All the relevant product data sheets are to be read for additional information like pot life, mixing instructions, surface preparation, ventilation, temperature application limitations, etc.
Surface Preparation
All surfaces shall be sound, clean and free from dust, plaster, oil, paint, grease, corrosion deposits, laitance, organic growth and any other deleterious substance.
Surfaces shall be cleaned by mechanical means, steam, pressure washing with clean water, grit blasting, or a combination to satisfy. Any remaining dust or loose material should be removed by blowing with oil-free clean compressed air.
Reinforcement Priming
Immediately following preparation and cleaning, the reinforcing steel shall be primed with dura.®rep ZR primer single component epoxy primer complying with the relevant parts of BS4652, 1971 (1979) Specification For Metallic Zinc Rich Priming Paint Type 2.
The dura.®rep ZR primer shall be brush applied to the cleaned reinforcement ensuring that all exposed steel is fully coated. Special attention shall be paid to the backs of the steel bars and where steel bars are tied together. It is essential that this coat is continuous with that of any adjacent repaired area where zinc-rich primer has been used. Avoid excessive over-painting onto the concrete and allow to dry.
Concrete Priming
The prepared substrate shall be thoroughly wetted with clean water to totally satisfy absorption and any standing or excess water shall be removed.
Repairs to concrete subject to permanent immersion shall be primed with epidermix 344 which shall be worked firmly into the damp substrate with a short-bristle brush to achieve a film intimate with the contact area for immediate repair.
If the primer dries before the mortar is applied, the area shall be cleaned and re-primed.
Void Filling
dura.®rep FR structural repair mortar is to be applied directly into the still tacky epidermix 344 wet to dry epoxy primer. The dura.®rep FR may be applied in multiple layers of 70 mm in depth, the subsequent layers are to follow on to the existing dura.®rep FR where the top surface has been scoured to receive the following layer as soon as the bottom layer will not be disturbed by the next application. Finish off to profile required and allow to cure for 3 days.
Never feather-edge the dura.®rep FR, always provide a neat saw-cut joint not less than 10 mm deep perpendicular to the surface where the product is terminated.
Curing
Curing techniques shall be instigated immediately following application of repair mortar to any given area. Large areas (0.5 m2 at a time) shall be cured as trowelling progresses without waiting for completion of the whole area. During application and curing all work shall be protected against direct strong sunlight.
CHRYSO®Cure R or dura.®bond GP may be low pressure spray applied as a curing membrane. In fast drying conditions it will be necessary to supplement this with polyethylene sheet taped around its edges.
Chemical Resistant Protection Layer
After the 3 day cure period of the dura.®rep FR remove the curing compound and laitance from the surface by light grinding or rubbing stones and clean thoroughly.
Apply a single coat of epidermix 116 epoxy at a rate of 2.5 m2/litre and scatter abe® silica sand No. 1 coarse into the still wet epidermix 116 at a rate of 500 grams/m2 and allow it to cure overnight then sweep off the excess sand to reveal a clean dust free surface. To this apply abe.®cote SF 356 epoxy coal tar screed at 5 mm thick and allow to cure overnight. The following day apply two coats of abe.®cote SF 356 at a rate of 5m2/litre/coat to the floor and the wall areas, the wall area must include a chemical resistant tissue “fibasil-genmat” to assist in film build etc. Allow the abe.®cote SF 356 to cure for a minimum of 3 days before commissioning.
Cleaning
epidermix products should be removed from tools, equipment and mixers with abe® super brush cleaner immediately after use. Hardened material can only be removed mechanically.
Products Required
- abe® super brush cleaner
- abe.®cote SF 356
- CHRYSO®Cure R
- dura.®bond GP
- dura.®rep FR
- dura.®rep ZR primer
- epidermix 116
- epidermix 344
- fibasil-genmat
- silica sand No.1 Coarse
Equipment Needed
- 100 mm paint brush
- Flat steel paddle 25 mm wide x 5 mm thick
- Pan mixer
- Suitable 10 litre plastic container
Important Note
This data sheet is issued as a guide to the use of the product(s) concerned. Whilst a.b.e.® Construction Chemicals endeavors to ensure that any advice, recommendation, specification or information is accurate and correct, the company cannot – because a.b.e.® has no direct or continuous control over where and how a.b.e.® products are applied – accept any liability either directly or indirectly arising from the use of a.b.e.® products, whether or not in accordance with any advice, specification, recommendation, or information given by the company.
Further Information
Where other products are to be used in conjunction with this material, the relevant technical data sheets should be consulted to determine total requirements. a.b.e.® Construction Chemicals has a wealth of technical and practical experience built up over years in the company’s pursuit of excellence in building and construction technology.