EPOXY NOVOLAK POLYMER CONCRETE NO. 265 ... - Sauereisen

EPOXY NOVOLAK POLYMER CONCRETE NO. 265Sauereisen Epoxy NovolaK PolymerConcrete No. 265 is a castable for thechemical-resistant construction of sumps,dikes, containment areas, trenches,walls, floors, and structural supportcolumns or bases. No. 265 has beenspecifically formulated for foundation constructionand should be installed withproper reinforcement. Mixing and formingmethods are similar to those used forPortland cement installations.Epoxy NovolaK Polymer Concrete canalso be used as a monolithic topping torehabilitate chemically deteriorated concreteor to protect new construction. Thissystem incorporates SauereisenConoWeld No. 501 primer to promote astrong bond.CHARACTERISTICS Resistant to a wide range of solvents,oils, acids and acid salts (excepthydrofluoric) over a pH range of0.0 to 14.0 Maximum service temperature of250 o F (121.1 o C). Fast chemical set - less down time. Low porosity.AREA PREPARATIONTemperature of Working AreaMaintain a temperature of 60 o -85 o F onair, substrate, Aggregate, Liquid, andHardener components during mixing,application, and cure. The monolithiccomponents and substrate should bemaintained at 60 o F to 85 o F for 48 hoursprior to beginning work.PHYSICAL PROPERTIESApplication timeWorking time at 70 o F30 MinutesInitial set at 70 o F18 hoursDensity (ASTM C-580) 142.8 pcf (2.3 gm/cm 3 )Compressive strength (C-579) 7 days 16,125 psi (1,133 kg/cm 2 )Maximum service temperature 250 o F (121.1 o C)Modulus of elasticity (ASTM C-580) 1.78 x 10 6 psi (1.2 x 10 5 kg/cm 2)Flexural strength (ASTM C-580) 3,900 psi (274 kg/cm 2 )Shrinkage (ASTM C-531) 7 days 0.090%Tensile strength (ASTM C-307) 2,260 psi (159 kg/cm 2 )Physical properties were determined on specimens prepared under laboratory conditions usingapplicable ASTM procedures. Actual field conditions may vary and yield different results; therefore,data are subject to reasonable deviation.Shading the substrate and using icewater to cool mixing equipment is notuncommon. In extreme temperatures itmay be necessary to postpone the applicationor apply during cooler hours.ReinforcementWhen applying Epoxy NovolaK PolymerConcrete No. 265, appropriate corrosionresistant reinforcement must be incorporated.All monolithic applications must beaffixed to the substrate by rebar anchors.Consult Sauereisen for recommendations.Surface PreparationFoundation Construction - The foundationbase should be constructed withappropriate materials to support the engineeringdesign and loads. No. 265 mustnot be applied over standing water orloose soil.Refer to SSPC-SP13/NACE 6 "SurfacePreparation of Concrete" for detailedguidelines.Old Concrete - Concrete must be dry, firmand structurally sound as specified by thearchitect/engineer. Surfaces should bemade free of oil, grease, water, and othercontaminants that may inhibit bond.This can be achieved by chemical cleaning.All structural cracks must berepaired. Abrasive blast or high-pressurewater blast concrete to remove laitanceand obtain uniform sound substrate.Brick - Remove oil, grease, water, andother contaminants that may inhibit bond.Abrasive blast or hydroblast mortar jointsto a depth of 1/2 inch to remove all loosematerial and provide a clean, firm surface.If abrasive or high-pressure water blastingis used as the method of surface preparation,all sand and/or debris must beremoved by thoroughly vacuuming thearea with an industrial vacuum cleaner. Ifsurface does not have desired profile ordegree of cleanliness, repeat surfacepreparation procedure.At temperatures below 60 o F, the applicationbecomes more difficult and curing isretarded.Above 85 o F, the material working timedecreases. It is recommended that thematerial components be stored in a coolerarea prior to mixing.New Concrete - Surfaces should bemade free of oil, grease, water, and othercontaminants that may inhibit bond. Thiscan be achieved by chemical cleaning.Abrasive blast or high-pressure waterblast concrete to remove laitance andobtain uniform surface texture.EXPANSION/CONTROLJOINTSJoints are to be provided on 14 ft. centerlines,around all fixed objects, peripheriesof rooms and over all points of movementin the base slab. The joint should then befilled with the appropriate expansion jointfiller. Consult Sauereisen for recommendations.

APPLICATIONMixingPrimer No. 501: Refer to product datasheet for detailed mixing instructions.Epoxy NovolaK Polymer ConcreteNo. 265 is packaged in pre-measuredunits of Aggregate, Liquid, and Hardenercomponents. Mixing should be donemechanically with a slow-speed mortarmixer. The mixing equipment must beclean and free of Portland cement orother contaminants.Remix both Liquid and Hardener prior tocombining components. Empty contentsof the Liquid into a clean, dry mixing container.Empty contents of Hardener intoLiquid and mix thoroughly with a "Jiffy"mixer blade and drill motor until blendedfor at least one minute. Empty liquidsinto a clean, dry mortar mixer. Addaggregate component gradually whilemixing to a uniform consistency.Mix only complete batches. Materialwhich has begun to set must be discarded.Do not try to retemper the material.Do not add solvent, additive or adulterantto any component or mixed material.Remove the entire batch from the mixerwhen mixing is completed to preventbuild-up in the equipment. While pouringone batch, another should be mixed inorder to eliminate delays and to permitcontinuous operation.InstallationConoWeld No. 501Apply primer at a nominal thickness of 5-10 mils using a short nap roller with anon-degradable core or by nylon brush.Epoxy NovolaK Polymer Concrete No.265 can be placed immediately afterapplication of Primer. Polymer Concreteshould be applied while the primer istacky. If topcoat time exceeds six hours,consult Sauereisen.Polymer Concrete No. 265When casting No. 265, forms should beconstructed of firmly braced wood ormetal, which has been given a light coatingof release agent.The release agent will prevent No. 265from adhering to the screeds or forms,but should not leave a residue on thefreshly cast material.Forms are to be completely sealed andrendered watertight with heavy consistencypliable caulking. Seal forms placedover rough surfaces. Do not apply polymerconcrete over standing water.The form and screed systems should bestrong enough to retain No. 265 in placewithout deformation. Forms and screedsmay be removed after set has occurredand No. 265 has sufficient strength tosupport itself.Tamping methods or pencil vibration aresuitable for distributing the material. Usea trowel or screed board to level the polymerconcrete flush with the top of theform. Trowel finish within 15 minutesafter mixing. Avoid imposing loads until afinal set has been achieved.COVERAGEConoWeld No. 5011 gallon unit 200 ft 2 @ 8 mils thick3 gallon unit 600 ft 2 @ 8 mils thickEpoxy NovolaK Polymer ConcreteNo. 265Regular unit yields 1.2 ft 3Large unit yields 1.98 ft 3No. 265 must be cast at a minimum 1-1/2inches thick. A 1-1/2 inch thickness ofNo. 265 will require approximately 18pounds of material per square foot.**Quantity estimations do not include lossesduring application or normal density variations.SETTING/CURINGThe No. 265 will take an initial set in 18hours at 70 o F. Proper curing of No. 265is critical to the serviceability of the completedstructure; therefore, the substrateand the material temperatures should notbe allowed to fall below 60 o F until final.cure has been achieved. Do not allowwater or chemicals on the material surfacefor a minimum of 48 hours. For temperaturesbelow 70 o F, cure a minimum of72 hours prior to water or chemical exposure.PACKAGINGNo. 265 Regular unit:Hardener: 3.5 lbs. in a canLiquid:Aggregate:15.2 lbs. in plastic pail150 lbs. (3-50 lb. bags)Unit weight is approximately 168.7 lbs.No. 265 Large unit:Hardener: 5.9 lbs. in a canLiquid:Aggregate:25.3 lbs. in plastic pail250 lbs. (5-50 lb. bags)Unit weight is approximately 281.2 lbs.CLEAN-UPAll equipment should be cleaned byscrubbing with a stiff brush and acetone,N-methyl pyrol or MEK at the end of eachworking period or when build-up becomespronounced. A mixture of sand and solventaids in cleanup. Consult Sauereisenfor recommendation.SHELF LIFEConoWeld and Epoxy NovolaK PolymerConcrete have a shelf life of one yearwhen stored in unopened, tightly sealedcontainers in a dry location at 70 o F. Ifthere is a doubt as to the quality of thematerials, consult a Sauereisen representative.CAUTIONConsult Material Safety Data Sheets andcontainer label Caution Statements forhazards in handling these materials.

WARRANTYWe warrant that our goods will conformto the description contained in the order,and that we have good title to all goodssold. WE GIVE NO WARRANTY,WHETHER OF MERCHANTABILITY,FITNESS FOR PURPOSE OR OTHER-WISE, EXPRESS OR IMPLIED, OTHERTHAN AS EXPRESSLY SET FORTHHEREIN. We are glad to offer suggestionsor to refer you to customers usingSauereisen cements and compounds fora similar application. Users shall determinethe suitability of the product forintended application before using, andusers assume all risk and liability whatsoeverin connection therewith regardlessof any suggestions as to application orconstruction. In no event shall we beliable hereunder or otherwise for incidentalor consequential damages. Our liabilityand your exclusive remedy hereunderor otherwise, in law or in equity, shall beexpressly limited to our replacement ofnonconforming goods at our factory or, atour sole option, to repayment of the purchaseprice of nonconforming goods. Distributors and agents in majorcities throughout the world. Consultmanufacturer for locations. Information concerning governmentsafety regulations availableupon request. Sauereisen also produces inorganiccompounds for assembling,sealing, electrically insulating andgrouting....since 1899160 Gamma DrivePittsburgh, PA 15238-2989 USAPhone 412/963-0303 Fax 412/963-7620www.sauereisen.comMay 2012 1996 © Sauereisen Printed in U.S.A.