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SF 5008 Epoxy-Modified Cement Concrete WD-510 3072

Description

Epoxy-Modified Portland Cement Concrete
EPI-REZ™ Resin WD-510 / EPIKURE™ Curing Agent 3072

Introduction

This formulation illustrates the modification of a Portland Cement concrete with an epoxy resin system which is easily dispersed into water at the job site prior to admixing with the concrete. Incorporation of this epoxy resin system provides several advantages over conventional Portland Cement concretes.

 

Features

  • Workable at lower water/cement ratios
  • Retains hydrating water in thin sections exposed to air during cure, eliminating the need for plastic film covers and special membrane coatings
  • Strengthens concretes cured under both ideal and adverse conditions
  • Bonds overlays, patches and extensions firmly to substrates, monolithic structure
  • Retards rate of acid attack in flooring, sewers, and treatment tanks located in acidic environments
  • Improves wear resistance of flooring subjected to steel wheel cart or skid tub traffic

 

Formula

Material

Supplier

Pounds

Gallons

 

PartA

 

 

 

 

Portland Cement, Type 1

 

100.0

3.61

 

Silica Aggregate, 4 to 8 mesh

Whitaker, Clark & Daniels, Inc.

Portage #48 Silica

120.0

5.44

 

Silica Sand, 10 to 30 mesh

Whitaker, Clark & Daniels, Inc.

#830 Sand Blast Sand

120.0

5.44

 

Silica Sand, 30 to 100 mesh

Whitaker, Clark & Daniels, Inc.

Portage #5 Sand

160.0

7.25

 

Pigment

Akrochem. Corp.

R-2899 Light Red Oxide

5.0

0.13

 

Water

Standard Ultramarine Co.

23.0

2.76

 

EPI-REZ WD-510 Resin

Hexion

10.2

1.06

 

Part B Blend 1

 

4.8

0.59

 

Water

 

15.0

1.80

 

 

Total

558.0

28.08

                                                  1 70:30 percent by weight of EPIKURE Curing Agent 3072 and nonylphenol.

 

Mixing Instructions

The converter blend is prepared at room temperature by mixing a 70:30, percent by weight, solution of EPIKURE Curing Agent 3072 and Nonylphenol (Rohm & Haas Co.). Store the blend in sealed metal or polyolefin plastic containers until ready for use. Mix the EPI-REZ Resin WD-510 with the converter blend. Add the designated amount of water and stir until a uniform emulsion is obtained. Mechanical agitation is preferred for thorough mixing. Add the freshly prepared emulsion to the other materials in the cement mixer and mix to a uniform, workable consistency. Aggregate mixtures of smaller particle size should be used in the formulation of mortars, stuccos and exposed aggregate matrices.

 

Application Instructions

Old concrete substrates should be cleaned by either sandblasting or scarification (Tennant grinding machines) to remove surface contaminants such as oils, fats, greases, waxes, curing compounds, and paints. The laitance on new concrete can be removed with an acid etch followed by a thorough water flushing and scrubbing step. Steel can be cleaned by sandblasting just prior to placement of the new concrete. While the substrates need not be dry, standing water should be removed before proceeding with the next step.

 

Prepare a 70% solids dispersion of the preblended epoxy/converter system in water and apply as a bond coat to seal the substrate and insure maximum interfacial adhesion. Application may be accomplished by brush, spray, roller, or squeegee at a coverage rate of 200 to 400 square feet per gallon.

 

Mix the modified concrete in a paddle type mortar mixer, KOL Mixal or other equipment used for Portland Cement concretes and place in the form. To develop maximum adhesion, placethe freshly mixed concrete before the bond coat gels. Depending on temperature, the bond coat will remain “open” for approximately 2 to 8 hours.

 

The epoxy modified concrete screeds and trowels more like conventional Portland Cement concrete than concretes modified with polyvinyl acetate, acrylic and styrene-butadiene emulsions. Working life of the epoxy modified concrete is shorter than that of the unmodified concrete. The epoxy modification results in more rapid development of strength properties, particularly for sections less than 2 inches thick where one surface is exposed to normal atmospheric conditions during cure. Under these conditions, flooring may be opened to rubber-tired traffic in 1 to 2 days; and ground, in the case of thin-set terrazos, after 3 to 4 days. Practical cure rates may be achieved at ambient temperatures as low as 7 °C.

 

Typical Formulation Properties

Table 1 / Formulation Properties

 

 

Units

Value

 

Combining Ratio, Epoxy System: Portland Cement by weight

 

 

 

Emulsion: Portland Cement

 

30 : 100

 

Emulsion Solids: Portland Cement

 

15 : 100

 

Pot Life of Water-thinned Epoxy System

 

 

 

at 70% Solids

min.

30

 

at 50% Solids

min.

50

 

Expected Pot Life of Concrete at 25 °C

hrs

1

 

Density

lbs/gal

19.9

                                                  1 All tests were conducted on 1/2-inch thick overlays applied to aged concrete substrate and cured at 25 °C and 40% R.H.

                                                    Except where noted, a 2-week cure period was given prior to testing.

                                                  2 Same formulation as 1101-84 except that no epoxy modification was used and the water to Portland Cement ratio was

                                                     increased to 45:100 by weight for purposes of equalizing slump. Surfaces of both overlays were exposed to room air at

                                                     25 °C and 50% R.H. during the cure period.

                                                  3 After 2 weeks partial water immersion.

 

Typical Cured State Properties

Table 2 / Cured State Properties 1

 

 

Units

Formulation 5008

Unmodified Control 2

 

Tensile Strength, Core and Pull Method

 

 

 

 

4 days

psi

280

90

 

12 days

psi

330

100

 

30 days

psi

340

100

 

Tensile Bond Strength

 

 

 

 

Tested Dry

psi

>300

>50

 

Tested Wet 3

psi

>300

>50

 

Chemical Resistance

 

 

 

 

10% HCl

 

Slowly attacked over a period of hours

Immediate attack

                                                  1 All tests were conducted on 1/2-inch thick overlays applied to aged concrete substrate and cured at 25 °C and 40% R.H.

                                                    Except where noted, a 2-week cure period was given prior to testing.

                                                  2 Same formulation as 1101-84 except that no epoxy modification was used and the water to Portland Cement ratio was

                                                     increased to 45:100 by weight for purposes of equalizing slump. Surfaces of both overlays were exposed to room air at

                                                     25 °C and 50% R.H. during the cure period.

                                                  3 After 2 weeks partial water immersion.

 

Storage

Recommendations regarding storage conditions can be obtained by visiting our web site at www.hexion.com

 

 

General Information

These are starting formulations and are not proven in the user’s particular application but are simply meant to demonstrate the efficacy of the products and to assist in the development of the user’s own formulation.  It is the user’s responsibility to fully-test and qualify the formulation, along with the ingredients, methods, applications or equipment identified herein (“Information”), by the user’s knowledgeable formulator or scientist, and to determine the appropriate use conditions and legal restrictions, prior to use of any Information.

 

Safety, Storage & Handling

Please refer to the MSDS for the most current Safety and Handling information.

 

Exposure to these materials should be minimized and avoided, if feasible, through the observance of proper precautions, use of appropriate engineering controls and proper personal protective clothing and equipment, and adherence to proper handling procedures. None of these materials should be used, stored, or transported until the handling precautions and recommendations as stated in the Material Safety Data Sheet (MSDS) for these and all other products being used are understood by all persons who will work with them. Questions and requests for information on Hexion Inc. ("Hexion") products should be directed to your Hexion sales representative, or the nearest Hexion sales office. Information and MSDSs on non-Hexion products should be obtained from the respective manufacturer.

 

 

Contact Information

For product prices, availability, or order placement, please contact customer service:

www.hexion.com/Contacts/

 

For literature and technical assistance, visit our website at: www.hexion.com

 

 
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