Expoband H45 is suitable in construction use and repair/ remedial applications.

5

4

Advantages

Accomodates continuous and pronounced cyclic movement Excellent resistance to weathering Waterproof and chemical resistant for joints above and below ground Heat weldable connection

3

2

5

2

1

Description 1. Expoband H45 2. *Supastik E10 Adhesive 3. *Supercast Waterstop

Expoband H45 is an un-reinforced Hypalon membrane incorporating a central release tape. Expoband H45 is available in 1mm thickness and widths of 100mm and 200mm, supplied in a 25 metre roll. When longer lengths are required Expoband H45 can be joined by hot welding. It is bonded to the structure on both sides of the joint using Supastik E10 two-part epoxy adhesive.

4. *Hydrocell 5. *Nitoseal MS600

* Also available from Fosroc


Example of a reservoir roof joint

Where indicated on the drawings, joints shall be sealed with Expoband H45 flexible expansion joint membrane system supplied by Fosroc. Expoband H45 shall be installed strictly in accordance with the manufacturer’s printed instructions.

(sealed internally with Expoband H45) 6

Properties Expoband H45 Hypalon membrane 4

3

1

7

5

1

2

8 9

Elastomeric Strips

Colour:

Dark Grey

Density:

1.7 approximate

Tensile Strength:

7.0 N/mm2

Elongation at break:

400%

Adhesion to concrete (with Supastik E10):

7

1 Expoband H45 2 Proofex Sheetdrain* 3 Proofex or Famguard GS100* 4 Famguard GS100* strap laid loose but spot bonded along each edge

Form:

5. Supastik E10 adhesive* 6. Earth Overlay 7. Nitoseal MS600* 8. Supercast waterstop* 9. Hydrocell*

* Also available from Fosroc 264

>tensile strength of substrate

18 CI/SfB: Ly June 2008

Fosroc® Expoband H45 Application instructions

The rate of cure of Fosroc Primer 13X is temperature dependent. Ideally the substrate should be above 10°C to ensure a reasonable cure rate, however this primer can be applied when substrate temperatures are 5°C and rising.

Joint preparation Expansion joints must be packed with a firm, consolidated joint filler prior to laying the Expoband H45. If necessary joints may be pre-sealed using a bituminous or elastomeric sealant. Ensure that any sealant used is capable of accommodating the anticipated joint movement. Where Expoband H45 has to be turned up parapets and the like, a splay should be provided so that the change in direction is smooth and progressive.

Preparation of the membrane This operation is vital to the adhesion and performance of the Expoband H45 system. Measure and cut the length of Expoband H45 to suit the joint. The Expoband H45 Hypalon membrane must be prepared by thoroughly wiping both faces with Fosroc Solvent 105 and a clean cloth. DO NOT use excessive quantities of solvent. Allow 1 hour to dry before placing.

Surface preparation Concrete surfaces onto which the Expoband H45 is to be laid must be sound, frost and dust free. New concrete must be fully cured and free from curing compound. The concrete surface ideally should be wood float finished for the width of Expoband H45 and free from irregularities, with well deigned arrises and no vertical misalignment between each side of the joint.

Mixing and application of the adhesive Transfer the entire contents of Part B of Supastik E10 adhesive into the Part A container and mix thoroughly using a slow speed drill and Fosroc sealant mixing paddle for 4 minutes, stopping to scrape down the sides of the container. When mixed, the adhesive should be a uniform grey colour. Use masking tape at extremities and along centre line of joint. Apply mixed Supastik E10 using a serrated spreader.

Prepare a suitable width of substrate slightly wider than the membrane width selected. Sharp arrises should be ground down pencil round. Remove all dirt, dust and laitance by rigorous wire brushing needle gun, abrasive blasting or grinding. Any spalling or honeycombing must be repaired prior to the application of the Expoband H45 system. Should the substrate be wet, dry gently with a gas torch or hot air blower. Dampness should not re-appear within 15 minutes for the substrate to be considered as being dry enough for the application of the Supastik E10. Masking tape should be applied over the sealant in the joint and, if required, on both arrises to provide an increased unbonded width and greater movement potential if required.

Following application, remove central masking tape, together with any additional tape applied to arrises (as described in Surface Preparation). Immediately position membrane into the Supastik E10 with central release film uppermost. Roll firmly to displace trapped air and to ensure extrusion of Supastik E10 through the edge perforations. Apply a second layer of Supastik E10 to the full width of the top surface of membrane. Remove central release film from membrane. Finally remove outer edge masking tapes and feather-edge the Supastik E10.

Priming of concrete Priming of concrete is not normally required with the Supastik E10 / Expoband H45 system. The use of Fosroc Primer 13X should be considered where there could be doubt about porosity or condition of the concrete.

Jointing the Expoband H45 membrane

Apply Fosroc Primer 13X by brush, working well in, to a width of 25 mm either side of the membrane. Fosroc Primer 13X should be left for about 40 to 60 minutes (depending upon temperature) to allow evaporation of the primer solvent prior to the application of the Supastik E10 adhesive.

For heat welded joints, a 50 mm overlap should be used. Welding is carried out using a proprietary hot air welding tool. The tool should be set to the correct heat output by trial to achieve a satisfactory weld.

The surfaces to be jointed must be clean and wiped with Fosroc Solvent 105 prior to jointing.

The faces of the overlap are heated by moving the welding tool along the joint and, simultaneously, pressure should be applied by roller to the heated overlap to ensure that the faces are fused together.

If the primer has been left longer than 8 hours or has become contaminated with dust, the surface must be reprimed.



Fosroc® Expoband H45

Fosroc Primer 13X should be stored in accordance with the Highly Flammable Liquids and Liquefied Petroleum Gases Regulations 1972.

Water applications After application the Expoband H45 system should be allowed to cure for 28 days at 7°C before permanent contact with water.

Precautions

Ancillary materials and equipment

Health and safety

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.

Expoband H45

Estimating


There are no known hazards associated with this product in normal use. Supastik E10, Fosroc Primer 13X, Fosroc Solvent 105

Supply Expoband H45:

Fire

1mm thick x 100mm wide, 25metre roll 1mm thick x 200mm wide, 25metre roll

Fosroc Primer 13X, Fosroc Joint Cleaner and Fosroc Solvent 105 are flammable. Do not expose to naked flames or other sources of ignition. No Smoking. Containers should be tightly sealed when not in use. In the event of fire, extinguish with CO2 or foam.

Coverage Supastik E10:

(based on a 2mm spread of adhesive above and below the

Additional information

membrane)

Technical data — ancillary materials

For 100mm wide Expoband H45: 5 to 6 linear metres per 2 litres Supastik E10 For 200mm wide Expoband H45: 2.5 to 3.5 linear metres per 2litres Supastik E10 Dependent upon surface roughness and film thickness Fosroc Primer 13X

Fosroc Solvent 105

10m2/litre

Flash Point:

43°C

Storage Life:

Indefinite

Pack Size:

5 litre

Supastik E10

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

Form:

Base: Off-white viscous paste Curing agent: Grey viscous paste

Storage Life:

12 months in originally sealed containers sotred below 25°C in cool dry conditions

Flash Point:

Above 65°C

Mixed density:

1.2 kg/litre

Pot Life: 5°C: 10°C: 20°C: 40°C:

3 to 4 hours 1 to 2 hours 50 to 60 minutes 20 to 30 minutes

Solids content:

100%

Limitations Joint layouts incorporating Expoband H45 should be kept as simple as possible to allow for site joints to be restricted to straight butt joints. Avoid complex changes of angle or skew giving rise to difficulty in jointing and installation.

Storage Expoband H45 should be stored in original unopened packaging, in cool dry conditions, away from sunlight.



Fosroc® Expoband H45 Cure duration:

Over 15°C:

Before trafficking:

5°C to 15°C: 96 hours

Before immersion: >7°C:

48 hours 7 days


5°C to 50°C

Mixed Colour:

Grey

Fosroc Primer 13X Flash Point:

Base: -7°C Curing Agent: -7°C

Density:

1.0 kg/litre

Storage Life:

12months in originally sealed containers

Pot Life:

30 minutes


5°C to 35°C

Tack-free time at 20°C:

10 to 60 minutes

Pack size:

200ml

Expoband is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

267



Proofex 3000MR


High performance methane, radon and CO2 resisting waterproof membrane for basements and structures

Application instructions Surface preparation All concrete surfaces must be a wood float or shutter finish and free from cavities or projections.

Uses A high performance self adhesive membrane for resisting methane, radon and CO2, and preventing water entering buildings. Proofex 3000MR also provides a vapour and waterproof membrane to water excluding structures and protects concrete from attack by aggressive ground salts.

Masonry surfaces must be flush pointed.

Advantages

Vertical and suspended slab surfaces shall be primed with Proofex Primer. Ensure complete coverage and allow to dry. Only prime an area to which the Proofex 3000MR can be applied the same day. Very porous surfaces may require more than one coat of primer.

All surfaces must be clean, dry and free from contamination, ice and frost. Priming

Aluminium film provides methane, radon and CO2 resistance, protection against damage and gives dimensional stability Combines toughness with flexibility for detailing around corners, pipes, etc.

Angle and corner details

Self adhesive layer system makes installation quick, simple and reliable

Use Proofex Angle Fillet strips fixed using 6 mm beads of Plastiseal at all wall to floor junctions.

Resistant to ground water, soluble sulphates and chlorides

All internal and external angles should be reinforced with Proofex Engage Detail Strip or a 300 mm wide strip of Proofex 3000MR. Where possible, a 25 mm chamfer should be provided to external angles.

Suitable for waterproofing basements grades 2, 3 and 4 as defined in BS 8102 : 1990, ‘Protection Of Structures Against Water From The Ground’

Application

Description

Application temperature range 5°C to 35°C.

Proofex 3000MR is a cold applied, flexible, methane resisting and waterproof high performance membrane incorporating an aluminium layer and a polymer modified bitumen compound on a high strength polymer backing film.

Vertical application: Cut the Proofex 3000MR to length allowing 150 mm for the end laps and position by peeling back the release paper and applying the self adhesive face to the prepared surface.

Where methane, radon or CO2 is present, a comprehensive site survey must be carried out and the building constructed accordingly. Refer to Building Research Establishment Report 212 and CIRIA Guide 149 for further information.

Start at the top of the wall and work down by progressively removing the release paper in stages. Proofex 3000MR should be applied to ensure that all end laps are weathered.

Proofex 3000MR should be laid in accordance with the provisions of BS 8102 : 1990.

In cold weather temporary batten support of the Proofex 3000MR membrane is recommended.

Typical properties Membrane thickness:

1.2 mm

Methane gas resistance:

60 kPa

Impermeable to ISO 12572 268


Fosroc® Proofex 3000MR The next roll or length is aligned against the previously applied piece allowing for the 50 mm minimum (or as specified) edge laps and 150 mm end laps and applied as stated previously. The edge and end laps should be rolled to ensure complete adhesion and continuity between the layers.

Estimating Proofex 3000MR Roll size:

1 m x 20 m

Roll area:

20 m²

Edge laps:

50 mm minimum

Penetrations

End laps:

150 mm minimum

Penetrations e.g. pipe entries through the Proofex 3000MR membrane require special attention to detail. Proofex Top Hats are recommended and should be stuck to membrane using Proofex Total Tape and sealed to pipe with Nitoseal MS50

Roll weight:

25 kg

Proofex Primer Storage life:

2 years

Coverage:

6 to 8 m²/litre

Minimum installation temperature:

+4°C rising

Protection Proofex 3000MR membrane should be protected from physical damage and weathering as soon as possible after application. Surfaces should be protected from damage by Proofex Protection Board.

Drying time @ 20oC:

1 to 2 hours

Pack size:

5 ltr and 25 ltr drums

Proofex Engage Detail Strip Thickness: 1.5 mm

Proofex 3000MR can also be covered with Proofex Sheetdrain to give both protection and a drainage layer.

Roll size:

Ancillary products

200 mm x 10 m

Proofex Protection Board

Proofex Protection Board Bitumen impregnated board, designed to protect membranes from damage through backfilling and trafficking.

3 mm Thickness:

1000 mm x 2000 mm

Coverage:

2.0 m2

Proofex Engage Detail Strip A reinforced, double sided waterproof adhesive tape for use as reinforcing at all floor and wall junctions. It consists of a strong synthetic fibre fabric impregnated and coated both sides with a butyl adhesive, which is protected by a removable siliconised paper..

Proofex 3000MR must be stored in dry conditions, away from sunlight, in an upright position at a temperature between 5°C and 40°C.

Storage


Proofex Top Hat MDPE sheathing, which encapsulates an aluminium foil layer.

For information on Proofex Primer refer to Product Safety Data Sheet. Proofex Primer is flammable. Keep away from soruces of ignition. No smoking. In the event of fire, extinguish with CO2 or foam. Do not use a water jet.

Proofex Angle Fillet Strips fixed at all floor and wall junctions with a 6mm bead of Plastiseal.

Flash Point Proofex Primer:

>39oC

Proofex is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

269


19 CI/SfB: (13.9)Ln6

Fosroc® Proofex Radon Barrier

July 2007


High performance, gas-impervious, reinforced membrane


Uses

Underslab ground membranes The hard-core bed should be blinded with soft sand and consolidated to provide a smooth bed free of sharp projections.

Preparation

Gas membrane designed to protect buildings and their occupants from the effects of radon, carbon dioxide and other harmful gases. Like conventional ground membranes, Proofex Radon Barrier also acts as a damp-proof membrane to help protect the building against the ingress of moisture from the ground.

Overslab ground membranes The top surface of the concrete slab should be free from ridges, undulations and sharp projections. If this is not the case a sand bed may be necessary to reduce the risk of puncturing the membrane.

Advantages Virgin co-polymer product design for maximum gas protection.

Laying The membrane should be laid neatly and tucked well into angles to prevent bridging. At corners in upstands folded welts should be formed.

Loose-laid system for ease of application. Can be used on ground-bearing concrete floors or on suspended concrete or beam and block floors.

Lapping and jointing

Description

Rolls of Proofex Radon Barrier should be lapped by a minimum of 150mm and sealed with a continuous strip of Proofex TOTAL Tape. Ensure that the membrane is clean and dry at the time of jointing. For increased performance, seal the edge of the upper sheet with Proofex Detail Strip or strips of Proofex 3000MR.

Proofex Radon Barrier is a radon and carbon dioxide impermeable membrane comprising a co-polymer virgin grade LDPE/MDPE blown film. Building Regulations and Technical Standards require measures to be taken to prevent the build up of harmful gases inside buildings.

Proofex Radon Barrier can also be heat welded by a specialist installer.

Approved Document C to the Building Regulations should be consulted. This document refers to BRE Reports 211 (Radon) and 414 (Housing on gas contaminated sites).

Protection Protect the completed membrane adequately to prevent puncturing using Typar SF56 80g/m2 geotextile or Proofex Protection Board. Alternatively, the overlying construction, such as insulation, can be installed prior to pouring of concrete. If used in an overslab situation, unbonded screeds should be at least 50mm thick and laid as soon as possible after completing the membrane to reduce the risk of puncture.

Proofex Radon Barrier offers protection from radon and carbon dioxide when included in schemes designed and installed with reference to the guidance offered by the above documents.

Typical properties

Penetrations

Membrane thickness:

370μm

Weight (DIN53104):

356g/m 2

Roll weights (4m x 20m):

28.48kg

Radon gas transmission rate :

4 x 10-12m2/s

Moisture vapour transmission:

0.16g/m2/day

Tear resistance MD: CD:

248N/mm 303N/mm

Tensile strength MD: CD:

21.5Mpa 29.4 Mpa

Elongation@ Max Load MD & CD:

>800%

Colour

Yellow

Where possible services should be routed such that they do not pass through the membrane, thus reducing the number of penetrations. Where penetrations are unavoidable Proofex Top Hats are recommended and should be stuck to membrane using Proofex Total Tape and sealed to pipe with Nitoseal MS50.

Standard compliances Independently certified performance, IAB Certificate (No. 03/0177).

270

19 ®

CI/SfB: (13.9)Ln6

Fosroc Proofex Radon Barrier

July 2007

Estimating

Additional information

Proofex Radon Barrier

Ancillary products

Roll width:

4m

Roll length:

20m

Proofex TOTAL Tape Double-sided butyl tape for sealing of side and end laps and for use in detailing work.

50mm 30m

Typar SF56 80 g/m2 geotextile as protection for membrane against damage.

Proofex TOTAL Tape Tape width: Tape length:

Maintenance

Proofex Protection Board Proofex Protection BoardP Bitumen impregnated board designed to protect membranes from damage through backfilling and trafficking.

Proofex Radon Barrier is robust and will resist puncture during and after installation providing adequate care is taken to protect the membrane directly after installation. The membrane should be inspected prior to pouring a ground slab or screed and, should any holes or tears be found, these should be repaired using patches of Proofex Radon Barrier taped in place using Proofex TOTAL adhesive tape with at least a 150mm lap beyond the extremity of the puncture.

Proofex 3000MR Methane and water resistant self-adhesive membrane. Proofex Top Hats MDPE sheathing, which encapsulates an aluminium foil layer.

Storage Store in original unopened packaging, in cool dry conditions, away from direct sunlight.

Precautions Health and safety There are no known health hazards associated with Proofex Radon Barrier in normal use.

Proofex is the trade mark of Fosroc International Limited

Important note



www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

271


19 CI/SfB: (13.9)Ln6 September 2009

Fosroc® Proofex Total


High performance, totally gas-impervious, reinforced membrane


Uses

Underslab ground membranes The hard-core bed should be blinded with soft sand and consolidated to provide a smooth bed free of sharp projections.

Preparation

Reinforced gas membrane designed to protect buildings and their occupants from the effects of methane, radon, carbon dioxide and other harmful gases. Like conventional ground membranes, Proofex Total also acts as a damp-proof membrane to help protect the building against the ingress of moisture from the ground.

Advantages

Overslab ground membranes The top surface of the concrete slab should be free from ridges, undulations and sharp projections. If this is not the case a sand bed may be necessary to reduce the risk of puncturing the membrane.

5-layer product design for maximum gas protection.

Laying

Polyester reinforcing grid for puncture resistance during application.

The membrane should be laid neatly and tucked well into angles to prevent bridging, with the black surface facing upwards. At corners in upstands folded welts should be formed.

Loose-laid system for ease of application. Can be used on ground-bearing concrete floors or on suspended concrete or beam and block floors.

Lapping and jointing

Can be used to form a cavity tray, eradicating the need for a separate product.

Rolls of Proofex Total should be lapped by a minimum of 150mm and sealed with a continuous strip of Proofex Total Tape. Ensure that the membrane is clean and dry at the time of jointing. For increased performance, seal the edge of the upper sheet with Proofex Detail Strip or strips of Proofex 3000MR.

Description Proofex Total is a black/silver, 5-layer, reinforced, gas impermeable membrane comprising an aluminium foil layer and a polyester reinforcing grid sandwiched between three layers of polyolefins.

Proofex Total can also be heat welded by a specialist installer.

Maintenance

Protection

Proofex Total is extremely robust and will resist puncture during and after installation providing adequate care is taken to protect the membrane directly after installation. The membrane should be inspected prior to pouring a ground slab or screed and, should any holes or tears be found, these should be repaired using patches of Proofex Total taped in place using Proofex Total adhesive tape with at least a 150mm lap beyond the extremity of the puncture.

Protect the completed membrane adequately to prevent puncturing using a geotextile or Proofex Protection Board. Alternatively, the overlying construction, such as insulation, can be installed prior to pouring of concrete. If used in an overslab situation, unbonded screeds should be at least 50mm thick and laid as soon as possible after completing the membrane to reduce the risk of puncture.

Properties

Where possible services should be routed such that they do not pass through the membrane, thus reducing the number of penetrations.

Membrane thickness

0.45 mm

Weight Roll weight (2m x 25m)

300 g/m2 17.5 kg

Water vapour permeability (ISO 9932)

0.01 g/m2/24hr

Methane gas transmission rate (BR212)

900 kPa

Radon permeability

Penetrations

Where penetrations are required, Proofex Top Hats are recommended and these should be stuck to membrane using Proofex Total Tape and sealed to pipe with Nitoseal MS50

Ancillary products -12

Proofex Total Tape 2

2.3 (10 m /24hr)

Double-sided butyl tape for sealing of side and end laps and for use in detailing work.

Standard compliances

Proofex Top Hats

BRE Digest 211 Radon : Guidance on protective measures for new buildings

MDPE sheathing, which encapsulates an aluminium foil layer.

BRE Digest 212: Construction of new buildings on gas contaminated land. 272

19 CI/SfB: (13.9)Ln6 September 2009

Fosroc® Proofex Total Estimating Proofex Total Roll width:

2m

Roll length:

50m

Proofex Total Tape Tape width:

50mm

Tape length:

30m

Storage Store in original unopened packaging, in cool dry conditions, away from direct sunlight.


Important note

Proofex is the trade mark of Fosroc International Limited



www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

273


20 CI/SfB: Yq4 June 2008

Fosroc® Conbextra BB


Non shrink cementitious bridge bearing grout

Properties

Uses

All properties at a water : powder ratio of 0.19

Grouting beneath:

Property

Test method

Compressive strength (typical results):

BS 1881 : 1983 Part 116

1 day: 28 N/mm² 7 days: 58 N/mm² 28 days: 67 N/mm²

Expansion:

ASTM C827-87

0.25% - 1.0%

Elastic stability (compressive strain): Total chloride ion content (as % of mass of cement):

DTp SHW 1991 Clause 2601 (viii)

Bridge bearings Parapet posts Flanged lighting columns Conbextra BB can be used in section thicknesses 10 mm to 100 mm.

Advantages Complies fully with the Department of Transport Specification for Highway Works March 1998 Clause 2601 Non shrink High strength Excellent flow, particularly at low temperature Low permeability ensures durability Can be poured or pumped

< 1%

—

< 0.1%

Total acid soluble sulphate SO3 (as % of mass of cement): —

< 4%


Description


Conbextra BB is a ready to use cementitious grout supplied in 25 kg moisture resistant bags. It has been formulated specifically for grouting of bridge bearings and parapet post baseplates.

All grouting of bridge bearings and parapet post baseplates must be carried out using a pre-packaged non-shrink cementitious grout manufactured by a registered firm under the ISO 9001 quality assurance scheme.

The dry powder is a blend of Portland cements, graded silica sands and additives to which only a controlled amount of clean water is added in situ to produce a highly flowable, non shrink grout.

Standards compliance Conbextra BB has been independently tested, by a NAMAS accredited laboratory, in accordance with the Department of Transport Specification for Highway Works March 1998 Clause 2601. Conbextra BB complies fully with the requirements of this specification.

The grout must comply fully with the Department of Transport Specification for Highway Works, March 1998 Clause 2601. The supplier shall confirm this compliance by providing test results from an independent NAMAS accredited laboratory. The storage, mixing, placing and curing of the grout shall all be in accordance with the suppliers technical data sheet.

Application instructions Preparation Concrete surfaces The substrate must be free from oil, grease or any loosely adherent material. If the concrete surface is defective or has laitance, it must be cut back to a sound base. Bolt holes or fixing pockets must be blown clean of any dirt or debris. Pre-soaking For a minimum of two hours prior to grouting, the area of cleaned substrate should be flooded with fresh water. Immediately before grouting takes place, any free water should be removed. Particular care should be taken to blow out all bolt holes and pockets. 274


Fosroc® Conbextra BB Bearing plate / parapet post baseplate It is essential that this is clean and free from oil, grease or scale. 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 as Conbextra BB is a free flowing grout. This can be achieved by using Fosroc Silicone Sealant 33HM beneath the constructed formwork and between joints.

the void to eliminate the entrapment of air or surplus presoaking water. This is best achieved by pouring the grout across the shortest distance of travel. The grout head must be maintained at all times so that a continuous grout front is achieved. Where large volumes have to be placed Conbextra BB may be pumped. A heavy duty diaphragm pump is recommended for this purpose. Screw feed and piston pumps may also be suitable. Once the Conbextra BB has reached trowelable consistency, the unrestained portion should be cut back to the baseplate/bearing plate. Curing

In some cases it is practical to use a sacrificial semi-dry sand and cement formwork. The formwork should include outlets for the pre-soaking water. The unrestrained surface area of the grout must be kept to a minimum. Generally the gap width between the perimeter formwork and the plate edge should not exceed 100 mm on the pouring side and 50 mm on the opposite side. There should be no gap at the flank sides. Mixing For best results a mechanically powered grout mixer should be used. For quantities up to 50 kg a slow speed drill fitted with a high shear paddle is suitable. Larger quantities will require a high shear vane mixer. Do not use a colloidal impeller mixer. It is essential that machine mixing capacity and labour availability is adequate to enable the grouting operation to be carried out continuously. This may require the use of a holding tank with provision for gentle agitation to maintain fluidity. The water should be accurately measured into the mixer. Slowly add the total contents of the Conbextra BB bag, mix continuously for 5 minutes, ensuring a smooth, even consistency is obtained. Water addition Add 4.8 litres of water to each 25 kg bag of Conbextra BB to produce a fluid grout.

On completion of the grouting operation, exposed areas should be thoroughly cured. This should be done by the use of Concure curing membrane, continuous application of water and/or wet hessian. Cleaning Conbextra BB should be removed from tools and equipment with clean water immediately after use. Cured material can be removed mechanically, or with Fosroc Acid Etch.

Estimating Allowance should be made for wastage when estimating quantities required. The approximate yield per 25 kg bag is 13.5 litres. Supply Conbextra BB is supplied in 25 kg bags.

Limitations Low temperature working Do not mix Conbextra BB at ambient temperatures below 5°C. For full cold weather working limitations, refer to Department of Transport Specification clause 2601 subclause 3

Placing Place the grout within 20 minutes of mixing to gain the full benefit of the expansion process. Conbextra BB can be placed in thicknesses up to 100 mm in a single pour. Any bolt pockets must be grouted prior to grouting between the substrate and the bearing or base plate. Continuous grout flow is essential.

High temperature working At ambient temperatures above 35°C the mixed grout should 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 dry store in sealed bags.

The mixed grout should be poured only from one side of If stored in high temperature and high humidity locations the shelf life may be reduced to less than 6 months.



Fosroc® Conbextra BB Precautions Health and safety For further information refer to appropriate Product Safety Data Sheet.

Fire Conbextra BB is non-flammable.

Conbextra is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

276



Fosroc® Conbextra GP


General purpose non-shrink cementitious grout


Uses

All grouting must be carried out with pre-packaged nonshrink cementitious grout manufactured and supplied by a BSi registered firm.


Conbextra GP is used for general purpose, non-shrink cementitious grouting of gap thicknesses 10 to 75 mm. Recommended applications at flowable consistency include stanchion base plates, bolt pockets and void filling. At trowellable consistency Conbextra GP is recommended for bedding load bearing components.

It shall be mixed with clean water to the required consistency. The grout must not bleed or segregate. A volumetric expansion of up to 1% shall occur while the grout is plastic by means of a gaseous system.

Advantages

The compressive strength of the grout must reach 40 N/mm² at 7 days and 60 N/mm² at 28 days.

Non-shrink

The storage, handling and placement of the grout must be in strict accordance with the manufacturer’s instructions.

Simply add correct quantity of water Can be used at flowable or trowellable consistency Chloride free

Properties

Non-staining

The following results were obtained at flowable consistency (ie 4.5 litres of water per 25 kg bag) and at a temperature of 20°C.

Description Conbextra GP is supplied as a ready to use dry powder. The addition of a controlled amount of clean water produces a flowing non-shrink grout for gap thicknesses 10 to 75 mm.

Test method for Compressive strength (BS 1881, Part 116: 1983 - restrained):

Conbextra GP is a blend of Portland cements, graded fillers and chemical additives. The low water demand ensures high early strength. The graded filler is designed to assist uniform mixing and produce a consistent grout.

Flexural strength (BS 6319, Part 3: 1990):

Typical detail of stanchion base plate Conbextra GP to underside of stanchion base plate (second stage)

Base plate

Shims

50 mm max

Conbextra GP or Lokfix to bolt pocket (first stage)

277

Typical result

16 N/mm² @ 1 day 42 N/mm² @ 7 days 60 N/mm² @ 28 days 7.0 N/mm² @ 7 days 13.0 N/mm² @ 28 days

Young’s modulus (BS 6319, Part 6: 1984):

23 kN/mm²

Time for expansion — Start: Finish:

15 minutes 2 hours

Fresh wet density:

Approximately 2170 kg/ m³ depending on actual consistency used

Expansion characteristics:

An expansion of up to 1% overcomes plastic settlement in the unset material


Fosroc® Conbextra GP Application instructions

measured into the mixer. The total contents of the Conbextra GP bag should be slowly added and continuous mixing should take place for 5 minutes. This will ensure that the grout has a smooth even consistency.

Preparation Foundation surface

Consistency of grout mix

The substrate surface must be free from oil, grease or any loosely adherent material. If the concrete surface is defective or has laitance, it must be cut back to a sound base. Bolt holes and fixing pockets must be blown clean of any dirt or debris.

The quantity of clean water required to be added to a 25 kg bag to achieve the desired consistency is given below.

Pre-soaking For a minimum of 2 hours prior to grouting, the area of cleaned foundation should be flooded with fresh water. Immediately before grouting takes place any free water should be removed with particular care being taken to blow out all bolt holes and pockets.

Trowellable:

3.4 to 3.6 litres

Flowable:

4.0 to 4.5 litres

Placing At 20°C place the grout within 20 minutes of mixing to gain the full benefit of the expansion process. Conbextra GP can be placed in thicknesses up to 75 mm in a single pour when used as an underplate grout. For thicker sections it is necessary to use Conbextra TS (thick section) grout.

Base plate It is essential that this is clean and free from oil, grease or scale. Air pressure relief holes should be provided to allow venting of any isolated high spots.

Any bolt pockets must be grouted prior to grouting between the substrate and the base plate.

Levelling shims If these are to be removed after the grout has hardened, they should be treated with a thin layer of grease.

Continuous grout flow is essential. Sufficient grout must be prepared before starting. The time taken to pour a batch must be regulated to the time to prepare the next one.

Formwork The formwork should be constructed to be leakproof. This can be achieved by using foam rubber strip or Silicone Sealant 33HM beneath the constructed formwork and between joints.

When the Conbextra GP has reached trowelable consistency, the unrestrained portion should be cut back to the baseplate/bearing plate. Typical hopper system

In some cases it is practical to use a sacrificial semi-dry sand and cement formwork. The formwork should include outlets for pre-soaking.

Pouring should be from one side of the void to prevent any air or pre-soaking water becoming trapped under the base plate. It is advisable to pour the grout across the shortest distance of travel. The grout head must be maintained at all times so that a continuous grout front is achieved.

Unrestrained surface area This must be kept to a minimum. Generally the gap width between the perimeter formwork and the plate edge should not exceed 150 mm on the pouring side and 50 mm on the opposite side. It is advisable where practical to have no gap at the flank sides.

Removable hopper: For larger pours the grout may be hand placed or pumped into a removable hopper (trough)

Mixing

Conbextra GP poured into removable hopper (second stage)

For best results a mechanically powered grout mixer should be used. When quantities up to 50 kg are used, a Bosch (or equivalent) 1150 watt, 280/640 rpm, 110 volt drill fitted with a Conbextra mixing paddle is suitable. Larger quantities will require a high shear vane mixer. Do not use a colloidal impeller mixer.

50 mm max

To enable the grouting operation to be carried out continuously, it is essential that sufficient mixing capacity and labour are available. The use of a grout holding tank with provision to gently agitate the grout may be required. The selected water content should be accurately

Conbextra GP or Lokfix (first stage)


75 mm max


Fosroc® Conbextra GP Curing

Storage

On completion of the grouting operation, exposed areas should be thoroughly cured with Concure curing membrane, continuous application of water and/or wet hessian.

Store unopened bags in cool dry internal conditions. Conbextra GP has a shelf life of 12 months if kept in a dry store in sealed bags. If stored in high temperature and high humidity locations the shelf life may be reduced to less than 6 months.

Cleaning

Precautions

Conbextra GP should be removed from tools and equipment with clean water immediately after use. Cured material can be removed mechanically, or with Fosroc Acid Etch.


Estimating

Fire

Supply

Conbextra GP is non-flammable.

Conbextra GP is supplied in 25 kg bags. Yield Allowance should be made for wastage when estimating quantities required. The approximate yield per 25 kg bag is: Consistency

Trowellable

Flowable

12 litres

13.25 litres

Yield:

Limitations Low temperature working When the air or contact surface temperatures are 5°C or below on a falling thermometer, warm water (30°C to 40°C) is recommended to accelerate strength development. For ambient temperatures below 10°C the formwork should be kept in place for at least 36 hours. Normal precautions for winter working with cementitious materials should then be adopted. High temperature working At ambient temperatures above 35°C cool water (below 20°C) should be used for mixing the grout prior to placement.



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279



Fosroc® Conbextra HF


High flow non-shrink cementitious grout

Properties

Uses

The following results were obtained at fluid consistency i.e. 4.8 litres of water per 25 kg bag.

Conbextra HF is used for free flow, non-shrink, cementitious grouting of gap thicknesses 10 to 100 mm. Recommended applications include:

Test method for

Typical result

Compressive strength (BS 1881, Part 116: 1983 - restrained)

25 N/mm² @ 1 day 44 N/mm² @ 7 days 56 N/mm² @ 14 days 64 N/mm² @ 28 days 82 N/mm² @ 180 days

Flexural strength (BS 4551: 1980):

2.5 N/mm² @ 1 day 8.0 N/mm² @ 7 days 9.5 N/mm² @ 14 days 10.0 N/mm² @ 28 days 11.0 N/mm² @ 180 days

Large stanchion baseplates Joints between pre-cast concrete panels Pumped grouting applications Grouting applications where pouring access is restricted Advantages Non-shrink Highly flowable High strength Chloride free Suitable for pumping

Description Conbextra HF is supplied as a ready to use dry powder. The addition of a controlled amount of clean water produces a free-flowing grout for gap thicknesses up to 100 mm. In addition the low water requirement ensures high early strength and long-term durability. Conbextra HF is a blend of Portland cements, graded fillers and chemical additives. The filler grading produces a highly flowable grout which will not segregate or bleed.


Young’s modulus (ASTM C-469-83):

29 kN/mm²

Flow characteristics (Efflux time) CRD-C Cone:

19 to 25 seconds

Setting time (BS 4550, Part 3: 1978) — Initial set: Final set:

5.5 hours 7.5 hours

Time for expansion Plastic state — Start: Finish:

15 minutes Initial set

Fresh wet density:

Approximately 2200 kg/m³ depending on actual consistency used


An expansion of up to 1% when measured according to ASTM C827 overcomes plastic settlement in the unset material

Conbextra HF conforms fully to U.S. Corps of Engineers Specification for non-shrink grout CRD-C621-82A and ASTM C1107-91 (Type C).




Preparation

All grouting must be carried out with a pre-packaged, nonshrink cementitious grout manufactured and supplied by a registered firm. The grout shall be chloride free.

Foundation surface The substrate surface must be free from oil, grease or any loosely adherent material. If the concrete surface is defective or has laitance, it must be cut back to a sound base. Bolt holes or fixing pockets must be blown clean of any dirt or debris.

It shall be mixed with clean water to the required consistency and not exhibit bleed or segregation. A volumetric expansion of up to 1% shall occur while the grout is in a plastic state by means of a gaseous system.

Pre-soaking

The compressive strength of the grout must exceed 40 N/mm² at 7 days and 60 N/mm² at 28 days.

For a minimum of 2 hours prior to grouting, the area of cleaned foundation should be flooded with fresh water. Immediately before grouting takes place, any free water should be removed. Particular care should be taken to blow out all bolt holes and pockets. Where water soaking is impossible contact Fosroc Customer Service Department.

The grout shall fully conform to the requirements of US Army Corps of Engineers Specification for non-shrink grout CRD-C621-82A. The storage, handling and placement of the grout must be in strict accordance with the manufacturer’s instructions. 280


Fosroc® Conbextra HF Base plate

Grout consistency

It is essential that this is clean and free from oil, grease or scale. Air pressure relief holes should be provided to allow venting of any isolated high spots.

Maximum flow distance in mm Gap depth 100 mm 250 mm mm head head

Flowable:

10 20 30 40 50

360 950 1500 2200 3000

1200 2600 3000 3000+ 3000+

Fluid:

10 20 30 40

900 1900 3000 3000+

2500 3000 3000+ 3000+

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 leakproof as Conbextra HF is a free-flowing grout. This can be achieved by using foam rubber strip or Silicone Sealant 33HM beneath the constructed formwork and between joints.

Placing Place the grout within 20 minutes of mixing to gain the full benefit of the expansion process.

In some cases it is practical to use a sacrificial semi-dry sand and cement formwork. The formwork should include outlets for the pre-soaking water.

Conbextra HF can be placed in thicknesses up to 100 mm in a single pour.

The unrestrained surface area of the grout must be kept to a minimum. Generally the gap width between the perimeter formwork and the plate edge should not exceed 150 mm on the pouring side and 50 mm on the opposite side. There should be no gap at the flank sides.

For thicker sections it is necessary to use Conbextra TS (thick section) grout. Any bolt pockets must be grouted prior to grouting between the substrate and the base plate.

Mixing

Continuous grout flow is essential.

For best results a mechanically powered grout mixer 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. Larger quantities will require a high shear vane mixer. Do not use a colloidal impeller mixer.

Example of a typical hopper system:

2

50 mm max

t

t

t

It is essential that machine mixing capacity and labour availability is adequate to enable the grouting operation to be carried out continuously. This may require the use of a holding tank with provision for gentle agitation to maintain fluidity.

t t

The selected water content should be accurately measured into the mixer. Slowly add the total contents of the Conbextra HF bag, mix continuously for 5 minutes, ensuring a smooth, even consistency is obtained.

100 mm

t 1

Consistency of mixed grout 1 Conbextra HF or Lokfix* (first stage) 2 Conbextra HF poured or pumped into removable hopper (second stage) * Also available from Fosroc.

To achieve the consistencies which are defined in CRD-C621-82A, the amount of clean water that is added to a 25 kg bag at 20°C is: Flowable:

4.5 litres

Fluid:

4.8 litres

Sufficient grout must be available prior to starting and the time taken to pour a batch must be regulated to the time taken to prepare the next one.

Maximum flow distance at 20°C

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 grout across the shortest distance of travel. The grout

The flow distances given below are intended as a guide. Actual flow distances will vary depending on site conditions.



Fosroc® Conbextra HF head must be maintained at all times so that a continuous grout front is achieved.

Limitations Low temperature working

Where large volumes have to be placed Conbextra HF may be pumped. Screw feed and piston pumps are also suitable for this purpose.

When the air or contact surface temperatures are 5°C or below on a falling thermometer, warm water (30°C to 40°C) is recommended to accelerate strength development.

When the Conbextra HF has reached trowelable consistency, the unrestained portion should be cut back to the baseplate/bearing plate.

For ambient temperatures below 10°C the grout consistency should be flowable and the formwork should be maintained in place for at least 36 hours.

Curing On completion of the grouting operation, exposed areas should be thoroughly cured with Concure WB curing membrane, continuous application of water and/or wet hessian.

Normal precautions for winter working with cementitious materials should then be adopted.

Cleaning

At ambient temperatures above 35°C the mixed grout should be stored in the shade. Cool water (below 20°C) should be used for mixing the grout.


Conbextra HF should be removed from tools and equipment with clean water immediately after use. Cured material can be removed mechanically, or with Fosroc Acid Etch.

Storage Store unopened bags in cool dry internal conditions. Conbextra HF has a shelf life of 12 months if kept in a dry store in sealed bags. If stored in high temperature and high humidity locations the shelf life may be reduced to less than 6 months.

Estimating Supply Conbextra HF is supplied in 25 kg bags. Yield

Precautions

Allowance should be made for wastage when estimating quantities required. The approximate yield per 25 kg bag for different consistencies is: Consistency

Flowable

Fluid

Yield:

13.25 litres

13.5 litres

Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Conbextra HF is non-flammable.



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282



Fosroc® Conbextra TS


Shrinkage compensated cementitious aggregate filled grout


Uses

All grouting of gap thicknesses 75-500 mm must be carried out with a pre-bagged, shrinkage compensated, cementitious aggregate filled grout supplied by a BSi registered firm. The compressive strength of the grout shall be at least 60 N/mm2 at 28 days.


Conbextra TS is used to grout gap thicknesses 75-500 mm. Applications include grouting thick section voids beneath baseplates; voids around below-ground tanks; large bolt pockets etc.

The aggregate filled grout must be stored, handled and placed in strict accordance with the manufacturers instructions. No site batched additions to the pre-bagged grout shall be allowed.

Conbextra TS is ideally suited to thick section grouting as it contains aggregates that reduces exothermic heat generation and risk of thermal cracking common with gap thicknesses in excess of 100 mm.


Advantages

All grouting of gap thicknesses 75-500 mm (specify details and areas of application) must be carried out using Conbextra TS manufactured by Fosroc and used in strict accordance with the manufacturers instructions.

Shrinkage compensated High compressive strength No need to site batch aggregates Highly flowable


Extended workability

Preparation

Can be pumped or poured

The substrates must be free from oil, grease or any loosely adherent material. If concrete surfaces are defective or have laitance they must be cut back to a sound base. Bolt holes and pockets must be blown clean of any dirt and debris.

Description Conbextra TS is supplied as a ready to use dry powder. The addition of a controlled amount of clean water will produce a fluid, aggregate-filled grout for pouring or pumping into large voids between structural elements.

Pre soaking Soak concrete substrates for a minimum of two hours continuously prior to placing the aggregate filled grout. Immediately before placing all free water should be removed using wet vacuuming if required.

Conbextra TS is a blend of Portland cements, graded aggregates and additives. The low water requirement produces a fluid grout of high strength with good workability.

Baseplates

Technical service

Must be clean and free from oil grease and scale. Air pressure relief holes should be provided to allow venting of any isolated high spots.

Fosroc offers a comprehensive range of high quality, high performance construction products. In addition Fosroc offers worldwide technical support to specifiers and users of its products.

Formwork The unrestrained surface area of the grout must be kept to a minimum. Generally the gap width between the perimeter formwork and the plate edge should not exceed 150 mm on the pouring side and 50 mm on the opposite side. There should be no gap at the flank sides. Formwork should be made leak-proof by using Fosroc Silicone Sealant 33HM beneath the formwork and between joints. Coat all formwork with Fosroc Demoulux H15 to enable easy formwork release.

Properties At a water powder ratio of 0.13 at 20°C. Test method Compressive strength (BS1881 Part 116): - restrained

Typical result 32 N/mm2 @ 3 days 48 N/mm2 @ 7 days 64 N/mm2 @ 28 days

Initial set (BS4550): Final set (BS4550):

6.5 hours 9 hours

Expansion characteristics (ASTM C827-87):

Up to 2% at 24 hours

Mixing and placing Water addition is 3.3 litres per 25 kg bag. Do not attempt part mixes. 25 kg bags of Conbextra TS may be mixed in a clean drum using a Conbextra mixing paddle in a slow speed

283


Fosroc® Conbextra TS Limitations

drill. Carefully measure out the water in a calibrated vessel and pour into the drum and, with the paddle rotating, slowly add the contents of Conbextra TS to the water and mix continuously for 3-5 minutes ensuring a smooth consistency is achieved.

Low temperature working When air or contact surface temperatures are 5°C or below on a falling thermometer warm water (30-40°C) is recommended to accelerate strength gain. Normal precautions for winter working with cementitious materials should always be adopted.

For larger quantities a forced action grout mixer is recommended. Refer to Fosroc Customer Services for advice on suitable mixers. Always add the powder to the water.


Continuous grout flow is essential and the necessary mixing equipment and labour must be available to achieve this.

At ambient temperatures above 35°C the mixed grout should be kept in the shade prior to placement. Water less than 20°C should be used for mixing.

Pour or pump Conbextra TS from one point only to eliminate the entrapment of air.

Storage

Conbextra TS is formulated to give extended workability but must be placed within 20 minutes of mixing.

Store in unopened bags in cool dry internal conditions. The product has a shelf life of 12 months from the date of manufacture if kept in a dry storage in the original, unopened bags.

If pumping Conbextra TS, use a piston pump (eg Putzmeizter P13) with a minimum pump line diameter of 50 mm.

If stored at high temperatures and/or high humidity conditions the shelf life may be reduced to less than 6 months.

Curing

Precautions

All exposed areas should be cured using Fosroc Concure WB, continuous application of water or with wet hessian.


Cleaning Conbextra TS should be removed from all tools and equipment with clean water immediately after use. Cured material can be removed mechanically or with Fosroc Acid Etch.

Fire Conbextra TS is non-flammable.

Estimating Supply Conbextra TS is supplied in 25 kg bags. Yield Approximate yield per 25 kg bag is 12 litres (0.012 m³).



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284



Fosroc® Conbextra UW Non-shrink cementitious grout for underwater installations



Uses Conbextra UW is used for free flow or pumped grouting applications underwater or in tidal zones. There will be no significant ‘wash-out’ of the cement phase. Applications include bridge columns, quay pillars, concrete piling, slipways and dams.

Controlled expansion occurs in the unset material to ensure that the grout, when cured, will continue to occupy its original volume within the confines of the void in which it was placed.

Application instructions Advantages

Preparation

No risk of significant ‘wash-out’ of cement phase when placed underwater

The substrate surface must be free from oil, grease or any loosely adherent material. If the concrete surface is defective or has laitance, it must be cut to a sound base.

Displaces water effectively Gaseous expansion system compensates for shrinkage and settlement in the plastic state High early and ultimate strength and exceptional resistance to freeze-thaw cycling ensure durability of the hardened grout

Substrates which are permanently immersed should be grit-blasted or cleaned with a high pressure water jet. Non-immersed or intermittently immersed substrates can be prepared using these techniques. Alternatively scabbling or bush hammering may be appropriate.

Chloride free

Formwork

Pre-packaged needing only on-site addition of water

The formwork should be constructed to be leakproof as Conbextra UW is a free flowing grout. This can be achieved by using foam rubber strip or Silicone Sealant 33HM beneath the constructed formwork and between joints.

Description Conbextra UW is supplied as a ready to use powder. The addition of a controlled amount of clean water produces a free flowing grout. The grout exhibits exceptional resistance to ‘washing-out’ of the cement phase when placed in stationary or moving water.

Mixing and placing Mixing

Conbextra UW is a blend of cement, graded fine aggregate and chemical additives which impart controlled expansion, water reduction and non ‘wash-out’ characteristics. The aggregate grading minimises segregation and bleeding whilst assisting the flow characteristics.

For best results a mechanically powered grout mixer should be used. It is essential that machine mixing capacity and labour availability is adequate to enable the grouting operation to be carried out continuously. This may require the use of a holding tank with provision for gentle agitation to maintain fluidity.

Properties

Measure accurately 5.5 litres of water for each 25 kg bag into the mixer. Slowly add the Conbextra UW whilst mixing continuously. When all the powder is added mix continuously for 5 minutes ensuring a smooth even consistency is obtained. (Fluidity will increase with increased mixing.)

The following results were obtained at a water : powder ratio of 0.22. Test method for

Typical result

Compressive strength (BS 4550, Part 3: 1978) — 1 day: 3 days: 7 days: 28 days:

5°C

20°C

6 N/mm² 24 N/mm² 36 N/mm² 50 N/mm²

25 38 44 53

Setting time (BS 5075, Part 1: 1982) — Initial: Final:

5°C

20°C

Density of hardened grout:

2050 kg/m³

Placing

N/mm² N/mm² N/mm² N/mm²

Place the grout within 20 minutes of mixing to gain the full benefit of the expansion process. Continuous grout flow is essential. The mixed grout should be poured or pumped through a flexible tube, having a minimum diameter of 50 mm, to the lowest point in the form.

13 hours 4.5 hours 16.5 hours 5.5 hours

Care must be taken at the start of the grouting operation to restrict the grout flow so that water is not entrapped.

285


Fosroc® Conbextra UW The tube may be raised as necessary to reduce any back pressure. It should not be raised above the surface level of the grout.

when mixed with 5.5 litres of water is 14.5 litres.

Conbextra UW can be placed in thicknesses up to 75 mm in one pour when used above water. When used underwater, the heat sink effect in this environment will allow thicknesses of up to 150 mm to be placed.

Store in unopened bags in cool dry internal conditions. The product has a shelf life of 12 months from the date of manufacture if kept in a dry storage in the original, unopened bags. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced to less than 6 months.

Storage

For thicker sections, up to 200 mm above water and 400 mm underwater, it is necessary to fill out Conbextra UW using a clean rounded well graded aggregate ranging from 2 to 10 mm. The ratio of aggregate added to Conbextra UW should not exceed 1 : 1 by weight. For such mixes a concrete mixer should be used. Unrestrained surface area should be kept to a minimum.

Precautions Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire

Curing

Conbextra UW is non-flammable.

Curing will not be required in intermittently or totally submerged situations. However, when cast above water, exposed areas should be thoroughly cured with Concure curing membrane, continuous application of water and/or wet hessian. Cleaning Because of its water resisting properties, equipment used for Conbextra UW will be difficult to clean. The use of hot water for cleaning purposes will assist. Cured material can 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 estimating quantities required. The approximate yield of a 25 kg bag



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286


287

288

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Fosroc® Lokfix


Polyester resin anchoring grout Standards compliance The material is tested in accordance with BS 5080, BS 7861 and BS 6319.

Properties Gel time Temperature

Gel time

(°C)

(minutes)

Minimum time before load (hours)

5 10 20 30

130 65 25 10

12 5 2 1

The following test results were obtained at a temperature of 20°C:

Uses

Lokfix S25

Lokfix P25

Compressive strength: (BS 6319 Part 2: 1983)

83 N/mm²

87 N/mm²

Tensile strength: (BS 6319 Part 7: 1985)

11 N/mm²

11 N/mm²

Flexural strength: (BS 6319 Part 3: 1983)

20 N/mm²

19 N/mm²

Compressive modulus: (BS 7861 Part 1: 1996)

13 GPa

13 GPa

Density:

1880 to 1920 kg/m³

1880 to 1920 kg/m³

Lokfix mix and place anchoring grouts are used for: High-strength corrosion-resistant anchoring of bolts and bars into concrete, rock, masonry or brickwork where high speed of installation and early application of load is required Permanent installation of reinforcement starter bars, MOT bolts, foundation bolts, base plates, balustrading, barriers and safety fences, railway tracks and tie-back anchors.

Advantages Easy to mix and apply Rapid strength gain

Chemical resistance

Vibration resistant

The cured resin is resistant to fresh and salt water, petrol, oils, grease and most acids, alkalis and solvents. Consult Fosroc Technical Department for specific chemical resistance.

Corrosion resistant Non-expansive Can be placed underwater Increased flowability

Description The two versions of Lokfix are pre-measured, two-part, filled polyester resin grouts. After hardening, the grout produces 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 diameter than the bar. Lokfix P25 (pumpable grade, 25 minute gel at 20°C): Used in overhead or horizontal holes where the hole is up to 25 mm greater in diameter than the bar. The thixotropic nature of Lokfix P25 reduces flow of grout out of the hole.

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21 CI/SfB: 12_Yn6 October 2005

Fosroc® Lokfix Application instructions

Hole preparation and formation

Selection of grout version

Optimum performance of Lokfix grouts requires rough sided, dust-free holes. Use of rotary percussive drills with air or water flushing is recommended.

The version of Lokfix grout chosen will depend on anchor conditions (see ‘Description’).

Diamond drilled holes should be under-reamed.

Parameters of anchor design

Cast holes should preferably be of inverse dovetail configuration. If parallel sided holes are cast they should be rough to provide adequate keying.

The high strength of the cured resin permits strong anchors to be created. Ultimate strength is varied by: Strength of host material

Bar preparation

Length of resin bond to bar

All bars should be deformed. They should preferably be degreased and all flaky rust removed.

Hole preparation and formation Type and dimension of bar

Mixing

Typical loads attained

A complete pack of resin and catalysed filler should be mixed in one operation. Mixing may be carried out manually or mechanically. When a smooth, even consistency is achieved the grout is ready for use and should be placed well within the gel time of the grout.

Concrete: 20 N/mm² unreinforced. Bar:

Deformed rebar to BS 4449.

Hole:

Air-flushed rotary percussive drilled.

Packs have been designed to produce practical and economic volumes of grout.

40

DO NOT attempt to mix partial pack components.

Estimating

30

Load (tonnes)

Refer to estimating guide table on the following page.

20

10

0 0

200

400

600

800

Resin embedded length (mm) Note: The graph illustrates typical failure loads. Minimum safety factors of 1.5 in non-critical and 2 in critical cases should be considered for design purposes. Where relevant, the local codes of practice or standards must also be considered in relation to anchorage length.



Fosroc® Lokfix 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 24.6

therefore

2.5

= 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 any wastage. A typical allowance to cover these factors is approximately 10%. To determine the quantity of material per 100 mm of hole depth Hole diameter 20 25 32 38 45 51 57 64 76

mm mm mm mm mm mm mm mm mm

12 mm

16 mm

20 mm

0.020 litre 0.038 litre 0.069 litre — — — — — —

— 0.029 litre 0.060 litre 0.093 litre — — — — —

— — 0.049 litre 0.082 litre 0.128 litre — — — —

Bolt diameter 25 mm 32 mm — — 0.031 litre 0.064 litre 0.110 litre 0.155 litre 0.206 litre 0.273 litre —

Installation

— — — — 0.079 litre 0.124 litre 0.175 litre 0.241 litre —

38 mm

44.5 mm

51 mm

— — — — 0.046 litre 0.091 litre 0.142 litre 0.208 litre 0.340 litre

— — — — — — 0.100 litre 0.166 litre 0.298 litre

— — — — — — — 0.117 litre 0.249 litre

the pot life of the grout. Fosroc Solvent 105 is available for this purpose.

Lokfix S25

Supply

Using the calculated volume of grout based on the estimating guide table, the grout should be poured steadily into the prepared holes. The anchor bar is then pressed into the hole to the required depth; slight agitation will assist in achieving a complete bond. The bar should be left undisturbed in the required position until the resin is set.

The pack consists of a can of resin and a plastic bag of hardener contained in a plastic mixing pail with a snap-on lid. Volume of mixed components: 2.5 litres.

Lokfix P25

Lokfix P25 - Yellow Lid

The grout should be injected to the rear of the hole to avoid air entrapment. The thixotropic nature of Lokfix P25 will prevent significant flow of resin out of the hole.

The pack consists of a can of resin and a plastic bag of hardener contained in a plastic mixing pail with a snap-on lid. Volume of mixed components: 2.5 litres.

Lokfix S25 - Blue Lid

Cleaning Any mixing drums, pumps, etc., should be cleaned within



Fosroc® Lokfix Flash points

Storage Store in accordance with the Highly Flammable Liquids and Liquefied Petroleum Gases Regulations 1972. Shelf life of 12 months at 20°C will be reduced at higher temperatures.

Lokfix S25:

29°C

Lokfix P25:

29°C

Fosroc Solvent 105:

43°C

Limitations Fire resistance and creep At operating temperatures above 40°C, the creep of Lokfix resin under load may become significant. Resin anchors should not be used where structural load bearing performance has to be maintained in anchors subjected to fire conditions. Conbextra GP or Conbextra HF would be suitable in this case.

Precautions Health and safety For further information see appropriate Product Safety Data Sheet. Fire Lokfix products and Fosroc Solvent 105 are flammable. Do not expose to naked flames or other sources of ignition. No Smoking. Containers should be tightly sealed when not in use. In the event of fire, extinguish with CO2 or foam.

Lokfix is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


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Fosroc® Cebex 100 Expanding and plasticising grout admixture Uses


Properties Chloride content:

Nil to BS 5075

Compressive Strength:

The plasticising action of Cebex 100 allows reduction of the water/cement ratio of cementitious grouts whilst maintaining flow properties. This gives improvement in strength and long term durability when cured under restraint.

Setting times:

Cebex 100 does not significantly affect the setting times of cement based grouts.

Expansion Character:

The controlled positive expansion in unset grouts incorporating Cebex 100 overcomes plastic settlement when measured in accordance with ASTM C827. An unrestrained expansion of up to 4% is typical.

Cebex 100 is a suitable pre-stressing grout admixture when complying with BS 8110 Part 1, 1997, Annex A.

Time for: expansion:

15 minutes to 2 hours. Temperatures over 20oC may slightly reduce these times.

Description

Compatibility:

Cebex 100 is compatible with all types of Portland cement.

Cebex 100 is an admixture for site batched cementitious grouts where a reduced water/cement ratio and positive expansion is required. Applications include bed grouting, duct grouting, non-shrink infilling and jointing.

Advantages Gaseous expansion system compensates for plastic shrinkage and settlement in properly designed cementitious grout. Reduced water/cement ratio in the grout mix ensures low 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 staining or deterioration due to rust expansion in the grout. Composition allows high early strength development in grouts, without the use of chlorides.

Standard compliance

Cebex 100 is supplied as a powder admixture. The material is a combination of a plasticising agent and a gas producing expansion medium. The plasticising agent allows the use of a reduced water/cement ratio with consequent increased strengths and durability. The expansive medium counteracts the natural settlement and plastic shrinkage of the grout and aids stability and cohesion. Sufficient restrained expansion is developed to ensure a high degree of interfacial contact.

Specification clauses Supplier specification All grouting (specify details and areas of application) must be carried out using a cement based grout, incorporating Cebex 100 manufactured by Fosroc and applied strictly in accordance with the manufacturer’s technical data sheet.

Cebex 100 may be used in mixes containing certain other Fosroc admixtures. Consult Fosroc for further information.

Instructions for use Mixing For best results a mechanically powered grout mixer must be used. For quantities up to 50 kg a slow speed drill fitted with a Conbextra mixing paddle is suitable. Larger quantities will require a high shear vane mixer. It is essential that machine mixing capacity and labour availability is adequate to enable the grouting operation to be carried out continuously. This may require the use of a holding tank with provision for gentle agitation to maintain fluidity. The selected water content should be accurately measured into the mixer. Slowly add the cement (and sand if required) and Cebex 100. Mix continuously for 5 minutes, making sure that a smooth even consistency is obtained.

294


Fosroc® Cebex 100 Application

Storage

Areas to be grouted should be prepared to ensure substrates are clean, sound, and then pre-wetted. The unrestrained surface area of the grout must be kept to a minimum. Place the grout within 20 minutes of mixing to gain the full benefit of the expansion process. Adopt usual placing or pumping procedures ensuring a continuous operation.

Cebex 100 has a shelf life of 12 months if kept in a dry store in its original packaging. High temperature and humidity storage may reduce this period.


Curing On completion of the grouting operation, any exposed areas which are not to be cut back should be thoroughly cured by means of water application, Concure curing membrane or wet hessian.


Cleaning Grouts mixed with Cebex 100 should be removed from tools and equipment with clean water immediately after use. Remove cured material mechanically or with Fosroc Acid Etch.

Estimating Packaging Cebex 100 is supplied in packs containing 24 x 225g units. Dosage OPC

Concreting sand

50 kg 50 kg

-50 kg

Water 20 to 22 litres 22 to 24 litres

Cebex 100 225 g 225 g

Approx yield 36 litres 57 litres

Note: For grout, mortar or concrete mixes with an aggregate/cement ratio more than 1, use 4 x 225 g units of Cebex 100 per 100 kg of cement. Effects of overdosing Drastic overdosing of Cebex 100 increases expansion and may cause frothing.

Cebex is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


telephone: +44 0 (1827) 262222

fax: +44 0 (1827) 262444


www.fosroc.com

295


Fosroc® Cebex 250


Underwater grouting admixture

stored, handled and placed strictly in accordance with manufacturer’s instructions.

Uses Application instructions Cebex 250 is an anti-washout grouting admixture. Mixing

Advantages Prepare the water cement grout in the usual manner. Sprinkle the admixture slowly onto the surface of the grout and continue mixing for a further 1 - 2 minutes. The grout is now ready for use.

Minimises the risk of washout of cement from grouts during placing under water.

Description Cleaning Cebex 250 underwater grouting admixture is supplied as a ready to use, chloride-free white powder. When added to the grout, the Cebex 250 produces a gel in the water phase which surrounds the cement particles and protects them from washout. Cement hydration is not impaired by the use of this admixture. The addition of Cebex 250 may appear to thicken the grout, but this product forms a lubricating layer between the cement particles, thus improving the overall pumping ability of the grout.

50 kg/m3

Chloride content:

Nil to BS 5075

Supply

Compressive strength using a neat cement grout, at water/cement ratio of 0.4 and dosage rate of 0.2% of cement. Test method for

Typical result

Compressive strength (BS 1881):

13.5 26.5 36.5 47.0

Dosage The dosage rate may be varied depending on tthe application. The range of dosage is between 0.05 to 0.2% by weight of cement.

Properties Bulk density:

Spillages should be removed in the dry state. Because of its water resisting properties, Cebex 250 will be harder to wash off equipment than normal cementitious grout. Use of hot water greatly reduces the time required for cleaning. Do not use hot water for mixing the grout.

Cebex 250 is supplied in a 1 kg bag.

Storage Cebex 250 has a shelf life of 12 months if kept in dry store in its orginal packaging.

N/mm2 @ 1 day N/mm2 @ 3 days N/mm2 @ 7 days N/mm2 @ 28 days

Limitations Grout should not be applied below 3oC. Overdosing may lead to air entainment, result in a decrease in compressive strength.

Specification clauses Performance specification

Precautions All grouting (specify details and areas of application) must be carried out with ordinary Portland cement grout at a water/cement ratio of 0.4 and incorporating an antiwashout admixture. The admixture shall be added to the grout at a dose of 0.05 to 0.2% by weight of cement depending on the application. The admixture must be

Health and Safety For further information refer to appropriate Product Safety Data Sheet. Cebex is the trade mark of Fosroc International Limited



www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

296



Fosroc® Cebex 653


Thixotropic stabiliser for cement grouts

Properties

Uses

Rapid gel

Cebex 653 will not signficantly alter the initial hardness of a cement grout but the gelation, which occurs almost immediately after pumping has stopped, makes the grout appear to have reached its initial set instantaneously.

Stabilisation of cement grouts for pumping into cavities or fissures subject to water flow Tunnel annulus grouting in soft ground or rock Shaft grouting

Advantages Setting times

Enables cement grouts to be used in moving water conditions Reduced wash-out saves cement Early invert support gives increased productivity in tunnel ring lining Can be used in marine environments in contact with sea water Gives production flexibility derived from controlled grout thixotropy

Cebex 653 does not significantly affect the final setting times of cement based grouts. Compressive strength Grouts retain high compressive strengths even in moving water.

Desciption


A blend of water soluble, high molecular weight polymers, supplied as a white powder. Cebex 653 is designed for addition to cementitious grout mixes to enable them to be placed in moving water conditions without excessive wash-out of cement.

Dosage One 0.27 kg plastic bag of Cebex 653 is required per 300 kg of cement. Overdosing

Cebex 653 is a tunnel annulus grout admixture used to produce an instantaneous gelation and fast set behind tunnel linings.

Overdosing should be avoided to ensure the grout can be pumped.


Mixing


Mix grout until homogenous as usual then add Cebex 653 as a slow stream into the mixer. Mix for 30 seconds to disperse Cebex 653 through the grout.

All grouting must be carried out with an OPC grout at a water/cement ratio of 0.3 to 0.45 and incorporating a thixotropic admixture.

Application

The admixture will ensure that the mixed grout is sufficiently thixotropic to avoid leakage and loss of grout. The admixture shall be added to the grout at a dose of 0.27 kg per 300 kg of cement.

Mixes containing Cebex 653 may be produced in standard grout shear mixing equipment. The grout produced is highly thickened and only non-valved pumps are recommended for placement.

The admixture must be stored, handled and placed strictly in accordance with the manufacturer’s instructions.

As the grout will thicken within 2 to 5 minutes, discharge should take place before this time. Holding tanks will require a discharge port of at least 75 mm to facilitate the passage of thickened grout.

Estimating Pack size Cebex 653 is supplied in plastic bags containing 0.27 kg.

297


Fosroc® Cebex 653 Storage Cebex 653 has a shelf life of 12 months if kept in a dry store in its original packaging.

Precautions Health and Safety For further information refer to appropriate Product Safety Data Sheet.

Cebex is the trade mark of Fosroc International Limited Important note Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions for the Supply 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 control over where or how its products are applied, accept any liability either directly or indirectly arising from the use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.


www.fosroc.com

telephone: +44 (0) 1827 262222

fax: +44 (0) 1827 262444

298


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