Fosroc Catalogue

constructive solutions
Technical data sheet catalogue

10th edition
Alphabetical index C Cebex 100

294 296 297 147 174 274 287 277 280 283 285 162
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
G H
Galvafroid
145
Hilastic LM Hydrocell XL Hydromax Integra Lokfix (P25 & S25) Mulseal DP 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
185 215 338 237 290 239 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
I L M N
Dekguard Clear Dekguard E2000 Dekguard Elastic Dekguard S Dekguard Textured Dekguard W Demokret Eco D1 Expandafoam Expoband H45 Expocrete UA Expoflex 800 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
117 120 123 126 129 132 359 211 264 86 183 234 203 207 164 213 107 109 111 113 115
Alphabetical index
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
Secofoam Silicone Sealant 33HM Supercast Butyl-Nek Supercast PVC Supercast SW Supercast Synkoflex Supercast Twinstop Thioflex 600
217 197 220 222 226 228 232 200
Product group index Concrete Repair & Remediation 1

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 Crack injection resins Nitofil LV/TH Nitokit LV/TH Road rehabilitation Fosroc XR 45 Fosroc XR 90 Fosroc XR Cobbleset Fosroc XR PE20 Fosroc XR RSC 15 16 18 22 24 28 32 36 40 44 48 52 56 60 64 68 70 74 78 82
Finishes 5
Anti-carbonation & chloride resistant coatings Dekguard Clear Dekguard E2000 Dekguard Elastic Dekguard S Dekguard Textured Dekguard W Nitoprime DG (see Dekguard) Chemical resistant coatings Nitocote EP403 Nitocote EP405 Nitocote EP410 Water resistant coatings Nitocote SN502 Nitocote SN511 Polyurea WPE Metal protective coating Galvafroid Flooring materials Cemtop (S, GP30, GP12, XD) Nitoflor FC130/FC140 Nitoflor Hardtop S Nitoflor Lithurin Polyurea FLM Surface treatments Concure WB Fosroc Acid Etch
117 120 123 126 129 132
135 137 139
141 143 245
8 9
145
86 88 91 94 98
147 151 154 157 159
102 105
10
162 164
107 109 111 113 115
Product group index Barriers

Joint Sealants Waterproofing
166 169 172
11
Water industry sealants Nitoseal 12 Nitoseal MS600 Plastijoint Road & pavement sealants Colpor 200PF Nitoseal 333 Nitoseal 878 Pliastic (N2 & 77) Building sealants Expoflex 800 Hilastic LM Nitoseal MS50 Nitoseal MS100 Nitoseal MS300 Nitoseal MS600 Plastiseal Silicone Sealant 33HM Thioflex 600 Fire protection sealants Flamex Fire Protection(Flamex One & Two) Flamex S Joint fillers Expandafoam Fosroc Fibreboard Hydrocell XL Secofoam
16
Waterstops Supercast Butyl-Nek Supercast PVC Supercast SW Supercast Synkoflex Supercast Twinstop 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 Joint overbanding system Expoband H45
220 222 226 228 232
12
174 176 178 180
17
13
183 185 187 189 192 169 194 197 200
234 237 239 241 245 248 250 252 254 257 259 262
18
203 207
264
14
Gas membranes
15
211 213 215 217
19
Gas membranes Proofex 3000MR Proofex Engage Proofex Radon Barrier Proofex Total
268 252 270 272
Cement & Concrete Technology

Grouts & Anchors
20
Cementitious grouts Conbextra BB Conbextra GP Conbextra HF Conbextra TS Conbextra UW Epoxy resin grouts Conbextra EP (EP10 & EPR) Lokfix (Lokfix P25 & S25) Grout admixtures Cebex 100 Cebex 250 Cebex 653
274 277 280 283 285
21 22
287 290
294 296 297
10
11
12
13
14
Fosroc Nitobond AR Nitobond HAR

Polymer emulsion bonding agents Uses
Nitobond AR and Nitobond HAR are recommended primers for the Renderoc cementitious repair systems. 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.
CI/SfB: June 2008
spray, brush or medium pile roller. Care should be taken to ensure complete and thorough wetting of the surface. Cleaning Wash all equipment with clean water immediately after use.
Estimating
Supply Nitobond AR 1 litre and 5 litre bottles, 25 litre drums 1 litre and 5 litrebottles, 25 litre drums
Advantages
Single component Easy to use High bond strength No site mixing Ready to use straight from the container Excellent bond strength between Renderoc systems and concrete Economical in use Can be used as curing membrane for Renderoc systems Nitobond HAR Coverage and yield As Primer Nitobond AR & Nitobond HAR As Curing Membrane Nitobond AR As Surface Sealer Nitobond AR
4-6m /litre
Cost effective Curing aid
6-8m /litre
Description
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.
6-10m /litre
Limitations
Do not use Nitobond AR or Nitobond HAR when the temperature is below 50C and falling.
Application instructions
Preparation All surfaces should be clean and free from dust and contamination.
Storage
Store in dry conditions at 5o-25oC. Shelf life is 12 months if stored in dry conditions. Protect from frost.
Precautions
Health and safety
Application 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
For further information refer to appropriate Product Safety Data Sheet.
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 email: uk@fosroc.com
Certificate number FM 610
15
1
CI/SfB: Yt3 June 2008
Fosroc Nitobond EP
Epoxy-resin concrete bonding agent Uses
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 Ideal for extensions and repairs to concrete in factories, loading bays, trucking aisles, bridges, roads, bonded or granolithic floor toppings, etc
Preparation All surfaces to be treated should be mechanically prepared (scabble or grit-blast) to expose aggregate and all debris and dust removed. 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. 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. Reinforcing steel priming 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. Mixing 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. To facilitate application at temperatures below 10C the separate components should be warmed in hot water to a maximum of 25C 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.
Advantages
Can be applied to dry or damp surfaces High mechanical strength Good positive adhesion Can be applied where a substrate/repair barrier is required Standard and slow set grades
Description
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. Coloured components, white base and green hardener, provide visual evidence that adequate mixing is achieved.
Properties
Standard Pot life @ 20C: Initial hardness: Full cure: Maximum overlay time @ 20C: Minimum application temperature: 35 to 45 minutes 24 hours 7 days 90 minutes 5C Slow set 5 to 6 hours 48 hours 7 days 24 hours 5C
Application
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 1 hours at 20C, or within 1 hour at 30C and Nitobond EP slow set within 24 hours at 20C, or within 8 hours at 30C. 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.
The following results were obtained at a temperature of 20C for Nitobond EP standard: Compressive strength (BS 6319, Pt. 2): 50 N/mm @ 7 days Flexural strength (BS 6319, Pt. 3): Tensile strength (BS 6319, Pt. 7): Slant shear bond (BS 6319, Pt. 4): Adhesive strength to concrete: 35 N/mm @ 7 days 20 N/mm @ 7 days 25 N/mm @ 7 days In general, the bond will always exceed the tensile strength of the concrete
16
1
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. 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. Cleaning Tools and equipment should be cleaned with Fosroc Solvent 102 immediately after use.
Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet.
Fire
Nitobond EP is non-flammable.
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 5C, or is 5C 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: Nitobond EP slow set: Fosroc Solvent 102: Pack weight 2.5 kg 4.5 kg 4.5 kg Coverage 5.5 m 10 m 10 m
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 5-25C.
Nitobond is the trademark of Fosroc International Limited

Important note
Fosroc Limited
Drayton Manor Business Park Coleshill Road, Tamworth, Staffordshire B78 3TL. UK telephone: +44 0 (1827) 262222 fax: +44 0 (1827) 262444 email: uk@fosroc.com
www.fosroc.com
17
Fosroc Nitobond SBR

Polymer bonding aid and mortar additive Uses
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. Test method Compressive strength (BS 6319, Pt 2: 1983): Tensile strength (ASTM C-190-85): Flexural strength (BS 6319, Pt 3: 1983): Slant shear bond (BS 6319, Pt 4: 1984): Chemical resistance:
CI/SfB: (4-) Vt3 August 2007
Typical result 62 N/mm2 3.3 N/mm2 9 N/mm2 53 N/mm2
Control 46 N/mm2 2.7 N/mm2 7.9 N/mm2 11 N/mm2
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.
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. 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. 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. 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.
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.
Properties
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
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. 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. 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. 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. 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 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. 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.
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. A wide range of mix designs is achievable using Nitobond SBR. Typical designs are detailed below: 1. Patching and repair mortar: 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. 2. Heavy-duty floor screed: 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.
Application
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. 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
Fosroc Nitobond SBR

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.
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.
Cleaning
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. 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.
Finishing
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.
Low temperature working

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.
Estimating
Supply Nitobond SBR: Nitoprime Zincrich Plus: Nitobond EP: Nitobond AR: Concure WB: Fosroc Solvent 102: Coverage and yield Nitobond SBR: Refer to mix designs Approximately 2 to 3 m2/litre 8 m2/litre 10 to 11.5 m2/pack 6 to 8 m2/litre 3.5 to 5 m2/litre Nitobond SBR (as slurry primer): Nitoprime Zincrich Plus: Nitobond EP: Nitobond AR: Concure WB: 5, 25 and 210 litre drums 1.9 litre and 800ml cans 4.5 kg packs 5 litre drums 20 litre drums 5 litre cans
High temperature working

At ambient temperatures above 35 C, the material should be stored in the shade and cool water used for mixing.
o
Curing
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.
Overcoating with protective decorative finishes

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
Limitations
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
20
Fosroc Nitobond SBR

may result in surface scour. If any doubts arise concerning temperature or substrate conditions, consult the local Fosroc office.
Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Nitobond SBR, Nitobond AR, Concure WB and Nitobond EP are non-flammable. 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. Flash points Nitoprime Zincrich Plus: Fosroc Solvent 102: 41 oC 33 oC
Storage
Shelf Life Store in unopened packaging in cool dry internal conditions. Nitobond SBR and Nitobond AR should be protected from frost. 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 must be stored in accordance with the Highly Flammable Liquids and Liquefied Petroleum Gases Regulations 1972.
For further information, refer to the Product Safety Data Sheet.
Nitobond is the trade mark of Fosroc International Limited

Important note
Fosroc Limited
Drayton Manor Business Park, Coleshill Road, Tamworth, Staffordshire B78 3TL. UK telephone: +44 0 (1827) 262222 fax: +44 0 (1827) 262444 email: uk@fosroc.com
www.fosroc.com
21
Fosroc Nitoprime Zincrich Plus

Single component epoxy zinc primer 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.
CI/SfB: October 2006
Properties
Test method Specific gravity: Recommended thickness per coat: Application thickness per coat: Drying times Touch dry: Fully dry/recoatable: Typical result 2.0 40 microns (dry) 100 microns (wet) @ 20C 90 minutes 3 hours
Advantages
Active zinc-rich system combats corrosion by electrochemical means Formulated for use with Renderoc repair products Single component product easy to use with no restrictive pot-life Economical single component ensures almost no waste
Note: at temperatures below 20C, the drying times will be slower.
Preparation 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. 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.
Description
Nitoprime Zincrich Plus is supplied as a single component grey-coloured liquid based on metallic zinc and epoxy resins.
Standards compliance
The product has also been approved by the British Board of Agrment, Certificate No. 98/3461 as part of the Renderoc System of Concrete Repair.
Application
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. 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 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.
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. 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 20C. It shall be fully compatible with the Renderoc system of concrete repair.
22
Fosroc Nitoprime Zincrich Plus

The application of concrete repair materials should proceed as soon as the Nitoprime Zincrich Plus is touch dry (generally 90 minutes see under Properties). Low temperature working The minimum application temperature is 5C. The material should not be applied when the substrate and/or air temperature is 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed. Cleaning Nitoprime Zincrich Plus should be removed from tools, equipment and mixers with Fosroc Solvent 102 immediately after use.
Storage
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. 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 the appropriate Product Safety Data Sheet Fire
Estimating
Supply Nitoprime Zincrich Plus: Fosroc Solvent 102 : Coverage Nitoprime Zincrich Plus: 8 m2 / litre 1.9 litre and 800ml cans 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: Fosroc Solvent 102: 41C 33C
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.
For further information, refer to the Product Material Safety Data Sheet.
Additional information Limitations

Nitoprime Zincrich Plus should not be applied when the temperature is below 5C or is 5C and falling. If any doubts arise concerning temperature or application conditions, consult the local Fosroc office. Nitoprime Zincrich Plus is the approved reinforcing steel primer for use with the Renderoc, Patchroc and Paveroc systems of concrete repair.
Nitomortar is the trade mark of Fosroc International Limited

Important note
Fosroc Limited
www.fosroc.com
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 Uses
For emergency and permanent reinstatement of localised patches in concrete pavements, airport aprons, access ramps and floors. Particuly useful when interuption of traffic must be minimised The product is alkaline in nature and will protect embedded steel reinforcement. It may be used internally and externally. For the reinstatement of large areas of concrete pavements and floors, the use of Paveroc is recommended. Patchroc GP is suitable for repair methods 3.2, 4.4, 7.1 and 7.2, as defined by BS EN 1504-3.
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 The cured mortar shall achieve a compressive strength of 65 MPa at 28 days and a drying shrinkage of <300 microstrain at 7 days.
Patchroc GP complies with the classification R4 according to EN 1504-3, repair methods 3.3, 4.4, 7.1 and 7.2
Advantages
Rapid strength gain will generally accept traffic in 2 hours. High strength, abrasion and weather resistance 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 Contains no chloride admixtures
Fosroc Ltd, Drayton Manor Business Park, Coleshill Road, Tamw orth, STAFFS, B78 3TL 09 0370-CPD-0845 EN 1504-3 Concrete repair products for structural repair mortar CC (based on hydraulic cement) Compressive strength Chloride ion content Adhesive bond strength Adhesive bond strength after freeze thaw thermal cycling Carbonation resistance Capillary absorption Elastic modulus in compression Skid resistance Reaction to fire Dangerous substances Class R4 ( 45 MPa) 0.05% 2.0 MPa 2.0 MPa dk control concrete 0.5kg/m-2.h-0.5 20 GPa Class III Class A1 Complies with 5.4
Description
Patchroc GP 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 long-term durability. Patchroc GP 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 4m. Consult the local Fosroc office for further information.
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1
Fosroc Patchroc GP
Properties
The following results were obtained at a water : powder ratio of 0.11 and a temperature of 20C unless otherwise stated.
Test method S tandard E N 1504 R4 Requirement Result @ 2 hours 20 MPa @ 1 D ays 50 MPa @ 7 D ays 55 MPa @ 28 D ays 65 MPa 2.2 MPa 0.02% 2.0 MPa C onforms 29 GPa @ 28 days C lass III C lass A1 Non-C ombusti ble Ini ti al set: 40 mi ns Fi nal set: 60 mi ns
C ompressive Strength
EN 12190:1999
45 MPa
B ond strength by pull off: C hloride ion content: Freez e thaw cycling: R esistance to carbonation dk Elastic Modulus in C ompression Skid R esistance Fire rating Setting time Working life: Traffic time Pedestrian: Vehicular:
EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 EN 13295:2005 E N 13412 EN 13036-4 EN 13501-1 BS 4551 Pt14:1980 -
2.0 MPa 0.05 % 2.0 MPa ref concrete 20 GPa C lass III >55 wet
@ 10C 40 mi n @ 10C 3 hours 3 hours
@ 20C 20 mi n @ 20C 2 hours 2 hours
C hemical resistance
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.
B uild C haracteristics (hand applied) Minimum thickness: Maximum thickness Max bay area
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. 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. 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. Where corrosion has occurred due to the presence of chlorides, the steel should be high-pressure washed with
25
1
Fosroc Patchroc GP
clean water immediately after abrasive-blasting to remove corrosion products from pits and imperfections within its surface. 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. Concrete Priming Pedestrian traffic 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. 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. 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. 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. 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 1 hours at 20C, or within 1 hour at 30C and Nitobond EP slow set within 24 hours at 20C, or within 8 hours at 30C. See separate product data sheet for further details. 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. For normal applications, place 2.4 to 2.8 litres of drinking quality water into the mixer. 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. 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. Mixing warning 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. Application 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. 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. 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. Reprime with Renderoc Primer or Nitobond EP and apply further Patchroc GP as described above. Low temperature working In cold conditions down to 5C, the use of warm mixing water (up to 30C) 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 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed. High temperature working At ambient temperatures above 35C, the material should be stored in the shade and cool water used for mixing.
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Fosroc Patchroc GP
Curing 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 Large areas should be cured as trowelling progresses (0.5 m2 at a time) without waiting for completion of the entire area. 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. 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. 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. 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. Coverage and yield Patchroc GP: Approximately 12 litres / 25 kg bag (approximately 12 m at 12 mm thickness) 8 m2/litre Approximately 2 m2 / kg Approximately 13 litres- 2m2/ litre 5 m2/ litre
Nitoprime Zincrich Plus: Nitobond EP Renderoc Primer Concure WB
Notes: the actual yield per bag of Patchroc GP will depend on the consistency used.
Limitations
Patchroc GP should not be used when the temperature is below 5C and falling. Do not mix part bags. 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.
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.
Precautions
Health and safety For further information refer to the appropriate Safety Data Sheets available at www.fosroc.com. Fire Patchroc GP, Nitobond EP and Renderoc Primer are nonflammable.
Estimating
Supply Patchroc GP: Nitoprime Zincrich Plus: Nitobond EP Renderoc Primer Concure WB Fosroc Solvent 102: 25 kg bags 1.9 litre and 800 ml cans 2.5 and 4.5 Kg packs 20 Kg Part A + 5 litres part B 20 and 200 litre drums 5 and 25 litre tins
Important note
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: Fosroc Solvent 102: 41C 33C
Fosroc Limited
Drayton Manor Business Park Coleshill Road, Tamworth, Staffordshire B78 3TL. UK telephone: +44 (0) 1827 262222 fax: +44 (0) 1827 262444 email: enquiryuk@fosroc.com
www.fosroc.com
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 Uses
For the reinstatement of large areas of concrete pavements and floors to avoid the total replacement of bays 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. Paveroc is suitable for repair methods 3.1, 3.3, 4.4, 7.1, 7.2 as defined by BS EN 1504-3.
The repair mortar shall be Paveroc a one component cementitious mortar conforming to the requirements of BS EN 1504-3 Class R4 The cured mortar shall achieve a compressive strength of 65 MPa at 28 days and a drying shrinkage of < 300 microstrain at 7 days.
Paveroc complies with the classification R4 according to EN 1504-3, repair methods 3.1, 4.4, 7.1 and 7.2.
Advantages
Rapid strength gain will generally accept pedestrian traffic at 12 hours, significantly reducing down-time High strength, abrasion and weather resistance 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 Contains no chloride admixtures
Fosroc Ltd, Drayton Manor Business Park, Coleshill Road, Tamw orth, STAFFS, B78 3TL 09 0370-CPD-0845 EN 1504-3 Concrete repair products for structural repair mortar CC (based on hydraulic cement) Compressive strength Chloride ion content Class R4 ( 45 MPa) 0.05% 2.0 MPa 2.0 MPa dk control concrete Class III 20 GPa Class A1 Complies with 5.4
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. 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 m. Consult the local Fosroc office for further information.
Adhesive bond strength Adhesive bond strength after freeze thaw thermal cycling Carbonation resistance Skid resistance Elastic modulus in compression Reaction to fire Dangerous substances
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Fosroc Paveroc
Properties
Test method
Standard
EN 1504 R4 Requirement 45
Result
EN 12190:1999 Compressive Strength Bond strength by pull off: Chloride ion content: Freez e thaw cycling: Resistance to carbonation dk Elastic Modulus in Compression Skid Resistance Fire rating Setting time Working life: Traffic time Pedestrian: Vehicular: EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 EN 13295:2005 E N 13412 EN 13036-4 EN 13501-1 BS 4551 Pt14:1980 -
@ 1 Day 20 MPa @ 7 Days 45 MPa @ 28 Days 65 MPa 2.2 MPa 0.01% 2.0 MPa Conforms 46 GPa @ 28 days Class III Class A1 Non-Combustible
2.0 MPa 0.05 % 2.0 MPa ref concrete 20 GPa Class III >55
Initial set: 3.5 hours Final set: 5.0 hours
@ 1 0 oC 60 min @ 10C 18 hours 36 hours
@ 2 0 oC 55 min @ 20C 12 hours 24 hours
@30oC 30min @ 30C 8 hours 16 hours
Chemical resistance
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.
Build Characteristics (hand applied) Minimum thickness: Maximum thickness Max bay area
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 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, 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.
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Fosroc Paveroc
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. 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. 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. 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. 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 1 hours at 20C, or within 1 hour at 30C and Nitobond EP slow set within 24 hours at 20C, or within 8 hours at 30C. See separate product data sheet for further details. 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. For normal applications, place 1.9 to 2.2 litres of drinking quality water into the mixer. 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. 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 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. Application 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. 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. 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. Reprime with Nitobond EP and apply further Paveroc as described above. Low temperature working In cold conditions down to 5C, the use of warm mixing water (up to 30C) 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 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed. High temperature working At ambient temperatures above 35C, the material should be stored in the shade and cool water used for mixing. 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 Large areas should be cured as trowelling progresses (0.5 m2 at a time) without waiting for completion of the entire area. 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.
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Fosroc Paveroc
Overcoating with protective decorative finishes 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. 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. 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.
Limitations
Paveroc should not be used when the temperature is below 5C and falling. Do not mix part bags. Paveroc 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.
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.
Precautions
Health and safety For further information refer to the appropriate Safety Data Sheets available at www.fosroc.com Fire
Estimating
Supply Paveroc: Nitoprime Zincrich Plus: Nitobond EP Concure WB Fosroc Solvent 102: Coverage and yield Paveroc: Approximately 11.5 litres / 25 kg bag (approximately 0.9 m at 12 mm thickness) 8 m2/litre Approximately 2 m2 / kg 5 m2/ litre 25 kg bags 1.9 litre and 800 ml cans 2.5 and 4.5 Kg packs 20 and 200 litre drums 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 Nitoprime Zincrich Plus: Fosroc Solvent 102: 41C 33C
Nitoprime Zincrich Plus: Nitobond EP Concure WB
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.
Important note
Fosroc Limited
www.fosroc.com
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 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/m. Renderoc DS is specifically designed to comply with the Highways Agency Specification Series 1700 and BD27/86 PE5). Renderoc DS is suitable for repair method 3.3 and 4.4 as defined by BS EN 1504.
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. The cured mortar shall achieve a compressive strength of 60 MPa at 28 days and a drying shrinkage of <300 microstrain at 7 days.
Renderoc DS complies with class R4 according to BS EN 1504-3 repair principals 3.3 and 4.4 Renderoc DS conforms to the requirements of the UK Highways Agency Design Manual for Roads and Bridges (BD27/86, Clause 5) Materials for the Repair of Concrete Highway Structures and has been formulated to comply with the requirements of the Specification for Highways Works Clause 1704.5 Control of Alkali-Silica Reaction.
Advantages
Non-reactive aggregates Controlled alkali level Low rebound Rapid strength gain Low water absorption and chloride ion diffusion High resistance to carbon dioxide penetration Excellent bond to the concrete substrate Single component ready to use No added caustic accelerators Contains no chloride admixtures
Fosroc Ltd, Drayton Manor Business Park, Coleshill Road, Tamworth, Staffs, B78 3TL 09 0370-CPD-0845 EN1504-3 Concrete repair products for structural repair PCC mortar (based on polymer modified hydraulic cement) Compressive strength Chloride ion content Adhesive bond strength Adhesive bond strength after freeze thaw thermal cycling Carbonation resistance Capillary absorption Elastic modulus in compression Reaction to fire Dangerous substances Class R4 ( 45 MPa) 0.05% 2.0 MPa 2.0 MPa dk control concrete 0.5kg / m-2.h-0.5 20 GPa Class A1 Complies with 5.4
Description
Renderoc DS is supplied as a ready to use blend of dry powders which is formulated for application using the dry spray process. The material is based on Portland cements, graded aggregates silica fume, chemical additives and polymer modifiers, providing a spray mortar with low rebound and good handling characteristics. The low water requirement ensures good strength gain and long term durability. Builds of up to 150 mm vertically and 90 mm overhead can be achieved in a single application.
32
1
CI/SfB: (4-) Pr4
November 2009
Fosroc Renderoc DS
Properties
Test method Standard EN 1504 R4 Requirement 45 MPa 2.0 MPa 0.05 % 2.0 MPa dk ref concrete 20 GPa Result @ 1 Day 20 MPa @ 7 Days 45 MPa @ 28 Days 60 MPa 2.7 MPa 0.02 % 2.9 MPa Complies 28.6 GPa @ 28 days Class A1 Non-Combustible Initial set: 3.5 hours Final set: 5.0 hours Nominally 2200kg/ m3 < 300 microstrain @ 7 days 1.0% vol % 0.41 kg/m2.h-0.5 28 - 30000 ohm cm 15x 10 -6 /oC The low permeability of Renderoc DS severely retards chemical attack in aggressive environments. The cured mortar is impermeable to acid gases, waterborne chloirde ions and oxygen.
Compressive Strength Bond strength by pull off: Chloride ion content: Freez e thaw cycling: Resistance to carbonation dk Elastic Modulus in Compression Fire rating Setting time Fresh w et density Shrinkage 25 x 25 x 285 prisms, 27 OC, 55% RH Alkali reactive particles Capillary absorption Resistivity Coefficient of thermal Expansion
EN 12190:1999 EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 E N 13295: 2005 E N 13412 EN 13505-1 BS 4551 Pt 14:1980
Method TI-B 52 E N 13057 -
<0.5 kg/m2.h-0.5 -
Chemical resistance
Build Characteristics Minimum thickness: Vertical: Horiz ontal: 10mm Up to 150 mm Up to 90 mm
Clarification of property values: The typical properties given are derived from laboratory testing. Results derived
from field applied samples may vary
33
1
CI/SfB: (4-) Pr4
November 2009
Fosroc Renderoc DS
Preparation 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, i.e. concrete is sound and of good quality, but cover is to be increased, roughen the surface and remove any laitance by light scabbling or abrasive-blasting. It will still be necessary to cut back the perimeter to a depth of 10 mm so that the repair patch may be toed-in and finished flush with the surrounding concrete. 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. 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. 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. Reinforcing steel priming Extra protection to the reinforcing steel can be achieved by application of one full coat of Nitoprime Zincrich Plus and allowing 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. Substrate priming Soak the prepared concrete surface thoroughly, allowing surplus water to drain off. Application Exposed steel reinforcing bars should be firmly secured to avoid movement during the application process as this will affect mortar compaction, build and bond. Renderoc DS should be emptied from the bags directly into the hopper of the dry spray process machine. The amount of water added should be controlled by the nozzleman. Too little water will increase rebound and dust emission, too wet a mix will slump. If sagging occurs during application to vertical or overhead surfaces, the Renderoc DS should be completely removed and re-applied at a reduced thickness on to the correctly prepared substrate. Coverage and yield Renderoc DS: Nitoprime Zincrich Plus: Approx. 12.5 litres / 25 kg bag (approx. 80 bags/m) 8 m2/ litre Finishing Renderoc DS is finished by striking off with a straight edge and closing with a steel float. Wooden or plastic floats, or damp sponges may be used to achieve the desired surface texture. The completed surface should not be overworked. Low temperature working 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 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed. High temperature working At ambient temperatures above 35C, the material should be stored in the shade. Curing Renderoc DS is a cement-based mortar. In common with all cementitious materials, Renderoc DS must be cured immediately after finishing in accordance with good concrete practice, i.e. using wet hessian or polythene. In cold conditions, the finished repair must be protected from freezing. Cleaning Renderoc DS should be removed from tools, equipment and mixers with clean water immediately after use. Cured material can only be removed mechanically. Equipment used with Nitoprime Zincrich Plus should be cleaned with Fosroc Solvent 102.
Estimating
Supply Renderoc DS: Nitoprime Zincrich Plus: Fosroc Solvent 102: 25 kg bags 1.9ltr and 800ml cans 5 and 25 litre tins
Notes: The actual yield per bag of Renderoc DS will depend on the water addition during application. The coverage figures are theoretical due to wastage factors and the variety and nature of possible substrates, practical coverage figures will be reduced.
34
1
CI/SfB: (4-) Pr4
November 2009
Fosroc Renderoc DS
Limitations
Renderoc DS should not be used when the temperature is below 5C and falling. The product 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 Technical Services Department.
Storage
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.
Precautions
Health and safety For further information refer to the appropriate Safety Data Sheets available at www.fosroc.com.
Fire
Renderoc DS is non-flammable. Nitoprime Zincrich Plus and Fosroc Solvent 102 are flammable. Keep away from sources of ignition. No Smoking. In the event of fire, extinguish with CO2 or foam. Do not use a water jet. Flash points Nitoprime Zincrich Plus: Fosroc Solvent 102: 41C 33C
Important note
Fosroc Limited
www.fosroc.com
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Fosroc Renderoc FC
Single component polymer modified cementitious fairing coat conforming to the requirements of BS EN 1504-3 Class R2 Uses
Renderoc FC is designed for application in thin layers to produce a fair-faced appearance to concrete surfaces or masonry surfaces in readiness to receive a protective/ decorative coating. Surface imperfections up to 3 mm in depth can be filled with the scrape-coat application. Voids of greater depth should be separately filled as a prior operation, again limiting the material thickness to 3 mm. Alternatively, consideration should be given to the use of Renderoc RP252 reprofiling and protection mortar. Where higher compressive strengths and low permeability characteristics are required, Renderoc RP 252 or Renderoc ST05 should be used. Renderoc FC can also be used in association with other Renderoc mortars. Renderoc FC is suitable for repair methods 3.1, 7.1, 7.2 as defined by BS EN 1504-3.
The product exhibits excellent thermal compatibility with concrete and is fully compatible with other Renderoc mortars and Dekguard coatings.e of exposed reinforcing steel.
Renderoc FC complies with the class R2 according to EN1504-3, repair methods 3.1, 7.1 and 7.2. Renderoc FC has been approved by the British Board of Agrement, Certificate No 98/3461.
Fosroc Ltd, D rayton Manor B usiness Park, C oleshill R oad, Tamw orth, Staffs, B 78 3TL 09 0370-C PD -0845 EN 1504-3 C oncrete repai r products for non-structural repai r PC C mortar (based on polymer modi fi ed hydrauli c cement) C ompressi ve strength C hlori de i on content Adhesi ve bond Adhesi ve bond strength after freeze thaw thermal cycli ng Reacti on to fi re D angerous substances C lass R2 ( 15 MPa) 0.05 % 0.8 MPa 0.8 MPa C lass A2 s1 d0 C ompli es wi th 5.4
Advantages
Compatibility with non-structural concrete of compressive strength 20 - 35 MPa Polymer-modification provides extremely low permeability to water, carbon dioxide and chlorides Excellent bond to concrete Can be applied quickly and efficiently One component, pre-bagged to overcome site-batched variations Contains no chloride admixtures
Description
Renderoc FC is designed for vertical and overhead use to infill honeycombing and voids up to 3 mm deep in the surface of concrete. Renderoc FC is supplied as a ready to use blend of dry powders requiring only the site addition of clean water to produce a highly consistent cementitious fairing mortar. The material is based on a blend of cements, graded aggregates, special fillers and chemical additives to provide a material with good handling characteristics, while minimising water demand.
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Fosroc Renderoc FC
Properties
The following results were obtained at a water : powder ratio of 0.28 and at a temperature of 20C unless otherwise stated.
Test method Standard EN 1504 R2 Requirement 15 MPa 0.8 MPa 0.05 % 0.8 MPa Test result @ 1 Day 10 MPa @ 28 Days 22 MPa 3.02 MPa 0.02 % 3.45 MPa Class A2 s1 d0 Non-Combustible Initial set: 50 minutes Final set: 70 minutes Nominally 2000 kg/m3 The low permeability of Renderoc HB severely retards chemical attack in aggressive environments. The cured mortar is impermeable to acid gases, waterborne chloride ions and oxygen.
Compressive Strength Bond strength by pull off: Chloride ion content: Freez e thaw cycling: Fire rating Setting time Fresh w et density
EN 12190:1999 EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 EN 13501-1 BS 4551 Pt 14:1980 -
Chemical resistance
Build Characteristics hand applied Minimum thickness: Overhead: Vertical:
0 Up to 3.0mm Up to 3.0 mm
Clarification of property values: The typical properties given above are derived from laboratory testing. Results derived from field applied samples may vary.
Preparation Clean the surface and remove any dust, unsound material, plaster, oil, paint, grease, corrosion deposits or algae. Roughen the surface to remove any laitance and expose the fine aggregate by light scabbling or grit-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. Renderoc repair mortars require no additional preparation prior to the application of Renderoc FC. No independent priming system is required. The cleaned areas should be blown clean with oil-free compressed air before continuing. All prepared areas should
be saturated surface dry immediately before the application of Renderoc FC, i.e. they should be thoroughly saturated with clean water and any residual surface water removed. Under severe drying conditions repeated soaking may be necessary to ensure the substrate is still saturated at the time of application. Care should be taken and the work scheduled to ensure the water does not run onto areas of recently applied Renderoc FC less than 12 hours old. Mixing Care should be taken to ensure that Renderoc FC is thoroughly mixed. Small quantities (up to 10 kg) can be mixed by hand using a suitable mixing drum or bucket. Greater quantities should be mixed using a forced-action mixer. Mixing in a suitably sized drum using a Renderoc spiral paddle with a slow speed (400/500 rpm) heavy-duty drill is an acceptable alternative.
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Mixing warning As with other one pack repair mortars, Renderoc FC 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. If mixing small quantities by hand, Renderoc FC should be volume-batched. Add three volumes of the Renderoc FC powder (loose-filled to excess and struck off level with the top of the measuring container) to one volume of drinking quality water. This should be mixed vigorously for a minimum of 3 minutes. For larger volumes, place 7.0 to 8.0 litres of drinking quality water into the mixer and, with the machine in operation, add one full 25 kg bag of Renderoc FC and mix for a minimum of 3 minutes (maximum 5 minutes). Dependent on the ambient temperature and the desired consistency, the amount of water required may vary slightly but should not exceed 8.0 litres per 25 kg bag of Renderoc FC. Do not subsequently retemper with extra water. Note: that in all cases Renderoc FC powder must be added to water. Curing Renderoc FC does not require any form of curing in moderate ambient conditions, but under strong drying conditions curing may be necessary. In this case Renderoc FC should be cured immediately after finishing in accordance with good concrete practice. The use of Nitobond AR, sprayed on to the surface of the finished Renderoc FC in a continuous film, is recommended. Large areas should be cured as trowelling progresses (0.5 m2 at a time) without waiting for completion of the entire area. In very fast drying conditions, supplementary curing with polythene sheeting taped down at the edges should be used. In cold conditions, the finished repair must be protected from freezing. Overcoating with protective decorative finishes Renderoc FC must be overcoated with the Dekguard range of coatings or suitable alternatives. The surrounding parts of the structure will benefit from the application of a barrier/ decorative coating to limit the advance of chlorides and carbon dioxide, bringing them 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. Other curing membranes must be removed prior to the application of Dekguard products. Cleaning Renderoc FC should be removed from tools, equipment and mixers with clean water immediately after use. Cured material can only be removed mechanically.
Application
Apply the mixed Renderoc FC to the prepared substrate by steel trowel as a scrape coat of minimal thickness. It should be applied with the minimum of working and be allowed to partly set before finally trowelling to a smooth finish. If a very smooth finish is required, a small amount of water may be flicked on to the surface of the Renderoc FC with a paint brush prior to final trowelling. Do not proceed with the application when rainfall is imminent unless in a sheltered or protected situation. Note: the maximum applied thickness of Renderoc FC is 3 mm from the depths of the imperfections to the finished surface. Low temperature working 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 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed. High temperature working At ambient temperatures above 35C, the material should be stored in the shade and cool water used for mixing.
Estimating
Supply Renderoc FC: Nitobond AR: Coverage and yield Renderoc FC: Approximately 15.0 litres / 25 kg bag (5 m at 3 mm thickness) 6 - 8 m2/ litre 25 kg bags 5 and 25 litre drums
Nitobond AR:
Notes: the actual yield per bag of Renderoc FC will depend on the consistency used.
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Fosroc Renderoc FC
Limitations
Renderoc FC should not be used when the temperature is below 5C and falling. Do not mix part bags. Due to the lightweight nature of Renderoc FC, the product should not be used in areas subjected to traffic (in these circumstances, Renderoc S should be considered). Renderoc FC 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.
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. Nitobond AR should be protected from frost.
Precautions
Health and safety For further information refer to the appropriate Safety Data Sheets available at www.fosroc.com. Fire Renderoc FC 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
Renderoc is the trade mark of Fosroc International Limited

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Renderoc HB
High performance lightweight concrete reinstatement mortar conforming to the requirements of BS EN 1504-3 Class R2 Uses
For the reinstatement of concrete where low permeability characteristics are required but where high compressive strength is not the most important consideration. If high compressive strengths and low permeability characteristics are required, Renderoc HB45 should be used. Renderoc HB has been specifically developed for vertical and overhead repair work where its lightweight nature and high build characteristics makes it ideal. Renderoc HB is suitable for repair methods 3.1, 3.3, 7.1, 7.2 as defined by BS EN 1504-3.
Renderoc HB can be quickly and efficiently applied by the wet spray technique. Consult the local Fosroc office for further information. The material should not be applied at less than 10 mm thickness.
Renderoc HB complies with the class R2 according to EN1504-3, repair methods 3.1, 3.3, 7.1 and 7.2. Renderoc HB, Nitoprime Zincrich Plus, Nitobond AR and Nitobond HAR have been approved by the British Board of Agrement, Certificate No 98/3461.
Advantages
Compatibility with non-structural concrete of compressive strength 20 - 35 N/mm` Lightweight formulation enables extra high-build fewer cold joints Frequently obviates the need for formwork Polymer-modification provides extremely low permeability to water, carbon dioxide and chlorides Exceptional system of shrinkage compensation provides long-term dimensional stability Can be applied quickly and efficiently by wet spraying One component, pre-bagged to overcome site-batched variations Contains no chloride admixtures
Fosroc Ltd, D rayton Manor B usiness Park, C oleshill R oad, Tamw orth, Staffs, B 78 3TL 09 0370-C PD -0845 EN 1504-3 C oncrete repai r products for non-structural repai r PC C mortar (based on polymer modi fi ed hydrauli c cement) C ompressi ve strength C lass R2 ( 15 MPa) 0.05 % 0.8 MPa 0.8MPa C lass A2 s1 d0 C ompli es wi th 5.4
Description
Renderoc HB is supplied as a ready to use blend of dry powders requiring only the site addition of clean water to produce a highly consistent, lightweight repair mortar. It is based on Portland cements, graded aggregates, lightweight fillers and chemical additives which provide a mortar with good handling characteristics while minimising water demand. The low water requirement ensures good strength gain and long-term durability. Renderoc HB has been specifically engineered for vertical and overhead repair work. It can be applied in sections up to 80 mm thickness in vertical locations and up to 50 mm thickness in overhead locations in a single application and without the use of formwork. Thicker sections can be achieved by the use of formwork or can be built up in layers. Deep pockets can sometimes be filled in a single application dependent on the configuration of the pocket and the volume of exposed reinforcing steel.
C hlori de i on content Adhesi ve bond Adhesi ve bond strength after freeze thaw thermal cycli ng Reacti on to fi re D angerous substances
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Fosroc Renderoc HB
Properties
Test method S tandard E N 1504 R2 Requirement 15 MPa 0.8 MPA 0.05 % 0.8 MPa Test result @ 1 D ay 10 MPa @ 28 D ays 22 MPa 1.0 MPa 0.02 % 0.8 MPa C lass A2 s1 d0 Non-C ombusti ble Ini ti al set: 3.5 hours Fi nal set: 5.5 hours Nomi nally 1430 kg/m3 < 300 mi crostrai n @ 7 days The low permeabi li ty of Renderoc HB severely retards chemi cal attack i n aggressi ve envi ronments. The cured mortar i s i mpermeable to aci d gases, waterborne chlori de i ons and oxygen.
C ompressive Strength B ond strength by pull off: C hloride ion content: Freez e thaw cycling: Fire rating Setting time Fresh w et density Shrinkage (25 x 25 x 285 prisms, 27 OC , 55% R H
EN 12190:1999 EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 EN 13501-1 BS 4551 Pt 14:1980
B uild C haracteristics hand applied Minimum thickness: Overhead: Vertical:
10 mm Up to 50 mm Up to 80 mm
Preparation Saw cut the edges of the repair to a depth of at least 10 mm to provide a square edge. Break out the complete repair area to a minimum depth of 10 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.
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. 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. 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.
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Fosroc Renderoc HB
Concrete Priming 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 Nitobond HAR. Under severe drying conditions repeated soaking may be necessary to ensure the substrate is still saturated at the time of application of the primer. Scrub Nitobond HAR into the surface. Renderoc HB can be applied as soon as the primer becomes tacky. If the Nitobond HAR is too wet, overhead and vertical build up of the Renderoc HB may be difficult. In exceptional circumstances, e.g. where a substrate/repair barrier is required or where the substrate is water immersed or likely to remain permanently damp, Nitobond EP bonding aid should be used. Contact the local Fosroc office for further information. Mixing Care should be taken to ensure that Renderoc HB 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. For normal applications, place 3.1 to 3.4 litres of drinking quality water into the mixer. With the machine in operation, add one full bag of Renderoc HB 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 3.4 litres. Note that the powder must always be added to the water. Mixing warning High temperature working As with other one pack repair mortars, Renderoc HB 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. Application Exposed steel reinforcing bars should be firmly secured to prevent movement during application. Apply the mixed Renderoc HB by gloved hand or trowel, thoroughly compacting onto the primed substrate and around exposed reinforcement. At ambient temperatures above 35C, the material should be stored in the shade and cool water used for mixing. Curing Renderoc HB 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 Nitobond AR, 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 Nitobond AR. Any excessive run-off on verticals or drips on soffits should be removed by brush before they harden. Large areas should be cured as trowelling progresses (0.5 m2 at a time) without waiting for completion of the entire area.
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If sagging or slumping occurs Renderoc HB should be completely removed and reapplied at a reduced thickness to a correctly primed substrate. Build-up Additional build-up can be achieved by application of multiple layers. The surface of the intermediate layers should be comb scratch-keyed and cured with Nitobond AR. Repriming with Nitobond HAR and a further application of Renderoc HB may proceed as soon as this layer has set. Spray application Renderoc HB can be quickly and efficiently applied by the wet spray technique. In circumstances where large areas of repair are required, the rapid placement and higher build attainable by this method offer economic advantages over hand-trowelling. The resultant repair also offers a generally more dense compound with enhanced mortar/substrate bond characteristics. For further details on wet spray techniques contact the local Fosroc office. Finishing Renderoc HB is finished by striking off with a straight edge and closing with a steel float. Wooden or plastic floats, or damp sponges, may be used to achieve the desired surface texture. The completed surface should not be overworked. After spray application, the mortar may need to be cut back to the required profile using a steel float and then finished with damp sponges as described above. Low temperature working In cold conditions down to 5C, the use of warm mixing water (up to 30C) 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 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed.
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Fosroc Renderoc HB
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. Overcoating with protective decorative finishes Renderoc HB is extremely durable and will provide long-term protection to the embedded steel reinforcement within the repaired locations. The surrounding parts of the structure will benefit from the application of a barrier/decorative coating to limit the advance of chlorides and carbon dioxide, bringing them 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. Other curing membranes must be removed prior to the application of Dekguard products. Cleaning Renderoc HB and Nitobond HAR 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 material cures using Fosroc Solvent 102. Notes: the actual yield per bag of Renderoc HB will depend on the consistency used. The yield will be reduced if the material is applied by a spray technique.
Limitations
Renderoc HB should not be used when the temperature is below 5C and falling. Do not mix part bags. Due to the lightweight nature of Renderoc HB, the product should not be used in areas subjected to traffic (in these circumstances, Renderoc S should be considered). Renderoc HB 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.
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. Nitobond AR and Nitobond HAR should be protected from frost.
Precautions
Health and safety For further information refer to the appropriate Safety Data Sheets available at www.fosroc.com
Estimating
Supply Renderoc HB: Nitoprime Zincrich Plus: Nitobond HAR Nitobond AR: Fosroc Solvent 102: Coverage and yield Renderoc HB: Approximately 14.5 -15.0 litres / 18 kg bag (approximately 1.5 m at 10 mm thickness) 8 m2/litre 6 - 8 m2/ litre 3 - 4 m2/ litre 18 kg bags 1.9 litre and 800 ml cans 5 and 25 litre drums 5 and 25 litre drums 5 and 25 litre tins
Fire Renderoc HB is non-flammable. Nitoprime Zincrich Plus and Fosroc Solvent 102: are flammable. Keep away from sources of ignition. No Smoking. In the event of fire, extinguish with CO2 or foam. Do not use a water jet Flash points Nitoprime Zincrich Plus: Fosroc Solvent 102: 41C 33C
Nitoprime Zincrich Plus: Nitobond AR: Nitoprime HAR

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Renderoc HB30

High performance fibre reinforced lightweight concrete reinstatement mortar conforming to the requirements of BS EN 1504-3 Class R3 Uses
For the reinstatement of concrete where low permeability characteristics are required but where high compressive strength is not the most important consideration. If high compressive strength is required Renderoc HB45 should be used. Renderoc HB30 has been specifically developed for vertical and overhead repair work where its lightweight nature and high build characteristics makes it ideal. Renderoc HB30 is suitable for repair methods 3.1, 3.3, 7.1, 7.2 as defined by BS EN 1504-3.
Renderoc HB30 can be quickly and efficiently applied by the wet spray technique. Consult the local Fosroc office for further information. The material should not be applied at less than 10 mm thickness.
The repair mortar shall be Renderoc HB30, a one component, polymer modified, high build cementitious mortar, conforming to the requirements of BS EN 1504-3 Class R3. The cured mortar shall achieve a compressive strength of 30 MPa at 28 Days and a drying shrinkage of <300 microstrain at 7 days.
Renderoc HB30 complies with the class R3 according to EN1504-3, repair methods 3.1, 3.3, 7.1 and 7.2.
Advantages
Maximum compatibility with concrete of compressive strength 20 - 35 N/mm Lightweight formulation enables extra high-build fewer cold joints Frequently obviates the need for formwork Polymer-modification provides extremely low permeability to water, carbon dioxide and chlorides Exceptional system of shrinkage compensation provides long-term dimensional stability Can be applied quickly and efficiently by wet spraying One component, pre-bagged to overcome site-batched variations Contains no chloride admixtures
Description
Renderoc HB30 is supplied as a ready to use blend of dry powders requiring only the site addition of clean water to produce a highly consistent, lightweight repair mortar. It is based on Portland cements, graded aggregates, lightweight fillers and chemical additives which provide a mortar with good handling characteristics while minimising water demand. The low water requirement ensures good strength gain and long-term durability. Renderoc HB30 has been specifically engineered for vertical and overhead repair work. It can be applied in sections up to 60 mm thickness in vertical locations and up to 40 mm thickness in overhead locations in a single application and without the use of formwork. Thicker sections can be achieved by the use of formwork or can be built up in layers. Deep pockets can sometimes be filled in a single application dependent on the configuration of the pocket and the volume of exposed reinforcing steel.
Fosroc Ltd, Drayton Manor Business Park, Coleshill Road, Tamw orth, Staffs, B78 3TL 09 0370-CPD-0845 EN 1504-3 Concrete repair products for structural repair PCC mortar (based on polymer modified hydraulic cement) Compressive strength Chloride ion content Adhesive bond Adhesive bond strength after freeze thaw thermal cycli ng Carbonation resistance Reaction to fire Dangerous substances Class R3 ( 25 MPa) 0.05 % 1.5 MPa 1.5 MPa dk control concrete Class A2 s1 d0 Complies with 5.4
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Properties
Test method S tandard E N 1504 R3 Requirement 25 MPa 1.5 MPa 0.05 % 1.5 MPa dk ref concrete Test result @ 1 D ay 10 MPa @ 28 D ays 30 MPa 1.8 MPa 0.02% 1.7 MPa C onforms C lass A2 s1 d0 Non-C ombusti ble 5.2 MPa @ 28 days 2.5 MPa@ 28 days Ini ti al set: 3 hours Fi nal set: 5 1/2 hours Nomi nally 1700 kg/m3 < 300 mi crostrai n @ 7 days 1.0 vol % The low permeabi li ty of Renderoc HB30 severely retards chemi cal attack i n aggressi ve envi ronments. The cured mortar i s i mpermeable to aci d gases, waterborne chlori de i ons and oxygen.
C ompressive Strength B ond strength by pull off: C hloride ion content: Freez e thaw cycling: R esistance to carbonation dk Fire rating Flexural strength Tensile strength Setting time Fresh w et density Shrinkage (25 x 25 x 285 prisms, 27 OC , 55% R H Alkali reactive particles
EN 2190:1999 EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 EN 13295:2005 EN 13501-1 BS 6319 Pt 3:1990 BS 6319 Pt 3:1985 BS 4551 Pt14:1980
Method TI-B 52
Preparation Saw cut the edges of the repair to a depth of at least 10 mm to provide a square edge. Break out the complete repair area to a minimum depth of 10 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.
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CI/SfB: (4-) Pr4 w7
November 2009

Concrete Priming 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. 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 and paddle until a homogeneous slurry is produced. Scrub Renderoc Primer slurry into the surface. Renderoc HB30 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. In exceptional circumstances, e.g. where a substrate/repair barrier is required or where the substrate is water immersed or likely to remain permanently damp, Nitobond EP bonding aid should be used. Contact the local Fosroc office for further information. Mixing Care should be taken to ensure that Renderoc HB30 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. For normal applications, place 3.8 to 4.2 litres of drinking quality water into the mixer. With the machine in operation, add one full bag of Renderoc HB30 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 4.2 litres. Note that the powder must always be added to the water. Mixing warning As with other one pack repair mortars, Renderoc HB30 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. Application Exposed steel reinforcing bars should be firmly secured to prevent movement during application. Apply the mixed Renderoc HB30 by gloved hand or trowel, thoroughly compacting onto the primed substrate and around exposed reinforcment. If sagging or slumping occurs the Renderoc HB30 should be completly removed and reapplied at a reduced thickness to a correctly primed substrate. Build-up Additional build-up can be achieved by application of multiple layers. The surface of the intermediate layers should be comb scratch-keyed and cured with Nitobond AR. Repriming with Renderoc Primer and a further application of Renderoc HB30 may proceed as soon as this layer has set. Spray application Renderoc HB30 can be quickly and efficiently applied by the wet spray technique. In circumstances where large areas of repair are required, the rapid placement and higher build attainable by this method offer economic advantages over hand-trowelling. The resultant repair also offers a generally more dense compound with enhanced mortar/substrate bond characteristics. For further details on wet spray techniques contact the local Fosroc office. Finishing Renderoc HB30 is finished by striking off with a straight edge and closing with a steel float. Wooden or plastic floats, or damp sponges, may be used to achieve the desired surface texture. The completed surface should not be overworked. After spray application, the mortar may need to be cut back to the required profile using a steel float and then finished with damp sponges as described above. Low temperature working In cold conditions down to 5C, the use of warm mixing water (up to 30C) 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 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed. High temperature working At ambient temperatures above 35C, the material should be stored in the shade and cool water used for mixing. Curing Renderoc HB30 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 Nitobond AR, 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 Nitobond AR. Any excessive run-off on verticals or drips on soffits should be removed by brush before they harden.
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1
CI/SfB: (4-) Pr4 w7
November 2009

Large areas should be cured as trowelling progresses (0.5 m2 at a time) without waiting for completion of the entire area. 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. Overcoating with protective decorative finishes Renderoc HB30 is extremely durable and will provide longterm protection to the embedded steel reinforcement within the repaired locations. The surrounding parts of the structure will benefit from the application of a barrier/decorative coating to limit the advance of chlorides and carbon dioxide, bringing them 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. Other curing membranes must be removed prior to the application of Dekguard products. Cleaning Renderoc HB30 and Renderoc Primer 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 material cures, using Fosroc Solvent 102. Nitoprime Zincrich Plus: Nitobond AR: Renderoc Primer 8 m2/litre 6 - 8 m2/ litre Approximately 13 litres - 2m2/litre
Notes: the actual yield per bag of Renderoc HB30 will depend on the consistency used. The yield will be reduced if the material is applied by a spray technique.
Limitations
Renderoc HB30 should not be used when the temperature is below 5C and falling. Do not mix part bags. Due to the lightweight nature of Renderoc HB30, the product should not be used in areas subjected to traffic (in these circumstances, Renderoc S should be considered). Renderoc HB30 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.
Storage
Renderoc HB30 and Renderoc Primer have 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. Nitobond AR and Renderoc Primer Part B should be protected from frost.
Precautions
Health and safety For further information refer to the appropriate Safety Data Sheets available at www.fosroc.com
Estimating
Supply Renderoc HB30: Nitoprime Zincrich Plus: Renderoc Primer Nitobond AR: Fosroc Solvent 102: Coverage and yield Renderoc HB30: Approximately 15.0 litres / 22 kg bag (approximately 1.5 m at 10 mm thickness)
Important note
22 kg bags 1.9 litre and 800 ml cans 20 Kg Part A + 5 litres part B 5 and 25 litre drums 5 and 25 litre tins
Fire Renderoc HB30 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 Nitoprime Zincrich Plus: Fosroc Solvent 102: 41C 33C

Fosroc Limited
www.fosroc.com
51
1

High performance fibre reinforced medium weight concrete reinstatement mortar conforming to the requirements of BS EN 1504-3 Class R4 Uses
For the reinstatement of reinforced concrete where low permeability characteristics are required and where higher compressive strength is a consideration. Where compatibility with lower strength concrete is required, Renderoc HB30 should be used. Renderoc HB45 has been specificaly developed for the repair of columns and beams, but because of its medium fresh wet density, is also suitable for soffit repairs. Renderoc HB45 is suitable for repair methods 3.1, 3.3, 4.4, 7.1, 7.2 as defined by BS EN 1504-3.
Renderoc HB45 can be quickly and efficiently applied by the wet spray technique. Consult the local Fosroc office for further information. The material should not be applied at less than 10 mm thickness.
The repair mortar shall be Rendreoc HB45 a one component polymer modified high build cementitious mortar conforming to the requirements of BS EN 1504-3 Class R4. The cured mortar shall achieve a compressive strength of 50 MPa at 28 days and a drying shrinkage of <300 microstrain at 7 days.
Renderoc HB45 complies with the classification R4 according to EN 1504-3, repair methods 3.1, 3.3, 4.4, 7.1 and 7.2.
Advantages
Maximum compatibility with concrete of compressive strength 35 - 60 N/mm High-build applications possible while maintaining higher compressive strengths fewer cold joints Frequently obviates the need for formwork Polymer-modification provides extremely low permeability to water, carbon dioxide and chlorides Exceptional system of shrinkage compensation provides long-term dimensional stability Can be applied quickly and efficiently by wet spraying One component, pre-bagged to overcome site-batched variations Contains no chloride admixtures
Fosroc Ltd, Drayton Manor Business Park, Coleshill Road, Tamworth, Staffs, B78 3TL 09 0370-CPD-0845 EN1504-3 Concrete repair products for structural repair PCC mortar (based on polymer modified hydraulic cement) Compressive strength Chloride ion content Adhesive bond strength Adhesive bond strength after freeze thaw thermal cycling Carbonation resistance Capillary absorption Elastic modulus in compression Reaction to fire Dangerous substances Class R4 ( 45 MPa) 0.05% 2.0 MPa 2.0 MPa dk control concrete 0.5kg / m-2.h-0.5 20 GPa Class A2 s1 d0 Complies with 5.4
Description
Renderoc HB45 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, medium-weight repair mortar. It is based on Portland cements, graded aggregates, lightweight fillers and chemical additives providing a mortar with good handling characteristics while minimising water demand. The low water requirement ensures good strength gain and long-term durability. Renderoc HB45 has been specifically engineered for vertical and overhead repair work. It can be applied in sections up to 40 mm thickness in vertical locations and up to 30 mm thickness in overhead locations in a single application without formwork. Thicker sections can be achieved by the use of formwork or can be built up in layers. Deep pockets can sometimes be filled in a single application dependent on the configuration of the pocket and the volume of exposed reinforcing steel.
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1

Properties
Test method Standard EN 1504 R4 Requirement 45 MPa 2.0 MPa 0.05 % 2.0 MPa ref concrete 0.5 kg/ m-2/h-0.5 20 GPa Result
C ompressive Strength B ond strength by pull off: C hloride ion content: Freez e thaw cycling: R esistance to carbonation dk C apillary absoprtion Elastic Modulus in C ompression Fire rating Flexural strength Tensile strength Setting time Fresh w et density Shrinkage (25 x 25 x 285 prisms, 27oC , 55% R H Alkali reactive particles
EN 12190:1999 EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 EN 13295:2005 EN1305:2002 E N 13412 EN 13501-1 BS 6319 Pt 3:1990 BS 6319 Pt 3:1985 BS 4551 Pt14:1980
@ 1 D ay 20 MPa @ 28 D ays 50 MPa 2.1 MPa 0.03% 2.0 MPa C onforms 0.09 kg/ m-2/h-0.5 25 GPa @ 28 days C lass A2 s1 d0 Non-C ombusti ble
7.5 MPa @ 28 days 4.0 MPa @ 28 days Ini ti al set: 3 hours Fi nal set: 5 hours Nomi nally 2000 kg/m-3 < 300 mi rcrostrai n @ 7 days
Method TI-B 52
1.0 vol % The low permeabi li ty of Renderoc HBS 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.
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 10 mm to provide a square edge. Break out the complete repair area to a minimum depth of 10 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. 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. 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.
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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. Concrete Priming 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. 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 slurry is produced. Scrub Renderoc Primer slurry into the surface. Renderoc HB45 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. In exceptional circumstances, e.g. where a substrate/repair barrier is required or where the substrate is wet or likely to remain permanently damp, Nitobond EP bonding aid should be used. Contact the local Fosroc office for further information. Mixing Care should be taken to ensure that Renderoc HB45 is thoroughly mixed. A forced-action mixer is essential. Mixing in a suitably sized drum using an approved Renderoc Spiral Paddle in 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. For normal applications, place 3.25 to 3.5 litres of drinking quality water into the mixer. With the machine in operation, add one full bag of Renderoc HB45 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 3.5 litres. Note that the powder must always be added to the water. Mixing warning As with other one pack repair mortars, Renderoc HB45 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. Application Exposed steel reinforcing bars should be firmly secured to prevent movement during application. Apply the mixed Renderoc HB45 by gloved hand or trowel, thoroughly compacting onto the primed substrate and around exposed reinforcment. If sagging or slumping occurs Renderoc HB45 should be completely removed and reapplied at a reduced thickness to a correctly primed substrate. Build-up Additional build-up can be achieved by application of multiple layers. The surface of the intermediate layers should be comb scratch-keyed and cured with Nitobond AR. Repriming with Renderoc Primer and a further application of Renderoc HB45 may proceed as soon as this layer has set. Spray application Renderoc HB45 can be quickly and efficiently applied by the wet spray technique. In circumstances where large areas of repair are required, the rapid placement and higher build attainable by this method offer economic advantages over hand-trowelling. The resultant repair also offers a generally more dense compound with enhanced mortar/substrate bond characteristics. For further details on wet spray techniques contact the local Fosroc office. Finishing Renderoc HB45 is finished by striking off with a straight edge and closing with a steel float. Wooden or plastic floats, or damp sponges, may be used to achieve the desired surface texture. The completed surface should not be overworked. After spray application, the mortar may need to be cut back to the required profile using a steel float and then finished with damp sponges as described above. Low temperature working In cold conditions down to 5C, the use of warm mixing water (up to 30C) 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 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed. High temperature working At ambient temperatures above 35C, the material should be stored in the shade and cool water used for mixing. Curing Renderoc HB45 is a cement-based repair mortar. In common with all cementitious materials, it must be cured immediately
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1

after finishing in accordance with good concrete practice. The use of Nitobond AR, 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 Nitobond AR. Any excessive run-off on verticals or drips on soffits should be removed by brush before they harden. Large areas should be cured as trowelling progresses (0.5 m2 at a time) without waiting for completion of the entire area. 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. Overcoating with protective decorative finishes Renderoc HB45 is extremely durable and will provide longterm protection to the embedded steel reinforcement within the repaired locations. The surrounding parts of the structure will benefit from the application of a barrier/decorative coating to limit the advance of chlorides and carbon dioxide, bringing them 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. Other curing membranes must be removed prior to the application of Dekguard products. Cleaning Renderoc HB45 and Renderoc Primer 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 material cures using Fosroc Solvent 102. Coverage and yield Renderoc HB45: Approximately 14 litres / 25 kg bag (approximately 1.4 m at 10 mm thickness) 8 m2/litre 6 - 8 m2/litre Approximately 13 litres- 2m2/ litre
Nitoprime Zincrich Plus: Nitobond AR: Renderoc Primer
Notes: the actual yield per bag of Renderoc HB45 will depend on the consistency used. The yield will be reduced if the material is applied by a spray technique.
Limitations
Renderoc HB45 should not be used when the temperature is below 5C and falling. Do not mix part bags. Renderoc HB45 should not be used in areas subjected to traffic (in these circumstances, Renderoc S should be considered). Renderoc HB45 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.
Storage
The Renderoc HB45 and Renderoc Primer have 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. Nitobond AR and Renderoc Primer Part B should be protected from frost.
Precautions
Health and safety For further information refer to the appropriate Product Safety Data Sheet available at www.fosroc.com Fire
Estimating
Supply Renderoc HB45: Nitoprime Zincrich Plus: Renderoc Primer Nitobond AR: Fosroc Solvent 102: 25 kg bags 1.9 litre and 800 ml cans 20 Kg Part A + 5 litres part B 5 and 25 litre drums 5 and 25 litre tins
Renderoc HB45 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 Nitoprime Zincrich Plus: Fosroc Solvent 102: 41C 33C
Important note
Fosroc Limited
www.fosroc.com
55
1
Fosroc Renderoc HBS

High performance fibre reinforced medium weight concrete reinstatement mortar conforming to the requirements of BS EN 1504-3 Class R4 Uses
For the reinstatement of reinforced concrete where low permeability characteristics are required and where higher compressive strength is a consideration. Renderoc HBS has been specificaly developed for the repair of columns and beams but, because of its relatively low fresh wet density, is also suitable for soffit repairs. Where compatibility with lower strength concrete is required, Renderoc HB30 should be used. Renderoc HBS is suitable for repair methods 3.1, 3.3, 4.4, 7.1, 7.2 as defined by BS EN 1504-3. Thicker sections can be achieved by the use of formwork or can be built up in layers. Deep pockets can sometimes be filled in a single application dependent on the configuration of the pocket and the volume of exposed reinforcing steel. Renderoc HBS can be quickly and efficiently applied by the wet spray technique. Consult the local Fosroc office for further information. The material should not be applied at less than 10 mm thickness.
Renderoc HBS complies with the classification R4 according to EN 1504-3, repair methods 3.1, 3.3, 4.4, 7.1 and 7.2.
Advantages
Compatible with concrete of compressive strength 35 60 N/mm High-build applications possible while maintaining higher compressive strengths fewer cold joints Frequently obviates the need for formwork Polymer-modification provides extremely low permeability to water, carbon dioxide and chlorides Shrinkage compensated to provides long-term dimensional stability Can be applied quickly and efficiently by wet spraying One component, pre-bagged to overcome site-batched variations Contains no chloride admixtures
Fosroc Ltd, Drayton Manor Business Park, Coleshill Road, Tamw orth, STAFFS, B78 3TL 09 0370-CPD-0845 EN 1504-3 Concrete repair products for structural repair PCC mortar (based on polymer modified hydraulic cement) Compressive strength Chloride ion content Adhesive bond strength Adhesive bond strength after freeze thaw thermal cycling Carbonation resistance Elastic modulus in compression Reaction to fire Dangerous substances Class R4 ( 45 MPa) 0.05% 2.0 MPa 2.0 MPa dk control concrete 20 GPa Class A2 s1 d0 Complies with 5.4
Description
Renderoc HBS 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, medium-weight repair mortar. It is based on Portland cements, graded aggregates, lightweight fillers and chemical additives which provide a mortar with good handling characteristics while minimising water demand. The low water requirement ensures good strength gain and long-term durability. Renderoc HBS has been specifically engineered for vertical and overhead repair work. It can be applied in sections up to 40 mm thickness in vertical locations and up to 30 mm thickness in overhead locations in a single application without the use of formwork.
56
1
Fosroc Renderoc HBS

Properties
Test method S tandard E N 1504 R4 Requirement 45 MPa 2.0 MPa 0.05 % 2.0 MPa ref concrete 20 GPa Result @ 1 D ay 20 MPa @ 28 D ays 50 MPa 2.1 MPa 0.03 % 2.0 MPa C onforms 25 GPa @ 28 days C lass A2 s1 d0 Non-C ombusti ble 6.5 MPa @ 28 days 2.9 MPa @ 28 days Ini ti al set: 3 hours Fi nal set: 5 hours Nomi nally 2000 kg/m-3 The low permeabi li ty of Renderoc HBS 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 ompressive Strength B ond strength by pull off: C hloride ion content: Freez e thaw cycling: R esistance to carbonation dk Elastic Modulus in C ompression Fire rating Flexural strength Tensile strength Setting time Fresh w et density
EN 12190:1999 EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 EN 13295:2005 E N 13412 EN 13501-1 BS 6319 Pt 3:1990 BS 6319 Pt 3:1985 BS 4551 Pt14:1980
Clarification of property values: The typical properties given above are derived from laboratory testing. Results derived from testing field applied samples may vary.
Application instructions Preparation Saw cut the edges of the repair to a depth of at least 10 mm to provide a square edge. Break out the complete repair area to a minimum depth of 10 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.
57
1
Fosroc Renderoc HBS

Concrete Priming 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. 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. Scrub Renderoc Primer slurry into the surface. Renderoc HBS 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. In exceptional circumstances, e.g. where a substrate/repair barrier is required or where the substrate is water immersed or likely to remain permanently damp, Nitobond EP bonding aid should be used. Contact the local Fosroc office for further information. Mixing Care should be taken to ensure that Renderoc HBS is thoroughly mixed. A forced-action mixer is essential. Mixing in a suitably sized drum using an approved Renderoc Spiral Paddle in 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. For normal applications, place 3.25 to 3.5 litres of drinking quality water into the mixer. With the machine in operation, add one full bag of Renderoc HBS 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 3.5litres. Note that the powder must always be added to the water. Mixing warning As with other one pack repair mortars, Renderoc HBS 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. Application Exposed steel reinforcing bars should be firmly secured to prevent movement during application. Apply the mixed Renderoc HBS by gloved hand or trowel, thoroughly compacting onto the primed substrate and around exposed reinforcment. If sagging or slumping occurs the Renderoc HBS should be completly removed and reapplied at a reduced thickness to a correctly primed substrate. Build-up Additional build-up can be achieved by application of multiple layers. The surface of the intermediate layers should be comb scratch-keyed and cured with Nitobond AR. Repriming with Renderoc Primer and a further application of Renderoc HBS may proceed as soon as this layer has set. Spray application Renderoc HBS can be quickly and efficiently applied by the wet spray technique. In circumstances where large areas of repair are required, the rapid placement and higher build attainable by this method offer economic advantages over hand-trowelling. The resultant repair also offers a generally more dense compound with enhanced mortar/substrate bond characteristics. For further details on wet spray techniques contact the local Fosroc office. Finishing Renderoc HBS is finished by striking off with a straight edge and closing with a steel float. Wooden or plastic floats, or damp sponges, may be used to achieve the desired surface texture. The completed surface should not be overworked. After spray application, the mortar may need to be cut back to the required profile using a steel float and then finished with damp sponges as described above. Low temperature working In cold conditions down to 5C, the use of warm mixing water (up to 30C) 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 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed. High temperature working At ambient temperatures above 35C, the material should be stored in the shade and cool water used for mixing. Curing Renderoc HBS 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 Nitobond AR, 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 Nitobond AR. Any excessive run-off on verticals or drips on soffits should be removed by brush before they harden.
58
1
Fosroc Renderoc HBS

Large areas should be cured as trowelling progresses (0.5 m2 at a time) without waiting for completion of the entire area. 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. Overcoating with protective decorative finishes Renderoc HBS is extremely durable and will provide longterm protection to the embedded steel reinforcement within the repaired locations. The surrounding parts of the structure will benefit from the application of a barrier/decorative coating to limit the advance of chlorides and carbon dioxide, bringing them 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. Other curing membranes must be removed prior to the application of Dekguard products. Cleaning Renderoc HBS and Renderoc Primer 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 material cures, using Fosroc Solvent 102. Nitoprime Zincrich Plus: Nitobond AR: Renderoc Primer 8 m2/litre 6 - 8 m2/ litre Approximately 13 litres- 2m-2/ litre
Notes: the actual yield per bag of Renderoc HBS will depend on the consistency used. The yield will be reduced if the material is applied by a spray technique.
Limitations
Renderoc HBS should not be used when the temperature is below 5C and falling. Do not mix part bags. Due to the lightweight nature of Renderoc HBS, the product should not be used in areas subjected to traffic (in these circumstances, Renderoc S should be considered). Renderoc HBS 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.
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. Nitobond AR and Renderoc Primer Part B should be protected from frost.
Precautions Estimating
Supply Renderoc HBS: Nitoprime Zincrich Plus: Renderoc Primer Nitobond AR: Fosroc Solvent 102: Coverage and yield Renderoc HBS: Approximately 15 litres / 25 kg bag (approximately 1.5 m at 10 mm thickness)
Important note
Health and safety 25 kg bags 1.9 litre and 800 ml cans 20 Kg Part A + 5 litres part B 5 and 25 litre drums 5 and 25 litre tins For further information refer to the appropriate Safety Data Sheets available at www.fosroc.com. Fire Renderoc HBS 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 Nitoprime Zincrich Plus: Fosroc Solvent 102: 41C 33C
Fosroc Limited
www.fosroc.com
59
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CI/SfB: Eq4 October 2009
Fosroc Renderoc LA
High performance free flowing low alkali microconcrete conforming to the requirements of BS EN 1504-3 Class R4 Uses
For the reinstatement of reinforced concrete where low permeability characteristics are required and where high compressive strength is a consideration. Renderoc LA has been specificaly developed for the repair of large areas of concrete where access is restricted or where reinforcement is conjested. It is suitable for use where excellent chloride and carbon dioxide resistance is required or for repairs to concrete affected by alkali-silica reaction (ASR). Renderoc LA is alkaline in nature and will protect embedded steel reinforcement. Renderoc LA is suitable for repair methods 3.2, 4.4, 7.1, 7.2 as defined by BS EN 1504-3.
Renderoc LA is designed for large volume repairs typically in excess of 50 mm deep. The product can be applied in sections generally up to 150 mm thick although greater thicknesses may be achievable dependent on the configuration of the repair location and the volume of exposed reinforcing steel. Consult the local Fosroc office for further information.
Renderoc LA complies with the classification R4 according to EN 1504-3, repair methods 3.2, 4.4, 7.1 and 7.2.
Advantages
Maximum compatibility with concrete of compressive strength 30 - 60 N/mm Dual expansion system compensates for shrinkage in the plastic and hardened states Low alkali content minimises risk of alkali-silica reaction Exceptional bond to concrete substrates without independent primer Suitable for placement by pumping or pouring techniques into restricted locations Self-compacting nature eliminates honeycombing and displaces air without vibration High strength and low permeability provide maximum protection against carbon dioxide and chlorides Pre-bagged to overcome site-batched variations only the site addition of clean water is required Contains no chloride admixtures
Fosroc Ltd, Drayton Manor Business Park, Coleshill Road, Tamw orth, STAFFS, B78 3TL 09 0370-CPD-0845 EN 1504-3 Concrete repair products for structural repair C C mortar (based on hydraulic cement) Compressive strength Chloride ion content Adhesive bond strength Adhesive bond strength after freeze thaw thermal cycling Carbonation resistance Elastic modulus in compression Reaction to fire Dangerous substances Class R4 ( 45 MPa) 0.05% 2.0 MPa 2.0 MPa dk control concrete 20 GPa Class A1 C omplies with 5.4
Description
Renderoc LA is supplied as a ready to use blend of dry powders requiring only the site addition of clean water to produce a free-flowing, shrinkage compensated microconcrete suitable for large volume concrete repairs at nominal thicknesses in excess of 50 mm. The material is based on Portland cement, graded aggregates and additives which impart controlled expansion in both the plastic and hardened states while minimising water demand. Its low alkali content minimises the risk of alkali-silica reaction. The hardened product exhibits excellent thermal compatibility with concrete.
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Fosroc Renderoc LA
Properties The following results were obtained at a water : powder ratio of 0.13 and a temperature of 20C unless otherwise stated.
Test method Standard EN 1504 R4 Requirement Result @ 1 Day 14 MPa @ 3 Days 30 MPa @ 7 Days 42 MPa @ 28 Days 60 MPa 2.7 MPa 0.02% 2.4 MPa Complies 31 GPa @28 Days Class A1 6.9 MPa @ 28 Days Initial set: 6 1/2 hours Final set: 9 hours Nominally 2300g/m3 < 300 microstrain @ 7 days 1% vol% Initial 5 seconds, 30 min 7 seconds The low permeability of Renderoc LA severely retards chemical attack in aggressive environments. The cured mortar is impermeable to acid gases, waterborne chloirde ions and oxygen. 0.146% after 6 months in 3% NaCL solution at 8-10mmm depth
Compressive Strength
EN 12190:1999
45 MPa
Bond strength by pull off: Chloride ion content: Freez e thaw cycling: Resistance to carbonation dk Elastic Modulus in Compression Fire rating Flexural strength Setting time Fresh w et density Shrinkage 25 x 25 x 285 prisms, 27 OC, 55% RH Alkali reactive particles Flow Properties
EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 EN 13295:2005 E N 13412 EN 13505-1 BS 6319 Pt 3:1990 BS 4551 Pt 14:1980
2.0 MPa 0.05 % 2.0 MPa ref concrete 20 GPa
Method TI-B 52 UK Highways Agency BD27/86 Clause 4.6(b) EN 13395-2
1000 mm within 10 seconds
Chemical resistance
Chloride ion ingress
E N 13396
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Fosroc Renderoc LA
The unrestrained surface area of the repair must be kept to a minimum. The formwork should be rigid and tight to prevent loss of material and have properly sealed faces to ensure that no water is absorbed from the repair material. The formwork should include drainage outlets for pre-soaking and, if beneath a soffit, provision for air-venting. Provision must also be made for suitable access points to pour or pump the mixed micro-concrete into place. 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 50 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. 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. 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. Reinforcing steel priming Priming of the steel reinforcement is not normally necessary unless it is to remain exposed in an environment likely to cause corrosion after preparation. When required 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 Substrate priming Several hours prior to placing, the prepared concrete substrates should be saturated by filling the prepared formwork with clean water. Immediately prior to the application of Renderoc LA, any excess water should be removed. 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. The mixed material should be placed within 30 minutes of mixing in order to gain the full benefit of fluidity and of the expansion process. If placing by pump, standard concrete pumping practice should be followed. Contact the Fosroc Office for further details. Low temperature working In cold conditions down to 5C, the use of warm mixing water (up to 30C) 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 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed. High temperature working At ambient temperatures above 35C, the material should be stored in the shade and cool water used for mixing. Mixing Care should be taken to ensure that Renderoc LA is thoroughly mixed. A forced-action mixer is essential. Mixing in a suitably sized drum using an approved Conbextra Spiral Paddle with a slow speed (400/500 rpm) heavy-duty drill is acceptable. Free-fall mixers must not be used. Mixing of part bags should never be attempted. It is essential that machine mixing capacity and labour availability is adequate to enable the placing operation to be carried out continuously. Measure 3.3 litres of drinking quality water and pour three-quarters into the mixer. With the machine in operation, add one full 25 kg bag of Renderoc LA and mix for 1 minute before adding the rest of the water. Mix for a further 2 to 3 minutes until a smooth even consistency is obtained. Note that powder must always be added to water. The quantities mixed may be scaled up as required. When the drill and paddle mixing method is used, the complete 3.3 litres of water should be placed in the mixing drum. With the paddle rotating, add one full 25 kg bag of Renderoc LA and mix for 2 to 3 minutes until a smooth even consistency is obtained. It is recommended that the mixed product be passed through a suitable coarse metal screen prior to placing or pumping to highlight any unmixed material. Mixing warning As with other one pack repair mortars, Renderoc LA 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. Placing
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Fosroc Renderoc LA
Curing The formwork should be left in place until the compressive strength of the Renderoc LA is 10 MPa or as otherwise specified by the Supervising Officer. Renderoc LA is a cementbased concrete reinstatement material. In common with all cementitious materials, Renderoc LA must be cured immediately after the formwork is stripped in accordance with good concrete practice. Immediately after striking the formwork, all exposed faces of the repair should be thoroughly soaked with clean water and then sprayed with a liquid curing membrane such as Concure WB. 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. Overcoating with protective decorative finishes Renderoc LA is extremely durable and will provide long term protection to the embedded steel reinforcement within the repaired locations. The surrounding parts of the structure will generally benefit 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. All traces of form-release oils and curing membranes must be removed prior to the application of Dekguard products. This is best achieved by light grit blasting. Cleaning Renderoc LA and Concure WB should be removed from tools, equipment and mixers with clean water immediately after use. Cured material can only be removed mechanically. Equipment used with Nitoprime Zincrich Plus and Nitobond EP should be cleaned with Fosroc Solvent 102.
Estimating
Supply Renderoc LA: Nitoprime Zincrich Plus: Nitobond EP: Concure WB: Fosroc Solvent 102: Coverage and yield Renderoc LA: Nitoprime Zincrich Plus: Nitobond EP: Concure WB: Approx. 12.0 litres / 25 kg bag 8 m2/litre 10m2 / 4.5kg pack 3.5 to 5 m2/ litre 25 kg bags 1.9 litre and 800 ml cans 4.5 kg packs 20 litre drums 5 and 25 litre tins
Notes: 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.
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. Concure WB should be protected from frost.
Precautions
Health and safety For further information refer to the Safety Data Sheet available at www.fosroc.com
Fire
Renderoc LA, Nitobond EP and Concure WB are nonflammable. 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: Fosroc Solvent 102: 41C 33C
Limitations
Renderoc LA should not be used when the temperature is below 5C and falling. Do not mix part bags. The product should not be used to reinstate horizontal areas where the surface would remain unrestrained during cure. It should not be exposed to moving water during application. If any doubts arise concerning temperature, application or substrate conditions, consult the local Fosroc office.

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Renderoc LA55

High performance free flowing low alkali microconcrete conforming to the requirements of BS EN 1504-3 Class R4 Uses
For the reinstatement of reinforced concrete where low permeability characteristics are required and where high compressive strength is a consideration. Renderoc LA55 has been specifically developed for the repair of large areas of concrete where access is restricted or where reinforcement is congested. It is suitable for use where excellent chloride and carbon dioxide resistance is required or for repairs to concrete affected by alkali-silica reaction (ASR). Renderoc LA55 is alkaline in nature and will protect embedded steel reinforcement. Renderoc LA55 is suitable for repair methods 3.2, 4.4, 7.1, 7.2 as defined by BS EN 1504-9.
of the repair location and the volume of exposed reinforcing steel. Consult the local Fosroc office for further information.
The repair mortar shall be Renderoc LA55, a one component micro-concrete conforming to the requirements of BS EN 1504-3 Class R4. The micro-concrete shall exhibit a 3 day compressive strength not less than 30 MPa and a 28 day compressive strength of 60 MPa ( at 20oC). Standards compliance Renderoc LA55 complies with the classification R4 according to EN 1504-3, repair methods 3.2, 4.4, 7.1 and 7.2. Renderoc LA55 conforms to the requirements of the UK Highways Agency Design Manual for Roads and Bridges (BD27/86, Clause 4) Materials for the Repair of Concrete Highway Structures and has been formulated to comply with the requirements of the Specification for Highway Works, Clause 1704.5 Control of Alkali-Silica Reaction.
Advantages
Maximum compatibility with concrete of compressive strength 30 - 60 N/mm Dual expansion system compensates for shrinkage in the plastic and hardened states Low alkali content minimises risk of alkali-silica reaction Exceptional bond to concrete substrates without independent primer Suitable for placement by pumping or pouring techniques into restricted locations Self-compacting nature eliminates honeycombing and displaces air without vibration High strength and low permeability provide maximum protection against carbon dioxide and chlorides Pre-bagged to overcome site-batched variations only the site addition of clean water is required Contains no chloride admixtures
Fosroc Ltd, Drayton Manor Business Park, Coleshill Road, Tamw orth, STAFFS, B78 3TL 09 0370-CPD-0845 EN 1504-3 Concrete repair products for structural repair PCC mortar (based on polymer modified hydraulic cement) Compressive strength Chloride ion content Adhesive bond strength Adhesive bond strength after freeze thaw thermal cycling Carbonation resistance Elastic modulus in compression Reaction to fire Dangerous substances Class R4 ( 45 MPa) 0.05% 2.0 MPa 2.0 MPa dk control concrete 20 GPa Class A1 Complies with 5.4
Description
Renderoc LA55 is supplied as a ready to use blend of dry powders which requires only the site addition of clean water to produce a free-flowing, shrinkage compensated microconcrete suitable for large volume concrete repairs at nominal thicknesses in excess of 50 mm. The material is based on Portland cement, graded aggregates and additives which impart controlled expansion in both the plastic and hardened states while minimising water demand. Its low alkali content minimises the risk of alkali-silica reaction. The hardened product exhibits excellent thermal compatibility with concrete. Renderoc LA55 is designed for large volume repairs typically in excess of 50 mm deep. The product can be applied in sections generally up to 150 mm thick although greater thicknesses may be achievable dependent on the configuration
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Properties
Test method
S tandard
E N 1504 R4 Requirement
Result @ 1 D ay 14 MPa @ 3 D ays 30 MPa @ 7 D ays 42 MPa @ 28 D ays 60 MPa 2.0 MPa 0.03% 2.0 / 3.1 MPa C ompli es 31 GPa @ 28 days C lass A1
EN12190:1999 45 MPa
B ond strength by pull off: C hloride ion content: Freez e thaw cycling: R esistance to carbonation dk Elastic Modulus in C ompression Fire rating Setting time Fresh w et density Shrinkage 25 x 25 x 285 prisms, 27 OC , 55% R H Alkali reactive particles Flow Properties
EN 1542:1999 EN 1015-17: 2000 EN 13687-1: 2002 E N 13295: 2005 E N 13412 EN 13505-1 BS 4551 Pt14: 1980
2.0 MPa 0.05 2.0 ref concrete 20 GPa
Ini ti al set: 6 1/2 hours Fi nal set: 9 hours Nomi naly 2300 kg/m3 < 300 mi crostrai n @ 7 days < 500 mi crostrai n @ 28 D ays <1% vol% 1000 mm wi thi n 10 seconds
Method TI-B 52 UK Hi ghways Agency BD 27/86 C lause 4.6(b) Mi dlands Li nks Speci fi cati on C lause 1770A R
R esistivity
11800 ohm cm @ 28 D ays The low permeabi li ty of Renderoc LA 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.
Preparation The unrestrained surface area of the repair must be kept to a minimum. The formwork should be rigid and tight to prevent loss of material and have properly sealed faces to ensure that no water is absorbed from the repair material. The formwork should include drainage outlets for presoaking and, if beneath a soffit, provision for air-venting. Provision must also be made for suitable access points to pour or pump the mixed micro-concrete into place. 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 50 mm up to the sawn edge.
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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. 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. 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. Reinforcing steel priming Priming of the steel reinforcement is not normally necessary unless it is to remain exposed in an environment likely to cause corrosion after preparation. When required 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 Substrate priming Several hours prior to placing, the prepared concrete substrates should be saturated by filling the prepared formwork with clean water. Immediately prior to the application of Renderoc LA55, any excess water should be removed. 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 Renderoc LA55 is thoroughly mixed. A forced-action mixer is essential. Mixing in a suitably sized drum using an approved Conbextra Spiral Paddle with a slow speed (400/500 rpm) heavy-duty drill is acceptable. Free-fall mixers must not be used. Mixing of part bags should never be attempted. It is essential that machine mixing capacity and labour availability is adequate to enable the placing operation to be carried out continuously. Measure 3.3 litres of drinking quality water and pour three-quarters into the mixer. With the machine in operation, add one full 25 kg bag of Renderoc LA55 and mix for 1 minute before adding the rest of the water. Mix for a further 2 to 3 minutes until a smooth even consistency is obtained. Note that powder must always be added to water. The quantities mixed may be scaled up as required. When the drill and paddle mixing method is used, the complete 3.3 litres of water should be placed in the mixing drum. With the paddle rotating, add one full 25 kg bag of Renderoc LA55 and mix for 2 to 3 minutes until a smooth even consistency is obtained. It is recommended that the mixed product be passed through a suitable coarse metal screen prior to placing or pumping to highlight any unmixed material. Mixing warning As with other one pack repair mortars, Renderoc LA55 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. Placing The mixed material should be placed within 30 minutes of mixing in order to gain the full benefit of fluidity and of the expansion process. If placing by pump, standard concrete pumping practice should be followed. Consult the Fosroc Office for further details. Low temperature working In cold conditions down to 5C, the use of warm mixing water (up to 30C) 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 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed. High temperature working At ambient temperatures above 35C, the material should be stored in the shade and cool water used for mixing. Curing The formwork should be left in place until the compressive strength of the Renderoc LA55 is 10 MPa or as otherwise specified by the Supervising Officer. Renderoc LA55 is a cement-based concrete reinstatement material. In common with all cementitious materials, Renderoc LA55 must be cured immediately after the formwork is stripped in accordance with good concrete practice. Immediately after striking the formwork, all exposed faces of the repair should be thoroughly soaked with clean water and then sprayed with a liquid curing membrane such as Concure WB. 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.
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Overcoating with protective decorative finishes Renderoc LA55 is extremely durable and will provide long term protection to the embedded steel reinforcement withinthe repaired locations. The surrounding parts of the structure will generally benefit 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. All traces of form-release oils and curing membranes must be removed prior to the application of Dekguard products. This is best achieved by light grit blasting. Cleaning Renderoc LA55 and Concure WB should be removed from tools, equipment and mixers with clean water immediately after use. Cured material can only be removed mechanically. Equipment used with Nitoprime Zincrich Plus and Nitobond EP should be cleaned with Fosroc Solvent 102. Coverage and yield Renderoc LA55: Nitoprime Zincrich Plus: Nitobond EP: Concure WB: Approx. 12.0 litres / 25 kg bag 8 m2/litre 10 m2/ 4.5kg pack 5 m2/litre
Notes: 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.
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. Concure WB should be protected from frost.
Precautions
Health and safety For further information refer to the Safety Data Sheets available at www.fosroc.com.
Limitations
Renderoc LA55 should not be used when the temperature is below 5C and falling. Do not mix part bags. The product should not be used to reinstate horizontal areas where the surface would remain unrestrained during cure. It should not be exposed to moving water during application. If any doubts arise concerning temperature, application or substrate conditions, consult the local Fosroc office.
Fire
Renderoc LA55, Nitobond EP and Concure WB are nonflammable. 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
Estimating
Supply
Nitoprime Zincrich Plus: Renderoc LA55: Nitoprime Zincrich Plus: Nitobond EP: Concure WB: Fosroc Solvent 102: 25 kg bags 1.9 litre and 800 ml cans 4.5 kg packs 20 litre drums 5 and 25 litre tins Fosroc Solvent 102:
41C 33C

Important note
Fosroc Limited
www.fosroc.com
67
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CI/SfB: (4-) Pr4 November 2009
Fosroc Renderoc Plug

Rapid setting cement-based, water-stopping mortars conforming to the requirements of BS EN 1504 Class R1 Uses
For the rapid patching and plugging of concrete segments, concrete and brick tunnel linings, sewage systems, below ground access chambers, pipes, basements, foundations and mines.
Renderoc Plug 1 and Renderoc Plug 20 comply with class R1 according to BS EN 1504-3 repair principal 3.1 Renderoc Plug 20: Conforms to: Regulation 31 of the Water Supply (Water Quality) Regulations 2000 Regulation 31 of the Water Supply (Water Quality) Regulations 2001 in Wales Regulation 27 of the Water Supply (Water Quality)(Scotland) Regulations 2001 Regulation 30 of the Water Supply (Water Quality) Regulations (Northern Ireland) 2007
Advantages
Emergency water-stopping capability Single component Excellent bond to the substrate Low exotherm minimises thermal cracking Pre-bagged to overcome variations in site batching Chloride-free Renderoc Plug 20: Approved for use in public water supplies Renderoc Plug 20 : BS6920 listed product.
Fosroc Ltd, Drayton Manor Business Park, Coleshill Road, Tamw orth, Staffs, B78 3TL 09 0370-CPD-0845 EN 1504-3 Concrete repair products for non-structural repair CC mortar (based on modified hydraulic cement) Compressive strength Chloride ion content Adhesive bond Reaction to fire Dangerous substances Class R1 10 MPa) 0.05 % 0.8 MPa Class A1 Complies with 5.4
Description
Renderoc Plug are rapid setting mortars which are easy to apply to horizontal, vertical or overhead surfaces at a wide range of thicknesses. There are two grades available: Renderoc Plug 1 with an initial set time of approximately 1 minute, and Renderoc Plug 20 with an initial set time of approximately 20 minutes. (Set times are based on ambient/substrate temperatures of 20C.)
Properties Material tested at a water:powder ratio of 1:3 by volume and temperature at 20oC
Test method Standard EN 1504 R1 Requirement 10 MPa 0.8 MPa 0.05 % Test result Renderoc Plug 1 @ 1 Hour 10 MPa @ 1 Day 19 MPa @ 28 Days 23 MPa 0.8 MPa @ 28 Days 0.01% Class A1 NonCombustible Approximately 1 minute Test result Renderoc Plug 20 @ 6 Hours 7 MPa @ 1 Day 11 MPa @ 28 Days 45 MPa 1.1 MPa @ 28 Days 0.01% Class A1 NonCombustible Approximately 20 minutes
Compressive Strength
EN 12190:1999
Bond strength by pull off: Chloride ion content: Fire rating Inital Setting time @ 20 oC
EN 1542:1999 EN 1015-17:2000 EN 13501-1 -
Clarification of property values: The typical properties given are derived from laboratory testing. Results derived from
field applied samples may vary.
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Fosroc Renderoc Plug

Preparation Areas to be patched should be cut back to a depth of 15 mm and given a good mechanical key. Feather-edges must not be allowed. Surface should be brushed clean to remove loose material, dust and laitance. Grease, slime or mould growth should be removed by steam cleaning or high-pressure water jetting. A proprietary degreasing agent should be used for removal of light oil or grease contamination. To seal leaks, crack openings must be chased out to approximately 20 mm square. The chase should always be undercut to avoid leaving a v-section. All loose material and debris should be removed. Mixing Renderoc Plug should be added to clean water in the following proportions: One part clean water to three parts Renderoc Plug (by volume). Mix to a stiff consistency in a suitable mixing vessel, using a trowel or gloved hand. Due to the rapid set characteristics of the product, only prepare a quantity of mortar which can be placed within the prescribed set time. Application Trowel apply or hand-knead the mixed mortar in place, ensuring maximum contact with the substrate before the material sets. No priming system is required but the substrate must be in a saturated surface dry state before application. If being used to plug running water, Renderoc Plug 1 should be used and held in place until the initial set is reached. The minimum application thickness of Renderoc Plug products is 15 mm. Low temperature working In cold conditions down to 1C, the use of warm water (up to 20C) is advisable to accelerate strength development. Normal precautions for winter working with cementitious materials should be adopted. The material should not be applied when the substrate and/or air temperature is 1C and falling. At 1C static temperature or at 1C and rising, the application may proceed. Set and cure times will be increased at low temperatures. If in doubt contact the local Fosroc office. High temperature working At ambient temperatures above 35C, the material should be stored in the shade and cooler water (down to 20C) used for mixing. Set and cure times will be reduced at high temperatures. Cleaning Renderoc Plug products should be removed from equipment with clean water prior to the initial set. Cured material can only be removed mechanically.
Estimating
Renderoc Plug 1 is supplied in 6 kg bags each yielding 3 litres. Renderoc Plug 20 is supplied in 25 kg bags each yielding 12.5 litres.
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 conditions the shelf life may be reduced to less than 6 months.
Precautions
Health and safety For further information, refer to the Safety Data Sheets available at www.fosroc.com. Fire Renderoc Plug products are non-flammable.
Important note
Fosroc Limited
www.fosroc.com
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Fosroc Renderoc RP252

Two component fibre and polymer modified cementitious mortar for re-profiling and protection conforming to the requirements of BS EN 1504-3 Class R3 Uses
Renderoc RP252 is designed for application from 3 mm to 20 mm to produce a smooth render finish to concrete or masonry surfaces. It can be used either to produce a surface in readiness for a protective coating or as a protective mortar layer. Renderoc RP252 can be used independently to infill surface imperfections and voids or to render large sections of concrete. Renderoc RP252 is suitable for repair methods 3.1, 7.1 and 7.2 as defined by BS EN1504-3.
The cured re-profiling mortar shall achieve a compressive strength of 42 MPa and a shrinkage of less than 300 microstrain at 7 days. Protection mortar The protection mortar shall be Renderoc RP252, a two component monofilament fibre reinforced modified cementbased blend of powders and liquid polymer conforming to the requirements of BS EN 1504-3 Class R3. The cured mortar shall achieve a compressive strength of 42 MPa and a shrinkage of less than 300 microstrain at 7 days.
Standards Compliance
Renderoc RP252 has been approved by the British Board of Agrment, Certificate No 98/3461. Conforms to the requirements of BS EN 1504-3 Class R3 repair methods 3.1, 7.1, and 7.2.
Advantages
Easy to use Wide range of application thicknesses Low permeability provides protection against carbon dioxide and water-borne chlorides Excellent bond to the concrete substrate Pre-blended to overcome site-batched variation Shrinkage compensated
Description
Renderoc RP252 is supplied as a ready to use blend of dry powders and polymer emulsion which when mixed produce a highly consistent cementitious re-profiling and protection mortar. The product exhibits excellent thermal compatibility with concrete and is compatible with other Renderoc mortars and Dekguard coatings. Renderoc RP252 is designed for vertical or horizontal use. It can be applied as a render from 3 mm to a practical maximum depth of 15 to 20 mm on verticals and 10 mm on soffits. On horizontal surfaces greater thicknesses e.g. 25 mm can be applied, however other grades of Renderoc may be more appropriate. Prior to the application of Renderoc RP252 any necessary repairs to the concrete should be undertaken using the Fosroc Systematic Approach. Consult the local Fosroc office for further information.
Fosroc Ltd, Drayton Manor Business Park, Coleshill Road, Tamw orth, Staffs, B78 3TL 09 0370-CPD-0845 EN 1504-3 Concrete repair products for structural repair PCC mortar (based on polymer modified hydraulic cement) Compressive strength Chloride ion content Adhesive bond Carbonation resistance Thermal compatibility / freeze thaw Reaction to fire Dangerous substances Class R3 ( 25 MPa) 0.05% 1.5 MPa dk control concrete 1.5MPa A 2 s1 d 0 Complies with 5.4
Re-profiling mortar The re-profiling mortar shall be Renderoc RP252, a two component, monofilament fibre reinforced modified cementbased blend of powders and liquid polymer conforming to the requirements of BS EN 1504-3 Class R3.
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Properties
The following results were obtained at a temperature of 20oC
Test method
Standard
EN 1504 R3 Requirement 25 MPa 1.5 MPa 0.05 % 1.5 MPa dk ref concrete -
Result @ 1 Day 7 MPa @ 7 Days 20 MPa @ 28 Days 42 MPa 2.8 MPa 0.02% 2 MPa Conforms Class A2 s1 d0 Non Combustable Initial set: 5 hours Final set: 8 hours Nominally 1900 kg/m3 < 300 microstrain @ 7 days 1.0 vol % The low permeability of Renderoc RP 252 severely retrads chemical attack in aggressive environments. The cured mortar is impermeable to acid gases, waterborne chloirde ions and oxygen.
Compressive Strength Bond strength by pull off: Chloride ion content: Freez e thaw cycling: Resistance to carbonation dk Reaction to fire Setting time Fresh w et density Shrinkage (25 x 25 x 285 prisms, 20Oc, 65% RH Alkali reactive particles
EN 12190:1999 EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 EN 13295:2005 EN 13823:2002 BS 4551 Pt 14:1980
Method TI-B 52
Chemical resistance
Build Characteristics hand applied Minimum thickness: Vertical:
3 mm Up to 20 mm
Clarification of property values:The typical properties given above are derived from laboratory testing. Results derived from testing field applied samples may vary.
Preparation All surfaces should be free from contamination. 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 conditioning The cleaned areas should be blown clean with oil-free compressed air before continuing. All prepared areas should be saturated surface dry immediately before the application of one coat of Renderoc RP252 Surface Conditioner, i.e. they should be thoroughly saturated with clean water and any residual surface water removed. Under severe drying conditions and on highly absorbent substrates, repeated soaking will be necessary. The Renderoc RP252 Surface Conditioner should be scrubbed well into the surface and
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Renderoc RP252 should be applied before the conditioner dries (film forms). Care should be taken to ensure that water does not run over fresh areas applied for less than 12 hours. In circumstances where a barrier is required between substrate and mortar, or where the substrate is likely to remain permanently damp, Nitobond EP bonding aid should be used. Contact the local Fosroc office for further information. Recently executed Renderoc mortar repairs require no additional preparation prior to the application of Renderoc RP252. Mixing Care should be taken to ensure that Renderoc RP252 is thoroughly mixed using a forced action mixer or in a suitably sized drum using a Renderoc Mixing Paddle in a slow speed (400/500 rpm) heavy-duty drill. Place all the Renderoc RP252 liquid polymer into the mixer and with the machine in operation, add one full bag of Renderoc RP252 powder and mix for a minimum of 3 minutes to a maximum of 5 minutes until homogeneous. Do not subsequently re-temper with extra water. Renderoc RP252 powder must be added to Renderoc RP252 liquid. Part-bag mixing is not permitted. Mixing warning As with other repair mortars, Renderoc RP252 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. Application Apply the Renderoc RP252 to the prepared substrate by steel, wood or plastic float from 3 mm minimum to the maximum practical thickness. The initial application should be worked firmly into the prepared surface as a scrape coat to provide a key to subsequent material. Further build of material should be applied in wet on wet layers. It should be finished with a minimum of working. If sagging occurs during application, the Renderoc RP252 should be completely removed and reapplied at a reduced thickness. Build-up Additional build-up can be achieved by application of multiple layers. The final thickness is dependent on the material consistency and substrate profile. The surface of the intermediate layers should be comb scratch-keyed and cured with Nitobond AR. A further application of Renderoc RP252 may proceed, without the necessity of RP252 Surface Conditioner as soon as this layer has set. Finishing Renderoc RP252 can be finished using several different techniques. Screed rails and guide wires can be used to advantage on large areas. Steel, wood and plastic floats can all be used to achieve the desired surface texture. The use of a damp sponge to remove trowelling marks is recommended. The completed surface should not be over worked. Low temperature working In cold conditions down to 5C normal precautions for winter working with cementitious materials should be adopted. At 5C static temperature or at 5C and rising, the application may proceed. High temperature working At ambient temperatures above 35C the materials should be stored in the shade. Curing Renderoc RP252 must be cured immediately after finishing in accordance with good concrete practice. The use of Nitobond AR sprayed onto the surface of the finished Renderoc in a continuous film is recommended. A low pressure atomising sprayer is essential for applying the Nitobond AR. Any excessive run-off on verticals or drips on soffits should be removed by brush before they harden. Large areas should be cured as trowelling progresses (0.5 m at a time) without waiting for completion of the entire area. In fast drying conditions, supplementary curing with polythene sheeting taped down at the edges should be used. In cold conditions, the finished repair must be protected from freezing. Overcoating with protective decorative finishes Renderoc RP252 may be overcoated with Fosrocs Dekguard range of protective primers/decorative coatings. The Renderoc RP252 should be primed/cured as trowelling progresses with Nitobond AR, applied as above and allowed to cure for 48 hours prior to the application of the topcoat. Cleaning Renderoc RP252, Nitobond AR, Renderoc RP252 Surface Conditioner should be removed from tools, equipment and mixers with clean water immediately after use. Cured material can only be removed mechanically.
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Renderoc RP252
Estimating
Supply Renderoc RP252: Renderoc RP252 Surface Conditioner: Nitobond AR: 20 kg bags, 3.4 litre bottles 5 and 25 litre drums 5 and 25 litre drums
Precautions
Health and safety For further information refer to the appropriate Safety Data Sheet available at www. fosroc.com. Fire Renderoc RP252, Nitobond AR and Renderoc RP252 Surface Conditioner are non-flammable.
Coverage and yield Renderoc RP252: Renderoc RP252 Surface Conditioner: Nitobond AR: 12 litres per pack (approximately 2.4 m at 5 mm thickness) 7 to 9 m/litre 6 to 8 m/litre
Notes: 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.
Limitations
Renderoc RP252 should not be used when the temperature is below 5C and falling. Due to the nature of Renderoc RP252, the product should not be used in areas subjected to traffic. Renderoc RP252 should not be exposed to moving water during application. Exposure to heavy rainfall before 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 packs. 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. Renderoc RP252 liquid, Renderoc RP252 Surface Conditioner and Nitobond AR should be protected from frost.
Important note
Fosroc Limited
Drayton Manor Business Park Coleshill Road, Tamworth, Staffordshire B78 3TL. UK telephone: +44 (0) 1827 262222 fax: +44 (0) 1827 262444 73 email: uk@fosroc.com
www.fosroc.com
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Fosroc Renderoc S
High performance concrete reinstatement mortar conforming to the requirements of BS EN 1504-3 Class R4 Uses
For the reinstatement of reinforced concrete where low permeability characteristics are required and where high compressive strength and abrasion resistance is a consideration. Where compatibility with lower strength concrete is required, Renderoc HB30 should be used. Renderoc S has been specificaly developed for the repair of large areas of concrete and also localised patch repairs. Where high build vertically and overhead is required Renderoc HB30 or Renderoc HB45 should be used. Renderoc S issuitable for repair methods 3.1,3.3, 4.4, 7.1, 7.2 as defined by BS EN 1504-9.
Therepair mortar shall be Rendreoc S a one component polymer modified high build cementitious mortar conforming to the requirements of BS EN 1504-3 ClassR4 The cured mortar shall acieve a compressive strength of 55 MPa at 28 days and a drying shrinkage of < 300 microstrain at 7 days. Standards compliance Renderoc S complies with the classification R4 according to EN1504-3, repair methods 3.1, 3.3, 4.4, 7.1 and 7.2. Renderoc S, Nitoprime Zincrich Plus and Nitobond AR have been approved by the British Board of Agrement, Certificate number 98/3461
Advantages
Maximum compatibility with concrete of compressive strength 30 - 60 MPa High abrasion resistance Polymer-modification provides extremely low permeability to water, carbon dioxide and chlorides Exceptional system of shrinkage compensation provides long-term dimensional stability Can be applied quickly and efficiently by wet spraying One component, pre-bagged to overcome site-batched variations Contains no chloride admixtures
Fosroc Ltd, D rayton Manor B usiness Park, C oleshill R oad, Tamw orth, STAFFS, B 78 3TL 09 0370-C PD -0845 EN 1504-3 C oncrete repai r products for structural repai r PC C mortar (based on polymer modi fi ed hydrauli c cement) C ompressi ve strength C hlori de i on content Adhesi ve bond strength Adhesi ve bond strength after freeze thaw thermal cyycli ng C arbonati on resi stance Elasti c modulus i n compressi on Reacti on to fi re D angerous substances C lass R4 ( 45 MPa) 0.05% 2.0 MPa 2.0 MPa dk control concrete 20 GPa C lass A2 s1 d0 C ompli es wi th 5.4
Description
Renderoc S 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. Renderoc S has been specifically engineered for vertical or horizontal use. It can be applied up to 10 mm thickness in vertical locations and up to 100 mm thickness in horizontal locations in a single application. Thicker sections can be built up in layers. Thicknesses vertically greater than 10 mm can be achieved by spray application. For horizontal trafficed locations individual bays should not exceed 4 m-2 in area. Renderoc S can be quickly and efficiently applied by the wet spray technique. Consult the local Fosroc office for further information. The material should not be applied at less than 5 mm thickness.
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Properties
Test method S tandard E N 1504 R4 Requirement 45 MPa 2.0 MPa 0.05 % 2.0 MPa dk ref concrete 20 GPa Result @ 1 D ay 20 MPa @ 28 D ays 55 MPa 2.1 MPa 0.03% 2.0 MPa C ompli es 37 GPa C lass A2 s1 d0 Non-C ombustable 13.8 MPa @ 28 days Ini ti al set: 3 hours Fi nal set: 5 hours Nomi naly 2150 Kg/m3 < 300 mi crostrai n @ 7 days 1.0% vol % The low permeabi li ty of Renderoc S severely retards chemi cal attack i n aggressi ve envi ronments. The cured mortar i s i mpermeable to aci d gases, waterborne chlori de i ons and oxygen.
C ompressive Strength B ond strength by pull off: C hloride ion content: Freez e thaw cycling: R esistance to carbonation dk Elastic Modulus in C ompression Fire rating Flexural strength Setting time Fresh w et density Shrinkage 25 x 25 x 285 prisms, 27 OC , 55% R H Alkali reactive particles
EN 12190:1999 EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 E N 13295: 2005 E N 13412 EN 13505-1 B S 6319 P t 3: 1990 BS 4551 Pt 14:1980
Method TI-B 52
B uild C haracteristics hand applied Minimum thickness: Vertical: H oriz ontal:
Clarification of property values: The typical properties given above are derived from laboratory testing. Results derived from testing field applied samples may vary.
Preparation Saw cut the edges of the repair to a depth of at least 5 mm to provide a square edge. Break out the complete repair area to a minimum depth of 5 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. 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. 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. 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.
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Concrete Priming 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 Nitobond AR. Under severe drying conditions repeated soaking may be necessary to ensure the substrate is still saturated at the time of application of the primer. Scrub Nitobond AR into the surface. Renderoc S can be applied as soon as the primer becomes tacky. If the Nitobond AR is too wet, vertical build up of the Renderoc S mortar may be difficult. In all areas subject to trafficking, where a substrate/repair barrier is required or where the substrate is wet or likely to remain permanently damp, Nitobond EP bonding aid should be used. Contact the local Fosroc office for further information. Mixing Care should be taken to ensure that Renderoc S 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. For normal applications, place 2.5 to 3.0 litres of drinking quality water into the mixer. With the machine in operation, add one full bag of Renderoc S and mix, for a minimum of 3 minutes and a maximum of 5 minutes, until fully homogeneous. The consistancy may be adjusted by the addition of small amounts of water up to the maximum total water content of 3.0 litres. Note that the powder must always be added to the water. Mixing warning As with other one pack repair mortars, Renderoc S 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. Application Exposed steel reinforcing bars should be firmly secured to prevent movement during application. Apply the mixed Renderoc S by gloved hand or trowel, thoroughly compacting onto the primed substrate and around exposed reinforcment. If sagging or slumping occurs the Renderoc HB should be completly removed and reapplied at a reduced thickness to a correctly reprimed substrate. Build-up Additional build-up can be achieved by application of multiple layers. The final thickness is dependent on the material consistency and substrate profile. The surface of the intermediate layers should be comb scratch-keyed and cured with Nitobond AR. Reprime with Nitobond AR and a further application of Renderoc S may proceed as soon as this layer has set. Spray application Renderoc S can be quickly and efficiently applied by the wet spray technique. In circumstances where large areas of repair are required, the rapid placement and higher build attainable by this method offer economic advantages over hand-trowelling. The resultant repair also offers a generally more dense compound with enhanced mortar/substrate bond characteristics. For further details on wet spray techniques contact the local Fosroc office. Finishing Renderoc S is finished by striking off with a straight edge and closing with a steel float. Wooden or plastic floats, or damp sponges, may be used to achieve the desired surface texture. The completed surface should not be overworked. After spray application, the mortar may need to be cut back to the required profile using a steel float and then finished with damp sponges as described above. Low temperature working In cold conditions down to 5C, the use of warm mixing water (up to 30C) 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 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed. High temperature working At ambient temperatures above 35C, the material should be stored in the shade and cool water used for mixing. Curing Renderoc S 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 Nitobond AR, 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 Nitobond AR. Any excessive run-off on verticals or drips on soffits should be removed by brush before they harden.
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Large areas should be cured as trowelling progresses (0.5 m2 at a time) without waiting for completion of the entire area. 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. Overcoating with protective decorative finishes Renderoc S is extremely durable and will provide long-term protection to the embedded steel reinforcement within the repaired locations. The surrounding parts of the structure will benefit from the application of a barrier/decorative coating to limit the advance of chlorides and carbon dioxide, bringing them 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. Other curing membranes must be removed prior to the application of Dekguard products. Cleaning Renderoc S and Nitobond AR 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 material cures, using Fosroc Solvent 102. Notes: the actual yield per bag of Renderoc S will depend on the consistency used. The yield will be reduced if the material is applied by a spray technique.
Limitations
Renderoc S should not be used when the temperature is below 5C and falling. Do not mix part bags. Renderoc HB is not suitable for use in areas subjected to traffic (in these circumstances, Renderoc S should be considered). Renderoc S 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.
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. Nitobond AR should be protected from frost.
Precautions
Health and safety For further information refer to the appropriate Safety Data Sheets available at www.fosroc.com. Fire Renderoc S is non-flammable.
Estimating
Supply Renderoc S: Nitoprime Zincrich Plus: Nitobond AR: Fosroc Solvent 102: Coverage and yield Renderoc S: Approximately 12 litres / 25 kg bag (approximately 1.2 m at 10 mm thickness) 8 m2/ litre 6 - 8 m2/ litre 25 kg bags 1.9 litre and 800 ml cans 5 and 25 litre drums 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: Fosroc Solvent 102: 41C 33C
Nitoprime Zincrich Plus: Nitobond AR:

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Renderoc SC
Polymer modified dry spray repair mortar conforming to the requirements of BS EN 1504-3 Class R4 Uses
Renderoc SC is designed for large area repairs such as bridges, tunnels, retaining walls, dams, etc. Renderoc SC is suitable for repair method 3.3, 7.1, 7.2 as defined by BS EN 1504-3.
Renderoc SC complies with class R4 according to BS EN 1504-3 repair principal 3.3.
Advantages
Low rebound Rapid strength gain Low water absorption and chloride ion diffusion High resistance to carbon dioxide penetration Excellent bond to the concrete substrate Single component ready to use No added caustic accelerators Contains no chloride admixtures
Fosroc Ltd, Drayton Manor Business Park, Coleshill Road, Tamworth, Staffs, B78 3TL 09 0370-CPD-0845 EN1504-3 Concrete repair products for structural repair CC mortar (based on polymer modified hydraulic cement) Compressive strength Chloride ion content Adhesive bond strength Adhesive bond strength after freeze thaw thermal cycling Carbonation resistance Reaction to fire Dangerous substances Class R4 ( 45 MPa) 0.05% 2.0 MPa 2.0 MPa dk control concrete Class A1 Complies with 5.4
Description
Renderoc SC is supplied as a ready to use blend of dry powders which is formulated for application using the dry spray process. The material is based on Portland cements graded aggregates silica fume, and chemical additives which provides a spray mortar with low rebound and handling characteristics. The low water requirement ensures good strength gain and long term durability. Builds of up to 150 mm vertically and 75 mm overhead can be achieved in a single application.
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Fosroc Renderoc SC
Properties
The following results were obtained at a temperature of 20C.
Test method
Standard
EN 1504 R4 Requirement 45 MPa 2.0 MPa 0.05 % 2.0 MPa dk ref concrete
Result @ 1 Day 20 MPa @ 7 Days 45 MPa @ 28 Days 60 MPa 2.7 MPa 0.02% 2.5 MPa Complies Class A1 Non-Combustible
Compressive Strength Bond strength by pull off: Chloride ion content: Freez e thaw cycling: Resistance to carbonation dk Fire rating Flexural strength Setting time Fresh w et density Shrinkage 25 x 25 x 285 prisms, 27 OC, 55% RH Alkali reactive particles Resistivity Coefficient of thermal Expansion
EN 12190:1999 EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 E N 13295: 2005 EN 13505-1 B S 6319 P t 3: 1990 BS 4551 Pt 14:1980
10 MPa @ 28 days Initial set: 3.5 hours Final set: 5.0 hours Nominaly 2200 Kg/m3 < 300 microstrain @ 7 days 1.0% vol % 28 - 30000 ohm cm 15x 10 -6 /oC The low permeability of Renderoc SC severely retards chemical attack in aggressive environments. The cured mortar is impermeable to acid gases, waterborne chloride ions and oxygen.
Method TI-B 52 -
Chemical resistance
Build Characteristics Minimum thickness: Vertical: Horiz ontal: 10 mm Up to 150 mm Up to 75 mm
Clarification of property values: The typical propertiesgiven are derived from laboratory testing. results derived
from testing field applied samples may vary
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Fosroc Renderoc SC
Preparation 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, i.e. concrete is sound and of good quality, but cover is to be increased, roughen the surface and remove any laitance by light scabbling or abrasive-blasting. It will still be necessary to cut back the perimeter to a depth of 10 mm so that the repair patch may be toed-in and finished flush with the surrounding concrete. 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. 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. 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. Reinforcing steel priming Extra protection to the reinforcing steel can be achieved by application of one full coat of Nitoprime Zincrich Plus and allowing to dry before continuing. If any doubt exists about having achieved an unbroken coating, a second applicatin should be made and, again, allowed to dry before continuing. Substrate priming Soak the prepared concrete surface thoroughly, allowing surplus water to drain off. Application Exposed steel reinforcing bars should be firmly secured to avoid movement during the application process as this will affect mortar compaction, build and bond. Renderoc SC should be emptied from the bags directly into the hopper of the dry spray process machine. The amount of water added should be controlled by the nozzleman. Too little water will increase rebound and dust emission, too wet a mix will slump. If sagging occurs during application to vertical or overhead surfaces, the Renderoc SC should be completely removed and re-applied. Finishing Renderoc SC is finished by striking off with a straight edge and closing with a steel float. Wooden or plastic floats, or damp sponges may be used to achieve the desired surface Equipment used with Nitoprime Zincrich Plus should be cleaned with Fosroc Solvent 102. texture. The completed surface should not be overworked. Low temperature working 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 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed. High temperature working At ambient temperatures above 35C, the material should be stored in the shade. Curing Renderoc SC is a cement-based mortar. In common with all cementitious materials, Renderoc SC must be cured immediately after finishing in accordance with good concrete practice, i.e. using a curing membrane, Concure WB or wet hessian or polythene. Concure WB should not be used when a subsequent coating is to be applied or cathodic protection systems are to be used. In cold conditions, the finished repair must be protected from freezing. Cleaning Renderoc SC should be removed from tools, equipment and mixers with clean water immediately after use. Cured material can only be removed mechanically.
Estimating
Supply Renderoc SC: Nitoprime Zincrich Plus: Fosroc Solvent 102: Concure WB: Coverage and yield Renderoc SC: Nitoprime Zincrich Plus: Concure WB: Approx. 12.5 litres / 25 kg bag (approx. 80 bags/m) 8 m2/litre 3.5 - 5.0 m2/litre 25 kg bags 1.9ltr and 800ml cans 5 and 25 litre tins 20 and 200 litre drums
Notes: The actual yield per bag of Renderoc SC will depend on the water addition during application. The coverage figures are theoretical due to wastage factors and the variety and nature of possible substrates, practical coverage figures will be reduced.
Limitations
Renderoc SC should not be used when the temperature is below 5C and falling. The product should not be exposed to
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Fosroc Renderoc SC
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 Customer Services Department.
Storage
Precautions
Health and safety For further information, refer to th eappropriate Safety Data Sheet available at www.fosroc.com.
Fire
Renderoc SC is non-flammable. Concure WB is non-flammable.. Nitoprime Zincrich Plus and Fosroc Solvent 102 are flammable. Keep away from sources of ignition. No Smoking. In the event of fire, extinguish with CO2 or foam. Do not use a water jet. Flash points Nitoprime Zincrich Plus: Fosroc Solvent 102: 41C 33C
Important note
Fosroc Limited
www.fosroc.com
81
Fosroc Renderoc ST 05
Protective cementitious coating and levelling mortar for applications from feather edge to 5mm conforming to the requirements of BS EN 1504-3 Class R4 Uses For application in thin layers, the filling of blow-holes or imperfections in concrete to produce a smooth surface. Providing a chloride and carbonation barrier. It can be left as a fair-face finish or overcoated. It can be used as a scrape-coat, brush or trowel applied, placed in thicknesses from 0-5 mm. Renderoc ST 05 is suitable for repair methods: 1.3, 2.2, 5.1, 6.1 and 8.2 as defined by BS EN 1504-2: 3.1, 7.1 and 7.2 as defined by BS EN 1504-3 Advantages Easy to mix and apply Vertical and horizontal applications Excellent bond to concrete without priming Formulated blow hole filler Carbonation barrier Chloride barrier High frost resistance High compressive strength Description Renderoc ST 05 consists of powder and polymer components The powder is added to the liquid, the mixing ratio depends on the required consistency and use. The powder consists of a blend of cements, graded aggregates and chemical additives, with a maximum grain sizes of 0.5 mm The liquid component, based on modified acrylic polymers, gives Renderoc ST 05 a creamy consistency with extremely good application and barrier characteristics. The product exhibits excellent thermal compatibility with concrete and is fully compatible with other Renderoc mortars and Dekguard coatings. Exposure to rainfall prior to the final set may result in water uptake and severe reduction in the performance of
CI/SfB: (4-)D7q4 November 2009
the hardened product. Exposure to mist or high humidity prior to sufficient hardening may result in discolouration of the surfaces. These white discolourations will decrease with time. Standards Compliance Renderoc ST 05 complies with repair principles 1.3, 2.2, 5.1, 6.1 and 8.2 as defined by BS EN 1504-2 Renderoc ST 05 complies with Class R4 according to BS EN 1504-3, repair principles 3.1, 7.1, 7.2.
Fosroc Ltd, Drayton Manor Business Park, Coleshill Road, Tamw orth, STAFFS, B78 3TL 09 0370-CPD-0845 EN 1504-2-3 Surface protection systems Concrete repair products for structural repair PCC mortar (based on polymer modified hydraulic cement) Compressive strength Chloride ion content Adhesive bond strength Adhesive bond strength after freeze thaw thermal cyycling Carbonation resistance Reaction to fire Dangerous substances Abrasion resistance Impact resistance Permeability to CO2 Permeability to water vapour Liquid water transmission rate Class R4 (>45 MPa) <0.05% >2.0 MPa
>2.0 MPa
dk<control concrete Class A2 s1 d0 Complies with 5.4 weight loss <3000mg Class III sd>50m Class I w<0.1 Kg/m2h0.5
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Properties Material tested at liquid : powder ratio of 0.22 and temperature at 20C
Test method S tandard E N 1504 Requirement Result
EN 12190:1999
45 MPa
@ 1 D ay 13 MPa @ 3 D ays 26 MPa @ 7 D ays 37 MPa @ 28 D ays 50 MPa 2.8 MPa 0.01% 2.7 MPa C ompli es C lass A2 S1 d0 ( noncombusti ble)
B ond strength by pull off: C hloride ion content: Freez e thaw cycling: R esistance to carbonation dk Fire rating Flexural strength
EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 EN 13295:2005 EN 13505-1 BS 6319 Pt 3:1990
2.0 MPa 0.05 % 2.0 MPa ref concrete
11 MPa @ 28 D ays Aproxi mately 60 mi nutes dependant on thi ckness of layer, temperature and porosi ty of substrate. Nomi nally 1950 Kg/m3 1 % vol%
Setting time
Fresh w et density Alkali reactive particles Method TI-B 52
Hardness reducti on <50% C lass III -28 days wi th pressure 0.5 kg/m2h-0.5 2MPa 0.1 kg/m2h-0.5 S d > 50m Wei ght loss < 3000mg Class III 20Nm -
R esistance to severe chemical attack C apillary absorption Application of repair mortar overhead Permeability to w ater vapour D etermination of liquid w ater transmission Permeability to C O2 Abrasion R esistance Impact resistance C hloride ion ingress
E N 13529
C lass III i n groups 3,10,11,12,14a
E N 13057 EN 13395-4 EN ISO 7783-2 EN 1062-3 EN 1062-6 EN ISO 5470-1 EN ISO 6272-1 E N 13396
0.2 kg/m2h-0.5 2.8 MPa Sd 0.48m (C lass I) 0.08 kg/m2h-0.5 S d= 57m 2785 mg 24.5 Nm 0.171% after 6 months i n 3% NaC l soln at 4-6 mm depth
Clarification of property values:The typical properties given above are derived from laboratory testing. Results derived from testing field applied samples may vary.
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Build characteristics :
Thickness
Volume of Liquid p er b ag p o w d er
Coverage per pack (Coverage can vary due to substrate)
Vertical applications Brush / roller Trowel Trowel blow hole filler Horizontal applications Trowel/ screed Brush / roller
1mm 2 mm Skim applied
4.5 -5.0 litres 4.0 - 4.5 litres 5 litres
11.5 - 12 m2 @ 1 mm 5.5 - 5.75 m2 @ 2mm Circa 12m2 dependent on surface
4 mm 4 mm
4.5 - 5 litres 5 litres
2.9 m2 @ 4 mm 3.0 m2 @ 4 mm
Preparation Surfaces must be clean and sound, with no traces of loose material, cement paste, laitance, dust, plaster, oil, grease, corrosion deposits or algae. Prepare the surfaces by abrasive grit blasting or light scabbling. Remove oil and grease with suitable detergent. Finally the cleaned surfaces should be blown clean with oil free compressed air before continuing. On floors, large pockets greater than 4 mm depth should be filled with Fosroc XR90, finished with a scratched surface. Allow one hour to cure before application of Renderoc ST 05. Pre-soaking All prepared areas should be thoroughly soaked with clean water prior to application of Renderoc ST 05, to achieve a saturated surface dry condition. Any residual surface water should be removed prior to application. Priming Under normal circumstances priming is not required. However, porous substrates may require sealing with Nitobond AR. This is scrubbed onto the pre-wetted substrate and allowed to become tacky before applying Renderoc ST 05. Mixing Renderoc ST 05 should be mixed in a forced action mixer of adequate capacity. Mixing in a suitable sized drum using a Conbextra paddle with a slow speed (500 rpm) heavy-duty drill is acceptable. Place the required amount of Renderoc ST 05 liquid component - see table - in the mixer and add the full bag of Renderoc ST 05 powder . Mix for 5 minutes until fully homogeneous. Let the mix rest for 5-10 minutes and adjust the consistency, if necessary by addition of additional liquid
component. Mix for another minute until the required consistency is obtained. Polymer level can be varied to application method. Mixing ratios: Brush coating - 5.0 ltrs liquid : 20 kg powder Fairing coat - 4.0 ltrs liquid : 20 kg powder The above mixing ratios can be used as guidelines. Part packs can be mixed provided mix ratios are maintained. Application Renderoc ST 05 can be applied by brush, roller or trowell depending on consistency and application. See table. The surface finish of the final coat can be obtained in the following ways: I) Smooth surface: Finish with a sponge. II) Rough, granulated surface: Finish with a roller. III) Skid resistant surface: Sprinkle dry quartz sand in the wet surface or brush finish. Multiple layers When applying multiple layers, allow the first application to dry for between 2-4 hours (at 20oC). Lightly scratch and dampen surface between layers. Patches at 300 mm2 or less can be applied up to 5mm in one application when cured. Low temperature working Normal precautions for winter working with cementitious materials should be adopted. In cold conditions down to +5C, both components should be kept at +15C to +25C. Protect applied product from freezing for the first 24 hours. Note: working time and time taken to gain strength will be increased at lower temperatures. High temperature working At ambient temperatures above 35oC both components should be stored in the shade. Note working times will be reduced at elevated temperatures.
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Curing Renderoc ST 05 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 Nitobond AR, 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 Nitobond AR. Any excessive run-off on verticals or drips on soffits should be removed by brush before they harden. Large areas should be cured as trowelling progresses (0.5 m2 at a time) without waiting for completion of the entire area. Overcoating with protective decorative finishes Renderoc ST 05 is extremely durable and will provide longterm protection to the embedded steel reinforcement within the repaired locations. The surrounding parts of the structure will benefit from the application of a barrier/decorative coating to limit the advance of chlorides and carbon dioxide, bringing them 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. Other curing membranes must be removed prior to the application of Dekguard products. Cleaning Renderoc ST 05 should be removed from tools, equipment and mixers with clean water immediately after use. Cured material can only be removed mechanically. Not suitable for heavily trafficked floors.
Estimating
Supply Renderoc ST 05 is supplied in 20kg bags of powder and 5.0 litres of liquid. Coverage and yield Approximatly 12 litres per pack depending on mix ratio see table.
Limitations
Renderoc ST 05 should not be applied when the substrate and/or air temperature is below +5C and falling.
Storage
Renderoc ST 05 Powder has a shelf life of 12 months if kept in a dry store in the original, unopened packaging. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced. Renderoc ST 05 Liquid should be protected against frost. If the product has been exposed to frost and the liquid component becomes grainy, it should not be used.
Precautions
Health and safety For further information refer to the Safety Data Sheets available at www.fosroc.com. Fire Rendreroc ST 05 is non-flammable.
Important note
Fosroc Limited
Drayton Manor Business Park Coleshill Road, Tamworth, Staffordshire B78 3TL. UK telephone: +44 (0) 1827 262222 fax: +44 (0) 1827 262444 85 email: uk@fosroc.com
www.fosroc.com
Fosroc Expocrete UA
Two-part epoxy resin mortars Uses
For use in exceptionally wet conditions and for underwater applications.
CI/SfB: Yr4 June 2006
Mixing Expocrete The 1.5 litre packs of Expocrete are suitable for hand mixing (wearing protective gloves) on a flat, clean surface. The mixing surface should be wetted and the whole of the base material spread out approximately 10 to 20 mm thick. All of the hardener should be emptied out onto the middle of the base and the base folded over the hardener and kneaded until the resultant mortar is of an even consistency and uniform colour. Underwater application Surfaces must be mechanically cleaned, free of weak or loose material, marine growth, rust, scale, etc. Mixed Expocrete UA should be carried in plastic bags to work area and small quantities, approximately 5 mm thick, pressed into position ensuring that all water is expelled from between the repair surface and the Expocrete UA. Mixed mortar should be applied within 30 minutes of mixing. Contact between the mixed mortar and water should be avoided until the point of application. Uncured material should be protected from scouring and displacement by moving water until cured. Fixing of slip bricks, tiles, etc The concrete surface should be scabbled, wire brushed and washed with clean water. Scrub bond face of brick or tile with clean water and shake to remove excess water. Rub Expocrete UA into the wetted bond surfaces. Apply 25 mm thick sausage of Expocrete UA to the tile. Firmly press tiles onto concrete with twisting action to ensure complete material bed of required thickness (usually 6 to 12 mm). Very thick beds should be made up by previous application of Expocrete UA to the prepared concrete surface. The tiles should be supported for 12 to 48 hours until the Expocrete UA has cured sufficiently to prevent slipping. The use of Expocrete UA is recommended as it allows the surfaces of the bricks and concrete to be thoroughly washed down immediately prior to fixing. Cleaning Expocrete should be removed whilst uncured using water or detergent solution. Cured mortar can only be removed by mechanical means.
Advantages
Possesses outstanding strength and adhesive powers Resistant to physical damage Excellent chemical resistance Can be used underwater
Description
Expocrete UA is recommended for fixing slip bricks and for reinstating structures exposed to heavy battering from the sea, such as sea walls and concrete jetties and for repairing submerged steelwork and concrete. Mixed mortar may be transported underwater in polythene bags.
Properties
Form: Two-part compounds Base: firm putty Hardener: soft putty 100% 2000 kg/m Base: off-white Hardener: black Mixed colour: dark grey 30 to 45 minutes at 20C Expocrete UA may be applied and cured underwater. Initial cure: 24 hours at 20C Final cure: 7 days at 20C After 48 hours at 20C Expocrete UA will have achieved between 60% to 70% of its final compressive strength After 1 week at 20C 65 N/mm After 1 week at 20C 35 N/mm After 1 week at 20C 12 N/mm Coefficient of linear expansion: 25C to +25C 3.0 x 10 5 perC
Solids content: Fresh wet density: Colour:
Pot life: Water immersion: Cure time:
Compressive strength (BS 6319, Pt 2): Flexural strength (BS 6319, Pt 3): Tensile strength (BS 6319, Pt 7): Thermal expansion:
Estimating
Expocrete compounds are supplied in 9 x 1.5 litre packs containing base and hardener in separate plastic buckets. Coverage rate is 1 litre/m per mm thickness.
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Fosroc Expocrete UA
Limitations
Expocrete should not be used when the temperature is below 5C and falling. Never mix part packs.
CI/SfB: Yr4 June 2006
Storage
All products have a shelf life of 12 months at between 5C and 20C and kept in a dry store in the original, unopened packs. Storage at higher temperature may reduce shelf life.
Precautions
Expocrete is the trade mark of Fosroc International Limited

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Nitomortar FC
Epoxy resin fairing coat Uses
For filling blow-holes, and eliminating minor irregularities prior to the application of Nitocote and Nitoflor epoxy coatings. Initial cure: Overcoating time: Full cure: Fresh wet density:
CI/SfB:(4-)Pr4 W7 November 2005
10 hours @ 20C 4 hours @ 35C 10 to 24 hours @ 20C 4 to 18 hours @ 35C 7 days @ 20C 4 days @ 35C Approximately 1700 kg/m (fully compacted) The low permeability of Nitomortar FC retards chemical attack in aggressive environments
Advantages
Non-slump, can be applied to vertical surfaces and trowelled into blow-holes Superior bond strength to virtually all substrates Smooth paste consistency is easy to apply and finish Reduced usage of subsequent coating Pre-weighed components ensure consistency Chemical resistance:
Performance of Nitomortar FC continually immersed at 20C: Citric acid Tartaric acid Diesel fuel / Petrol Sugar solution Lactic acid Hydrocarbons Phosphoric acid 10% 10% 100% Saturated 10% 100% 50% Excellent Excellent Excellent Very good Very good Very good Very good
Description
Nitomortar FC is a two-component thixotropic material based on high quality solvent-free epoxy resin systems. The colour coded material is supplied in pre-weighed quantities ready for on-site mixing and use. Nitomortar FC can be applied to damp surfaces and quickly cures to form a completely impermeable surface ready for overcoating. Nitomortar FC can be applied up to 5 mm thickness on vertical and overhead locations in a single application without the use of formwork. Greater thicknesses than those specified can be achieved by application of subsequent layers. Consult Fosroc Customer Services Department for further information. For higher build characteristics to vertical or overhead locations, Nitomortar HB is recommended.
Preparation Clean the surface and remove any dust, unsound or contaminated material, plaster, oil, paint, grease, corrosion deposits or algae. The surface should preferably be prepared using highpressure water jetting or light abrasive blasting, followed by thorough washing to remove dust and remaining particles. 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. All steel surfaces should be abrasive blasted to meet the requirements of BS 7079, SA2.5 immediately before application. No independent priming system is required. Mixing
Epoxy resin based fairing coat mortar The epoxy resin based fairing coat mortar shall be Nitomortar FC a two-component solvent-free epoxy resin mortar with a density not greater than 1700 kg/m. The cured mortar shall achieve a compressive strength of 70 N/mm. The material shall be colour coded to facilitate mixing.
Properties
The following properties were obtained at a temperature of 20C unless otherwise specified. Test method Typical results
Care should be taken to ensure that Nitomortar FC is thoroughly mixed to produce a fully homogeneous trowellable mortar. Nitomortar FC can be mixed by hand or with a slow speed drill fitted with a suitable paddle. The base and hardener components should be stirred thoroughly in order to disperse any settlement before mixing them together. The entire contents of the
Compressive strength (BS 6319, Pt 2): 70 N/mm @ 7 days Pot life: 4 hours @ 20C 1 hours @ 35C
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hardener tub should be emptied into the base container and the components mixed thoroughly until a uniform colour consistency is obtained, taking particular care to scrape the sides and bottom of the container. Under no circumstances should part packs be used. Application Apply the mixed Nitomortar FC to the prepared substrate by spatula, filling knife, squeegee or steel float, tight trowelling onto the substrate to ensure positive adhesion and that all blow-holes and defects are completely filled to produce a smooth even finish. Application thickness will vary with profile and alignment of substrate. Where necessary, mortar should be built-up in layers. Build-up Additional build-up can be achieved by application of multiple layers. Where thicker sections are required, the surface of the intermediate applications should be lightly abraded and the resulting dust removed to provide a suitable surface for subsequent layers. The application of additional layers should follow between 10 and 24 hours (at 20C) after the first application. This time should be increased at lower temperatures. Application of Nitomortar FC may then proceed. If sagging occurs during application, the Nitomortar FC should be completely removed and re-applied at a reduced thickness on to the substrate. Finishing Any ridges left by the trowel can be brushed out while the material is still wet or ground down with a carborundum stone before overcoating. Important note: Do not use solvent to thin components as this will prevent proper cure. High temperature working At ambient temperatures above 35C, Nitomortar FC will have shorter pot life and working life. The materials should be stored in the shade or in air-conditioned environments and should not be applied in direct sunlight. Curing Curing protection is not necessary for Nitomortar FC. Overcoat with protective/decorative finishes. The Nitomortar FC should be overcoated within 24 hours at 20C. For surrounding areas not subjected to chemical or physical wear, Fosroc recommend the use of the Dekguard range of anti-carbonation, anti-chloride
coatings, thus bringing them up to the same protective standard as the repair itself. 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. Nitocote epoxy resin coatings should be applied within 24 hours. Dekguard products should not be applied over the repair area until the Nitomortar FC is at least 3 days old. For further advice, consult Fosroc Customer Services Department. Cleaning Nitomortar FC should be removed from tools, equipment and mixers with Fosroc Solvent 102 immediately after use. Hardened material can only be removed mechanically.
Estimating
Supply Nitomortar FC: Fosroc Solvent 102: Coverage and yield Nitomortar FC: 1 kg pack = 0.6 ltr Coverage 0.6 m2 @ 1mm thickness 1 kg packs 5 and 25 litre tins
The coverage figure is theoretical due to wastage factors and the variety and nature of possible substrates, practical coverage figures may be substantially reduced.
Limitations
Do not mix part packs under any circumstances. Nitomortar FC should not be exposed to moving water during application. Exposure to heavy rainfall prior to final set may result in surface scour. If any doubt arises concerning temperature or substrate condition, consult Fosroc Customer Services Department. Application should not be undertaken if the temperature is below 5C or is 5C and falling, nor when the prevailing humidity exceeds 90%.
Storage
Store in dry conditions in the original, unopened containers. All products have a shelf life of 12 months at 20C if kept in a dry store in the original, unopened containers.
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Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Nitomortar FC 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. Flash point Fosroc Solvent 102: 33C

Important note
Fosroc Limited
Drayton Manor Business Park Coleshill Road, Tamworth, Staffordshire B78 3TL. UK
www.fosroc.com
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Fosroc Nitomortar HB
High build epoxy reinstatement mortar Uses
For the fast and permanent reinstatement of concrete, particularly where resistance to chemicals is required. Nitomortar HB can be used for small, localised patch repairs and, because of its lightweight nature, is ideally suited for use in vertical and overhead locations, and for emergency repairs where fast strength gain is important. When properly compacted, the mortar is highly impermeable. For fast repairs to floors and other locations subjected to wear and abrasion, the use of Nitomortar S is recommended. Chemical resistance:
CI/SfB: (4-) Pr4 February 2007
The low permeability of Nitomortar HB retards chemical attack in aggressive environments
Performance of Nitomortar HB blocks continually immersed at 20C: Citric acid Tartaric acid Hydrochloric acid Sodium hydroxide Diesel fuel/petrol Sulphuric acid Sugar solutions Lactic acid Hydrocarbons Phosphoric acid Nitric acid Acetic acid 10% 10% 25% 50% 100% 10% Saturated 10% 100% 10% 10% 5% Excellent Excellent Excellent Excellent Excellent Very good Very good Very good Very good Very good Good Limited
Advantages
Lightweight formulation enabling extra high build and thereby saving time and expense Obviates the need for formwork Early development of strength minimises disruption Highly resistant unaffected by a wide range of chemicals Extremely low permeability Equal to the strength of high quality concrete within 3 days Pre-weighed components ensure consistency
Preparation Clean the surface and remove any dust, unsound material, plaster, oil, paint, grease, corrosion deposits or algae. Roughen the surface and remove any laitance by light scabbling or grit-blasting. 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 10 mm up to the sawn edge. 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. 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. Reinforcing steel priming The cleaned steel should be coated within 3 hours. 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. Substrate priming The dry substrate should be primed using Nitoprime 28. The primer should be mixed in the proportions supplied, adding the entire contents of the hardener tin to the
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Description
Nitomortar HB is based on a high performance solventfree epoxy resin system. The special lightweight filler is specifically designed to give excellent hanging properties for vertical and overhead work. Nitomortar HB is a threecomponent material supplied in pre-weighed quantities ready for on-site mixing and use.
Properties
The following results were obtained at a temperature of 20C unless otherwise specified. Test method Compressive strength (BS 6319, Pt 2): Tensile strength (BS 6319, Pt 7): Compressive modulus (ASTM C 469-65): Pot life: Initial hardness: Full cure: Fresh wet density: Typical result 40 N/mm @ 7 days 7 N/mm @ 7 days 4.5 kN/mm @ 7 days 45 minutes @ 20C 20 minutes @ 35C 24 hours 7 days Approximately 1160 kg/m (fully compacted)
Flexural strength (BS 6319, Pt 3): 15 N/mm @ 7 days
base tin. The two components should be thoroughly mixed together for 3 minutes. The mixed primer should be scrubbed well into the prepared substrate, taking care that all imperfections in the surface are properly coated and avoiding puddling in depressions. If the Nitoprime 28 is absorbed within 30 minutes, a second coat should be applied before continuing. Nitomortar HB can be applied as soon as the primer has started to gel but still has surface tack. This is normally between 30 minutes and 4 hours dependent on the ambient and substrate temperatures. If Nitoprime 28 cures hard, a second application must be made before application of Nitomortar HB. The usable life of the mixed primer is approximately 60 minutes at 20C or 30 minutes at 35C. Mixing Care should be taken to ensure that Nitomortar HB is thoroughly mixed to produce a fully homogeneous, trowellable mortar. Standard packs may be mixed by hand. The hardener and base components should be stirred thoroughly in order to disperse any settlement before mixing them together. The entire contents of the hardener and base containers should then be emptied into the plastic bucket and thoroughly mixed for 3 minutes. While mixing continuously, the entire bag of aggregate should then be added slowly and the three components blended together for a further 2 to 3 minutes, ensuring that the aggregate is thoroughly wetted out with the mixed resins. Under no circumstances should part packs be used. Industrial packs must be mixed mechanically. Again, the hardener and base components should be stirred thoroughly in order to disperse any settlement before mixing them together. The entire contents of the hardener container should then be emptied into the base container and thoroughly mixed for 3 minutes, then emptied into a forced action mixer of adequate capacity (e.g. Cretangle or Pennine). Add the aggregate slowly with the mixer running and continue for 2 to 3 minutes until all the components are thoroughly blended. Under no circumstances should part packs be used. Application Apply the mixed Nitomortar HB to the prepared substrate by wood float, pressing firmly into place to ensure positive adhesion and full compaction. Thoroughly compact the mortar around any exposed reinforcement. In restricted locations, or where exposed reinforcing steel is present, application by gloved hands is an acceptable alternative but, in all cases, the product must be finished to a tight surface with a steel trowel. Nitomortar HB can be applied
in sections up to 50 mm thickness in vertical locations or overhead locations in a single application and without the use of formwork. Thicker sections should be built up in layers but are sometimes possible for smaller repairs, generally up to 75 mm, in a single application dependent on the actual configuration of the repair area and the volume of exposed reinforcing steel. When larger areas are being rendered (generally over 2 m) a chequerboard application technique is recommended. Note: the minimum applied thickness of Nitomortar HB is 10 mm. Build-up Additional build-up can be achieved by application of multiple layers. Exposed steel reinforcing bars should be firmly secured to avoid movement during the application process as this will affect mortar compaction, build and bond. Where thicker sections are required, the surface of the intermediate applications should be scratch-keyed to provide a suitable surface for subsequent layers. The application of additional layers should follow between 8 and 24 hours (@ 20C) after the first application. This time should be reduced at higher temperatures. Repriming with Nitoprime 28 and a further application of Nitomortar HB may then proceed. If sagging occurs during application, the Nitomortar HB should be completely removed and reapplied at a reduced thickness on to the correctly reprimed substrate. Finishing Nitomortar HB is finished by the use of a wood float and closed with a steel trowel wiped with a cloth dampened with Fosroc Solvent 102. The completed surface should not be overworked. Low temperature working Nitoprime 28 and Nitomortar HB can be applied in cold conditions down to 5C. The materials should not be applied when the substrate and/or air temperature is 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed. High temperature working At ambient temperatures above 35C, Nitoprime 28 and Nitomortar HB will have shorter pot lives and working lives. The materials should be stored in the shade or in an air-conditioned environment and should not be applied in direct sunlight. Curing Unlike cementitious materials Nitomortar HB does not
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require curing immediately after finishing, but does require protection from rain and wet conditions during the initial 24 hours after placement. Overcoating with protective/decorative finishes Nitomortar HB is extremely durable and resistant to a wide range of acids, alkalis and industrial chemicals and will provide excellent protection to the concrete and embedded steel reinforcement within the repaired locations. The surrounding parts of the structure may benefit from the application of a protective coating, thus bringing them up to the same protective standard as the repair itself. Fosroc recommend the use of the Nitocote range of epoxy resin, chemical-resistant, protective coatings. For surrounding areas not subjected to chemical attack or physical wear, Fosroc recommend the use of the Dekguard range of anti-carbonation, anti-chloride protective 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. Nitocote epoxy resin protective coatings should be applied within 24 hours. Dekguard products should not be applied until the Nitomortar HB is at least 3 days old. For further advice, consult the local Fosroc office. Cleaning Nitoprime Zincrich Plus, Nitoprime 28 and Nitomortar HB should be removed from tools, equipment and mixers with Fosroc Solvent 102 immediately after use. Nitoprime 28:
2.4 m / 0.45 kg Handy pack 20 m / 4.2 kg Industrial pack
Notes: the coverage figures for Nitoprime Zincrich Plus and Nitoprime 28 are theoretical due to wastage factors and the variety and nature of possible substrates, practical coverage figures will be reduced.
Limitations
Nitomortar HB should not be used when the temperature is below 5C and falling. Do not mix part packs under any circumstances. Due to the lightweight nature of Nitomortar HB, the product should not be used in areas subjected to traffic, point loading or abrasion. Neither should it be exposed to moving water during application. Exposure to heavy rainfall prior to the final set will result in surface softening and scour. Nitoprime 28 is not a damp tolerant primer. If any doubts arise concerning temperature or substrate conditions, consult the local Fosroc office.
Storage
Store in dry conditions in the original, unopened packaging. All products have a shelf life of 12 months at 20C if kept these conditions. If stored at high temperatures, the shelf life may be reduced to 4 to 6 months.
Precautions
Health and safety For further information see appropriate Product Safety Data Sheet. Fire
Estimating
Supply Nitomortar HB: 2.9 kg Standard packs 9.3 kg Industrial packs 0.45 kg Handy packs 4.2 kg Industrial packs 5 and 25 litre tins
Nitomortar HB is non-flammable. Nitoprime Zincrich Plus, Nitoprime 28 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: 1.9litre and 800ml cans Nitoprime 28: Fosroc Solvent 102: Coverage and yield Nitomortar HB: 2.5 litres / 2.9 kg Standard pack 8.0 litres / 9.3 kg Industrial pack
Nitoprime Zincrich Plus: Fosroc Solvent 102: Nitoprime 28
41C 33C 27C
Nitoprime Zincrich Plus: 8 m/litre
Important note
Fosroc Limited
www.fosroc.com
93
Fosroc Nitomortar PE
High strength jointing and multi-purpose repair compounds Uses
For fast and emergency reinstatement of concrete, bedding, jointing and reprofiling of concrete, masonry and brickwork. Nitomortar PE is ideally suited for the repair and reprofiling of precast concrete units, damaged arrises and treads. It can be used to infill hollows and holes in concrete floors, bedding and fixing kerbstones, manhole sets, frames, brick slips, ceramic tiles, slabs and coping stones. Nitomortar PE Concrete should be used to repair larger voids. The products are especially useful where fast strength gain is important. When properly compacted, they are highly impermeable.
Shrinkage: The polyester resin used in Nitomortar PE is formulated to reduce shrinkage to a minimum. Linear shrinkage will be approximately 0.8%. No further shrinkage will occur after the material has cured. Durability: Cured Nitomortar PE performs under temperatures as high as 60C and down to sub-zero conditions. Chemical resistance: Fully cured Nitomortar PE is unaffected by water, petrol, oil and many corrosive chemicals. It is not recommended for use in contact with ketones, phenols, strong alkalis and oxidising agents. Because chemical resistance can be affected by external variable factors (e.g. temperature), the local Fosroc office should be consulted for specific applications. Underwater use: Nitomortar PE will cure under water. The local Fosroc office should be consulted when considering this type of application. Working time
Advantages
Fast development of strength minimises disruption stronger than concrete within 2 hours No primer required High chemical and oil resistance Extremely versatile can be poured, trowelled or modified with aggregate without significantly affecting setting times or strengths Extremely low wastage due to ability to mix part packs to consistencies required Will cure down to 0C Pre-weighed components ensure consistency
Temperature 5C: Winter grade: 15C: Winter grade: 25C: 35C:
Nitomortar PE 160 minutes 60 minutes 35 minutes 20 minutes 15 minutes 5 minutes
Nitomortar PE Concrete 250 minutes 90 minutes 50 minutes 25 minutes
Description
Nitomortar PE products are based on a polyester resin system. There are two grades. Nitomortar PE: The standard material for general purpose use. Nitomortar PE Concrete: A special grade allowing users to add suitable aggregate, thereby substantially reducing the cost of infilling larger voids. Winter versions of Nitomortar PE is available which are faster setting at low ambient temperatures. Both grades of Nitomortar PE are supplied as two-component products with pre-weighed quantities of liquid resin and powdered hardener, ready for on-site mixing and use. The hardener system enables the mix to be varied from a pourable consistency to a trowellable mortar without significantly affecting the setting times or strengths achieved.
Compressive strength gain: All grades of Nitomortar PE will develop strengths equivalent to mature concrete within a 2 to 6 hour period at temperatures above 15C. Typical compressive strength development is shown below. Nitomortar PE
Properties
General Bond strength: Nitomortar PE forms a strong bond to most structural materials provided the surfaces are dry and suitably prepared. The resulting bond between Nitomortar PE and concrete will be stronger than the tensile strength of the concrete itself.
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Note: The performance of Nitomortar PE winter grade at 5C is similar to that of the standard grade at 20C.
Nitomortar PE Concrete Fluid: 1.6 : 1 2.0 : 1 1,680
0.60
Mix design Nitomortar PE Concrete For each full pack of Nitomortar PE Concrete containing 5 litres (5.5 kg) resin and 3.75 litres (5.5 kg) powdered hardener, use one of the alternative aggregate types described in the table. Dried aggregate Grade C sand: Grade M sand: Grade F sand: Grade M sand: 10 mm aggregate: Grade M sand: 10 mm aggregate: 20 mm aggregate: Quantity 17 litres (30 kg) 14 litres (25 kg) 11.5 litres (21 kg) 6.5 litres (12 kg) 12 litres (21 kg) 5.5 litres (10 kg) 5.5 litres (9.5 kg) 11 litres (19 kg) Yield 20 litres 17.5 litres 15 litres 22.5 litres
27.5 litres
Preparation Property at 20C Nitomortar PE flowable consistency Nitomortar PE Concrete* Saw cut or cut back the extremities of the repair locations to a depth of at least 5 mm to avoid feather-edging and to provide a square edge. Break out the complete repair area to a minimum depth of 5 mm up to the sawn edge. The surface should be free from any contamination. Where breaking out is not required, roughen the surface and remove any laitance by light scabbling or grit-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. Fully expose 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. 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. Reinforcing steel priming Density kg/m 1,920 1,840 Yield litres/kg 0.52 0.54 Exposed steel reinforcement should be treated with one full coat of Nitoprime Zincrich Plus. This should be allowed 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.
Compressive strength at 7 days (BS 6319, Pt 2): Flexural strength (BS 6319, Pt 3): Tensile strength (BS 6319, Pt 7): Youngs Modulus of Elasticity: Thermal conductivity: Coefficient of thermal expansion:
100 N/mm 28 N/mm 14 N/mm 16 kN/mm 1.0 Watt/m/C 30 x 10 6 per C
100 N/mm 25 N/mm 12 N/mm 23 kN/mm
* Note that the strengths quoted for Nitomortar PE Concrete may vary dependent on the type of aggregate selected.
Mix design Nitomortar PE Hardener : resin ratio (volume) (weight) Trowellable: Flowable: 3.2 : 1 2.5 : 1 4.2 : 1 3.5 : 1
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Substrate priming No priming is necessary when using Nitomortar PE products. Mixing Pour the required quantity of liquid resin into a clean plastic mixing bucket and add the powdered hardener slowly, stirring continuously. Continue mixing for 3 minutes until a uniform consistency is achieved. For Nitomortar PE Concrete, measure out the correct volume of surface dry aggregate (coarse/fine) appropriate to the proposed application. Add this to the previously mixed resin (see above) until a uniform consistency is achieved. Mechanical mixing is recommended for Nitomortar PE Concrete and a forced-action mixer (e.g. Mixal or Cretangle type) should be used. Do not mix more material than can be used within the pot-life of the product. Application Apply the mixed Nitomortar PE to the prepared substrate by steel trowel, pressing firmly into place to ensure positive adhesion and full compaction. In the case of repairs to very dense or non-absorbent substrates, the first layer of Nitomortar PE should be made slightly resinrich to ensure that the surface to be bonded is properly wetted-out. Thoroughly compact the mortar around any exposed reinforcement. Refer to the Design criteria chart for maximum thicknesses in a single application. Thicker sections should be built up in layers. If sagging occurs during application, the Nitomortar PE should be completely removed and reapplied at a reduced thickness. When larger areas are being rendered (generally over 0.25 m for Nitomortar PE and 0.50 m for Nitomortar PE Concrete) a chequerboard application technique is recommended. For certain applications, particularly where access is restricted, the mixed Nitomortar PE can be poured into place. The local Fosroc office should be consulted before proceeding. When used for bedding purposes or for fixing brick slips, ceramic tiles, slabs, coping stones, etc, provision might be necessary for temporary support. Note: The minimum applied thickness of Nitomortar PE and Nitomortar PE Concrete is 5 mm. Maximum thickness: Minimum thickness: Maximum plan area: Maximum linear run: Build-up The following guidelines should be used. Nitomortar PE 12 mm 5 mm 0.25 m 1 metre
Nitomortar PE Concrete 40 mm 5 mm* 0.50 m 1 metre
Greater thicknesses should be built up in layers and larger areas should be applied in a chequerboard fashion. Consult the local Fosroc office for further information. * Note: When using aggregate larger than a sand grading, the minimum thickness will be increased. Consult the local Fosroc office for further information. Additional build-up can be achieved by application of multiple layers. Exposed steel reinforcing bars should be firmly secured to avoid movement during the application process as this will affect mortar compaction, build and bond. Where thicker sections are required, the surface of the intermediate applications should be scratch-keyed to provide a suitable surface for subsequent layers. The application of additional layers should follow between 8 and 24 hours after the first application. Finishing Nitomortar PE is finished by the use of a steel trowel which may be wiped from time to time with a cloth moistened with Fosroc Solvent 105. The completed surface should not be overworked. Low temperature working Nitomortar PE can be applied in cold conditions down to 0C. The material should not be applied when the substrate and/or air temperature is below freezing or where the substrate is contaminated with frost or ice. In cold conditions, the winter grade may be more appropriate. Consult the local Fosroc office for further information. High temperature working At ambient temperatures above 25C, Nitomortar PE will have shorter pot lives and working lives. The material should not be used at ambient or surface temperatures above 35C. At elevated temperatures, the product should be stored in the shade or in an air-conditioned environment for 24 hours prior to use and should not be applied in direct sunlight.
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Curing Curing protection is not necessary for Nitomortar PE products. Cleaning Nitomortar PE should be removed from tools, equipment and mixers with Fosroc Solvent 105 immediately after use.
temperature or substrate conditions, consult the local Fosroc office.
Storage
Store in dry conditions in the original, unopened bags or packs. All products have a shelf life of 12 months at 20C if kept in a dry store in the original, unopened packaging. If stored at high temperatures and/or high humidity conditions the shelf life may be significantly reduced. 14 kg packs 14 kg packs 11 kg packs 1.9 litre and 800ml cans
Estimating
Supply Nitomortar PE: Nitomortar PE winter grade: Nitomortar PE Concrete: Nitoprime Zincrich Plus Coverage and yield Nitomortar PE: Nitomortar PE winter grade: Nitomortar PE Concrete: 7.5 litres / 14 kg pack 7.5 litres / 14 kg pack 15 to 27.5 litres / 11 kg pack (dependent on aggregate addition) 8.0 m2 per litre
Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Nitomortar PE products 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 point Nitomortar PE resin: Nitoprime Zincrich Plus 29C 41 oC
Nitoprime Zincrich Plus
Note: 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 products should not be applied to damp or wet surfaces where there is total reliance on bond nor should they 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

Important note
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Fosroc Nitomortar S
High strength, abrasion-resistant epoxy reinstatement mortar Uses
For the fast and permanent reinstatement of concrete, particularly where high strength, abrasion-resistance and resistance to chemicals is required. The product is designed for horizontal use but can be applied vertically, although generally in thinner sections. It is ideally suited for acid tanks, sea walls, industrial floors and for use as a bedding mortar. Nitomortar S can be used for emergency repairs where fast strength gain is important. When properly compacted, the mortar is highly impermeable. In certain instances, Nitomortar S can be used on metal substrates. Contact the local Fosroc office for advice in this respect. For fast repairs in vertical and overhead locations where a higher-build, lightweight formulation is required, the use of Nitomortar HB is recommended. Pot life: Initial hardness: Full cure: Fresh wet density:
45 minutes @ 20C 20 minutes @ 35C 24 hours 7 days Approximately 2015 kg/m (fully compacted) The low permeability of Nitomortar S retards chemical attack in aggressive environments
Chemical resistance:
Performance of Nitomortar S blocks continually immersed at 20C: Citric acid Tartaric acid Hydrochloric acid Sodium hydroxide Diesel fuel / petrol Sulphuric acid Sugar solutions Lactic acid Hydrocarbons Phosphoric acid Nitric acid Acetic acid 10% 10% 25% 50% 100% 10% Saturated 10% 100% 50% 10% 5% Excellent Excellent Excellent Excellent Excellent Very good Very good Very good Very good Very good Good Limited
Advantages
High ultimate strength suitable for structural use Early development of strength minimises disruption Abrasion-resistance suitable for heavily trafficked areas Highly resistant to a wide range of chemicals Cured product is highly impermeable to water when tight trowel finished Typically twice as strong as good quality concrete Pre-weighed components ensure consistency
Preparation
Description
Nitomortar S is based on a high quality solvent-free epoxy resin system. The special silica aggregates provide high strength and excellent abrasion resistance. Nitomortar S is a three-component material supplied in pre-weighed quantities ready for on-site mixing and use.
Properties
The following results were obtained at a temperature of 20C unless otherwise specified. Test method Compressive strength (BS 6319, Pt 2): Flexural strength (BS 6319, Pt 3): Tensile strength (ASTM C 307): Compressive modulus (ASTM C 469): Water absorption: Typical result 70 N/mm @ 7 days 20 N/mm @ 7 days 10 N/mm @ 7 days 16.2 kN/mm @ 28 days 0.2% (concrete - 5.0%)
Clean the surface and remove any dust, unsound material, plaster, oil, paint, grease, corrosion deposits or algae. Roughen the surface and remove any laitance by light scabbling or grit-blasting. Saw cut or cut back the extremities of the repair locations to a depth of at least 5 mm to avoid feather-edging and to provide a square edge. Break out the complete repair area to a minimum depth of 5 mm up to the sawn edge. 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. 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.
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Fosroc Nitomortar S
Reinforcing steel priming The cleaned steel should be coated within 3 hours. 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. Substrate priming Horizontal or damp substrates should be primed using Nitoprime 25. Predominantly vertical and metal substrates should be primed using Nitoprime 28. In both cases, the primer should be mixed in the proportions supplied, adding the entire contents of the hardener tin to the base tin. The two components should be thoroughly mixed together for 3 minutes. The mixed primer should be scrubbed well into the prepared substrate, taking care that all imperfections in the surface are properly coated and avoiding puddling in depressions. If the primer is absorbed within 30 minutes, a second coat should be applied before continuing. Nitomortar S can be applied as soon as the primer has started to gel but still has surface tack. This is normally between 30 minutes and 4 hours dependent on the ambient and substrate temperatures. If the primer cures hard, a second application must be made before application of Nitomortar S. The usable life of the mixed primer is approximately 60 minutes at 20C or 30 minutes at 35C. Mixing Care should be taken to ensure that Nitomortar S is thoroughly mixed to produce a fully homogeneous, trowellable mortar. Standard packs may be mixed by hand. The hardener and base components should be stirred thoroughly in order to disperse any settlement before mixing them together. The entire contents of the hardener and base containers should then be emptied into the plastic bucket and thoroughly mixed for 3 minutes. While mixing continuously, the entire bag of aggregate should then be added slowly and the three components blended together for a further 2 to 3 minutes, ensuring that the aggregate is thoroughly wetted out with the mixed resins. Under no circumstances should part packs be used. Industrial packs must be mixed mechanically. Again, the hardener and base components should be stirred thoroughly in order to disperse any settlement before mixing them together. The entire contents of the hardener container should then be emptied into the base container and thoroughly mixed for 3 minutes, then emptied into a forced action mixer of adequate capacity (e.g. Daines, Cretangle or Pennine). Add the aggregate slowly with the mixer running and continue for 2 to 3 minutes until all the components are thoroughly blended. Under no circumstances should part packs be used. Application Apply the mixed Nitomortar S to the prepared substrate by wood float, pressing firmly into place to ensure positive adhesion and full compaction. Thoroughly compact the mortar around any exposed reinforcement. In restricted locations, or where exposed reinforcing steel is present, application by gloved hands is an acceptable alternative but, in all cases, the product must be finished to a tight surface with a steel trowel. Nitomortar S can be applied in sections up to 50 mm thickness in horizontal locations or up to 6 mm thickness in vertical locations in a single application and without the use of formwork. Thicker vertical sections may sometimes be possible dependent on the profile of the substrate and the volume of exposed reinforcing steel but should generally be built up in layers. When larger areas are being rendered, a chequerboard application technique is recommended. Note: the minimum applied thickness of Nitomortar S is 5 mm. Build-up Additional build-up can be achieved by application of multiple layers. Exposed steel reinforcing bars should be firmly secured to avoid movement during the application process as this will affect mortar compaction, build and bond. Where thicker sections are required, the surface of the intermediate applications should be scratch-keyed to provide a suitable surface for subsequent layers. The application of additional layers should follow between 8 and 24 hours (@ 20C) after the first application. This time should be reduced at higher temperatures. Repriming and a further application of Nitomortar S may then proceed. If sagging occurs during application, the Nitomortar S should be completely removed and reapplied at a reduced thickness on to the correctly reprimed substrate. Finishing Nitomortar S is finished by the use of a wood float and closed with a steel trowel. The completed surface should not be overworked. Low temperature working Nitoprime 25, Nitoprime 28 and Nitomortar S can be applied in cold conditions down to 5C. The materials should not be applied when the substrate and/or air temperature is 5C and falling. At 5C static temperature or at 5C and rising, the application may proceed. High temperature working At ambient temperatures above 35C, Nitoprime 25, Nitoprime 28 and Nitomortar S will have shorter pot lives and working lives. The materials should be stored in the
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Fosroc Nitomortar S
shade or in an air-conditioned environment and should not be applied in direct sunlight. Curing Unlike cementitious materials Nitomortar S does not require curing immediately after finishing, but does require protection from rain and wet conditions during the initial 24 hours after placement. Overcoating with protective/decorative finishes Nitomortar S is extremely durable and resistant to a wide range of acids, alkalis and industrial chemicals and will provide excellent protection to the concrete and embedded steel reinforcement within the repaired locations. The surrounding parts of the structure may benefit from the application of a protective coating, thus bringing them up to the same protective standard as the repair itself. Fosroc recommend the use of the Nitocote range of epoxy resin, chemical-resistant, protective coatings. For surrounding areas not subjected to chemical attack or physical wear, Fosroc recommend the use of the Dekguard range of anti-carbonation, anti-chloride protective 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. Nitocote epoxy resin protective coatings should be applied within 24 hours. Dekguard products should not be applied until the Nitomortar S is at least 3 days old. For further advice, consult the local Fosroc office. Cleaning Nitoprime Zincrich Plus, Nitoprime 25, Nitoprime 28 and Nitomortar S should be removed from tools, equipment and mixers with Fosroc Solvent 102 immediately after use. pack Nitoprime Zincrich Plus: Nitoprime 25: Nitoprime 28: 8 m/litre 5 m / 0.95 kg Handy pack 26 m / 5 kg Industrial pack 2.4 m / 0.45 kg Handy pack 20 m / 4.2 kg Industrial pack Coverage and yield Nitomortar S: 2.5 litres / 5 kg Standard pack 8.0 litres / 16 kg Industrial
Notes: the coverage figures for Nitoprime Zincrich Plus and Nitoprime 28 are theoretical due to wastage factors and the variety and nature of possible substrates, practical coverage figures will be reduced. Limitations Nitomortar S should not be used when the temperature is below 5C and falling. Do not mix part packs under any circumstances. Nitomortar S should not be used in overhead locations use Nitomortar HB for this purpose. Nitomortar S should not be exposed to moving water during application. Exposure to heavy rainfall prior to the final set will result in surface softening and scour. Nitoprime 28 is not a damp tolerant primer. 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 packs. All products have a shelf life of 12 months at 20C if kept in a dry store in the original, unopened bags or packs. If stored at high temperatures, the shelf life may be reduced to 4 to 6 months.
Precautions Estimating
Supply Nitomortar S: Nitoprime Zincrich Plus: Nitoprime 25: Nitoprime 28: Fosroc Solvent 102: 5 kg Standard packs 16 kg Industrial packs 1.9 litre and 800ml cans 0.95 kg Handy packs 5 kg Industrial packs 0.45 kg Handy packs 4.2 kg Industrial packs 5 and 25 litre tins Nitomortar S is non-flammable. Nitoprime Zincrich Plus, Nitoprime 28 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 For further information refer to the appropriate Product Safety Data Sheet. Fire
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Fosroc Nitomortar S
Flash points Nitoprime Zincrich Plus: Fosroc Solvent 102: Nitoprime 28 41C 33C 27C
For further information, refer to the Product Safety Data Sheets.

Important note
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Fosroc Nitofil LV and TH

Low viscosity or thixotropic epoxy resin injection grout Uses
Nitofil LV Is a low viscosity system for the injection of cracks between 0.25 mm and 9 mm wide in concrete and masonry, where both sides of the crack can be sealed to prevent resin drainage. Nitofil TH Has been developed for the injection of cracks 0.5 to 9 mm wide in concrete and masonry, and has been specially formulated to minimise the drainage of resin from cracks which are incompletely sealed. repaired crack.
CI/SfB: Yn6 June 2006
The usable life of the product is 20 to 25 minutes at 20C.
Properties
The following properties were obtained for Nitofil LV and Nitofil TH at a temperature of 20C: Compressive strength (BS 6319, Pt. 2): Tensile strength (BS 6319, Pt. 7): Flexural strength (BS 6319, Pt. 3): 70 N/mm @ 7 days 27 N/mm @ 7 days 50 N/mm @ 7 days
Slant shear bond (BS 6319, Pt. 4) To dry concrete: 50 N/mm @ 7 days To wet concrete: 40 N/mm @ 7 days
Advantages
Nitofil LV Low viscosity: Permits maximum resin penetration Nitofil TH
Pot life The time for which bulk mixed material remains fluid will vary with temperature. Typical values in minutes are: 10C Nitofil LV: 40 minutes 40 minutes Nitofil TH: 20C 20 minutes 20 minutes 30C 10 minutes 10 minutes
Thixotropic: Permits injection of open-ended cracks Nitofil LV and Nitofil TH Adhesion: Achieves high strength bond to dry or wet concrete Minimum creep: Material designed for low creep Non-shrink: No loss of bond or surface contact High strength: High compressive, tensile and flexural strengths Chemical resistance: Withstands most chemicals, acids and alkalis, also water and frost
Chemical resistance Nitofil LV and Nitofil TH are resistant to oil, grease, fats, most chemicals, mild acids and alkalis, fresh and sea water. Where constant contact with specific concentrated chemicals or solvent is anticipated the Fosroc Customer Services Department should be consulted for advice. Temperature limitations During application: Injection can be carried out without special precautions at ambient temperatures from 5C to 25C. For application at higher or lower temperatures the Fosroc Customer Services Department can advise on recommended procedures. In service: The cured grout is completely resistant to frost and extreme sub-zero temperatures, and is suitable for continuous use up to 35C.
Description
Nitofil LV Is a two pack low viscosity epoxy resin product for the repair of cracked concrete and masonry by the injection process. Nitofil TH Is a two pack thixotropic epoxy resin product for the repair of cracked concrete and masonry by the injection process. Nitokit Surface Sealant This is a polyester resin compound which combines the dual function of sealing the surface of the crack and bonding on the injection points. It is supplied as a liquid resin together with a powder hardener, which are mixed together to give a stiff paste. Nitokit Surface Sealant has the added advantage that it can be rubbed down with suitable hand or power tools to give a smooth finish which readily blends with surrounding concrete, minimising the visual impact of the
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Preparation Ensure all contact surfaces are free from oil or grease contamination. Where feasible, insert drinking straws or wires into the crack at sites (150 to 400 mm apart) selected for injection ports. Bond injection ports over the crack at these points with Nitokit Surface Sealant, removing the straws or wires after the Nitokit Surface Sealant has hardened. (If crack is obstructed at the surface, access may first be gained by vacuum flush drilling.) The crack should then be sealed between ports with Nitokit Surface Sealant.
Fosroc Nitofil LV and TH

Mixing Nitokit Surface Sealant Mix only the quantity of sealant that can be applied within the usable life. Pour a small quantity of the resin into a suitable bucket and slowly add the powder. Stir until a smooth thick cream consistency is obtained. Mix further quantities as required. Mixing Nitofil Pour all the contents of Hardener pack into Base container. Mix for 2 minutes or more until homogeneous. At extreme temperatures refer to gel time information to enable required handling procedures to be adopted. NB: Mechanical mixing is preferable (i.e. Jiffy mixer in slow speed drill) ensuring that the sides and bottom of the container are repeatedly scraped. Injection The product may be pumped into place using a standard grease gun technique. The size of the injection pump should be related to the job in hand. For small-scale jobs a Fosroc G Gun may be used. Where greater rates of injection are required a Tecelmit hand pump may be used, or bulk supplies of Nitofil LV and Nitofil TH may be used with twin metering/mixing machines. Connect the pump to the injection port using nylon reinforced PVC hose and Unex clips. Injection should commence at the widest part of the crack, or at the lower end if crack is uniform, closing that port and transferring injection to the next when the resin is seen to have reached it. 12 to 18 hours after injection, the injection tubes should be broken off and any damage made good using Nitokit Surface Sealant. Cleaning Tools and application equipment should be cleaned using Fosroc Solvent 102 for Nitofil LV and Nitofil TH and Fosroc Solvent 105 for Nitokit Surface Sealant immediately after use. Cured material can only be removed mechanically. Spillages should be absorbed with sand or sawdust and disposed of in accordance with local regulations.
CI/SfB: Yn6 June 2006
Estimating
Packaging Nitofil LV: Nitofil TH: Nitokit Surface Sealant: Fosroc Solvent 102: Fosroc Solvent 105: 3 litre pack 1 litre pack 5.5 litre pack 5 and 25 litre tins 5 litre tin
Storage
Nitofil LV, Nitofil TH and Nitokit Surface Sealant have a shelf life of 12 months if stored in dry conditions at 20C. Nitokit Surface Sealant should be stored in accordance with the Highly Flammable Liquids and Liquefied Petroleum Gases Regulations 1972.
Precautions
Health and safety For further information refer to appropriate Product Safery Data Sheet. Disposal To eliminate risk of exotherm, this product should only be mixed when ready for use and then applied without delay. Any unused residue should be poured on to a disposable impervious surface to allow cure before disposal. Fire Nitofil LV and Nitofil TH are non-flammable. Fosroc Solvent 102, Fosroc Solvent 105 and Nitokit Surface Sealant are flammable. Do Not use near naked flames. No Smoking during use. In the event of fire, extinguish with CO2 or foam. Flash points Nitokit Surface Sealant: Fosroc Solvent 102: Fosroc Solvent 105: 29C 33C 43C
Nitocote is the trademark of Fosroc International Limited

Important note
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Fosroc Nitokit LV and TH

Pre-packaged low viscosity or thixotropic epoxy crack injection systems Uses
Nitokit LV and Nitokit TH are designed for injecting cracks in concrete and masonry where there is a need to consolidate a structure or exclude water and air from contact with reinforcement. Nitokit LV is a low viscosity system and is suitable for cracks down to 0.2 mm at the surface and internal cracks tapering down to 0.01 mm. Nitokit TH is a thixotropic system and can be injected into open ended cracks where depth and quantity of resin need to be controlled. The Nitokit systems are ideal for small scale repairs on site and are also suitable for in-situ or precast concrete elements.
CI/SfB: Yr4 November 2007
Properties
Nitokit LV and Nitokit TH resin Usable life at 10C: 20C: 30C: 40C: 10C: 20C: 30C: 100 50 25 15 minutes minutes minutes minutes
Viscosity at (Nitokit LV only) Set time at
400 to 800 mPas 250 to 500 mPas 100 to 250 mPas
10C: 12 hours 20C: 7 hours 30C: 5 hours 40C: 3 hours When cured for 7 days at 20C Compressive strength: Flexural strength: Tensile strength: Modulus of elasticity: Elongation at break: Tensile bond strength: > 70 N/mm (BS 6319) > 45 N/mm (ISO R178) > 55 N/mm (ISO 527) 2800 N/mm 2.5% When tested to BS 3900, Pt E10 in both dry and wet states is greater than average concrete
Advantages
Self contained packs include everything necessary to complete the crack injection Convenient to use disposable cartridge contains both resin and hardener Safe and clean to use, non-return valves avoid leakage and spills High strength, excellent bond to concrete, brickwork and masonry Low viscosity and thixotropic options allow cost effective and efficient repair
Nitokit Surface Sealant Usable life at 20C: Set time at 20C: 15 to 35 minutes dependent on mix ratio and quantities 1 to 2 hours dependent on mix ratio
Description
Nitokit LV or Nitokit TH basic pack incorporates a two-part epoxy crack injection resin contained in a patented single cartridge, complete with injection nipples and hoses. A selection of either Nitokit LV, a low viscosity system or Nitokit TH, a thixotropic system, ensures the most cost effective and efficient solution. The Nitokit accessory pack contains additional items which are complementary to the basic pack a two-part surface sealer and adhesive for fixing nipples and sealing cracks, an injection gun and the basic safety wear, gloves and goggles.
Personal protection Refer to Health and safety section of this data sheet before commencing work. Surface preparation Nitokit Surface Sealant has to retain the injection system under pressure. Care must be taken to provide a bond surface which is dry and free from any contamination. Mixing the surface sealant
Low viscosity crack injection The crack injection system shall be Nitokit LV. It shall be applied strictly in accordance with Application instructions given in the product data sheet. Thixotropic crack injection The crack injection system shall be Nitokit TH. It shall be applied strictly in accordance with Application instructions given in the product data sheet.
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Only mix enough sealant that can be applied within the usable pot-life. Pour a small quantity of the resin into the mixing bucket provided and slowly add the powder. Stir until a smooth thick cream consistency is obtained. Application of the surface sealant Immediately after mixing, apply a small amount of sealant to the back of each nipple ensuring that the valve will not be blocked, then place the nipple to ensure the valve (centre) is firmly over the crack. Nipples should be placed

between 200 and 500 mm apart dependent on crack size. Additional sealant should be applied to the flange of the nipple to ensure a resin-tight seal to the substrate. Nitokit Surface Sealant should be knifed into the crack between nipples to ensure a resin-tight seal. Where cracks can be sealed on one side only, nipples should be placed at centres which are 80% of the depth to which the resin is required to penetrate. Application of the injection resin may commence as soon as the Nitokit Surface Sealant has fully hardened (at least 1 hour at 20C or 2 hours at 10C). Injection of the Nitokit LV epoxy resin Lightly tap the side of the resin capsule near the base with a hammer two or three times on different sides to break internal glass container of hardener. (The glass can be heard moving when broken.) To mix the resin, invert the cartridge twenty to thirty times slowly. Do not shake vigorously otherwise air will be incorporated. Pierce the foil sealed threaded end of the cartridge. Screw the Nitokit LV hose on to the cartridge. Ensure the O ring is in place on the cartridge. Do not over tighten the fitting as this may distort the O ring. Use the mixed material within the useable life. Place the cartridge into the gun supplied with the accessory pack. Push the free end of the Nitokit hose on to the lowest nipple and tighten the locking cap. Do not over tighten. Insert an air release pin into the next nipple adjacent to the injection point. Note: do not start pumping until the air release pin is inserted to release the non-return valve and enable it to release trapped air. Commence pumping slowly. Do not use excessive pressure. The rate of acceptance into fine cracks may be very slow. (Figure 4). When resin appears at the nipple adjacent to the injection point: (a) Stop pumping. (b) Release the pressure on the injection gun. (c) Remove the air release pin. (d) Unscrew the cap and, with a twisting movement, pull off the Nitokit hose. Attach the Nitokit hose to the next nipple, insert air release pin in the nipple beyond and recommence pumping. Repeat the process until the entire length of crack has been injected.
On completion of pumping, the last cartridge can be left connected and pressurised slightly to allow for possible seepage into deep-seated cracks. Injection of the Nitokit TH epoxy resin Cut the top off the conical nozzle and insert T-shaped rod and turn clockwise to engage mixing head in cartridge. (Figure 1). Push rod down the full length of the cartridge to break the membrane separating the resin and hardener. Pump up and down thirty to forty times to mix resin and hardener. (Figure 2). Turn the T-shaped rod anti-clockwise to disengage and then remove. Do not shake. Unscrew the conical nozzle and discard. Screw the Nitokit hose onto the cartridge. Ensure the rubber O ring is in place on the cartridge. Do not over tighten the fitting as this may distort the O ring. (Figure 3). Use the mixed material within the usable life. Place the cartridge into the gun supplied with the accessory pack. Push the free end of the Nitokit hose on to the nipple positioned over the widest point of the crack and tighten the locking cap. Do not over tighten. Insert an air release pin into the next nipple adjacent to the injection point. Note: do not start pumping until the air release pin is inserted to release the non-return valve and enable it to release trapped air. Commence pumping slowly. Do not use excessive pressure. The rate of acceptance into fine cracks may be very slow. (Figure 4). When resin appears at the nipple adjacent to the injection point: (a) Stop pumping. (b) Release the pressure on the injection gun. (c) Remove the air release pin. (d) Unscrew the cap and, with a twisting movement, pull off the Nitokit hose. Attach the Nitokit hose to the next nipple, insert air release pin in the nipple beyond and recommence pumping. Repeat the process until the entire length of crack has been injected. On completion of pumping, the last cartridge can be left connected and pressurised slightly to allow for possible seepage into deep-seated cracks.
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Nitokit (accessory pack): 1 injection gun 1 plastic bucket 2 pairs goggles 1 x 5.5 litre pack Nitokit Surface Sealant Also available separately Nitokit injection nipples: Nitokit TH hoses: Fig 1 Fig 2 Fig 3 Nitokit air release pins: Nitokit Surface Sealant: Each Each Each 5.5 litre pack
Limitations
Nitokit LV and Nitokit TH should not be used for cracks where movement is expected to continue. Other measures should be taken to accommodate such movement, ie cutting and forming a movement joint.
Storage
Nitokit LV, Nitokit TH and Nitokit Surface Sealant have a shelf life of 12 months and should be stored in internal dry conditions at temperatures between 8C and 25C.
Fig 4 Making good After the Nitokit injection resin has set, remove the nipples. These can be knocked off with a hammer. Make good any holes or voids with Nitokit Surface Sealant. The existing surface sealant can then be removed by either grinding or heating with a hot air gun and scraping the concrete surface until the original substrate profile is restored. Cleaning Tools and application equipment should be cleaned using Fosroc Solvent 102 for Nitokit TH and Nitokit LV and Fosroc Solvent 105 for Nitokit Surface Sealant.
Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Nitokit LV and Nitokit TH are non-flammable. Nitokit Surface Sealant and Fosroc Solvent 105 are flammable. Do not use near naked flames. No Smoking during use. In the event of fire extinguish with dry powder or CO2. Do not use water jet. Flash point Nitokit Surface Sealant: Fosroc Solvent 105 29C 43C
Estimating
Nitokit LV & Nitokit TH 12 cartridges - (0.25 litre of mixed resin (basic pack): per cartridge) 30 injection nipples 6 hoses 4 air release pins (Nitokit TH also includes 6 mixing rods)
Nitokit is the trademark of Fosroc International Limited

Important note
Fosroc Limited
www.fosroc.com
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CI/SfB: 12_Yq4 October 2008
FOSROC XR 45
Rapid Setting Cementitious Bedding and Repair Mortar
FOSROC XR 45 has been specifically formulated for bedding highways ironwork with rapid return to service and is particularly useful when temperatures are expected to be at, or just above freezing. Properties Property Compressive Strength @ 20oC Typical result 45 mins:21N/mm 2 7 days: >50N/mm 2 28 days: >60N/mm 2 60 mins: 20N/mm2 3N/mm 2 5 10 minutes* 5 15 minutes* 45 minutes* 2200 kg/m
Compressive Strength cured @ 5oC Tensile strength Working life Setting time Return to service Uses 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. Fosroc XR 45 can also be used for the emergency repair of industrial floors, roads, runways, bridge decks and car park decks. 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. Fresh wet density *dependant on temperature 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. 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. Where repairs are required due to steel corrosion, then standard concrete repair practices should be followed. For more information contact Fosroc. Substrate priming Pre-wet the area with clean water and remove any excess to leave a damp surface. 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
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Standards compliance Conforms to Department of Transport Specification, HD27/04. Design Manual for Roads and Bridges, Vol. 7:Sec 2: 3.11. requirements for rapid repair. Description Fosroc XR 45 is supplied as a ready to use blend 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.
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FOSROC XR 45
speed drill and paddle. Due to its rapid setting characteristics the paddle should be cleaned immediately after each mixing operation. When ambient temperature is between 1C and 10C the use of warm water up to a maximum of 25C is recommended. Application 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. Cleaning Fosroc XR 45 should be removed from tools, equipment and mixers with clean water immediately after use. Cured material can only be removed mechanically. Limitations Fosroc XR 45 should not be used when the temperature is below 1C and falling. For cold weather working below 5C, preheat mixing equipment and gauging water to a temperature of 25-30C, 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 5C and 35C. 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. Fosroc XR 45 is non-flammable. Estimating Supply 25 kg bags Coverage and yield Approximately 12.0 litres / 25 kg bag (1.0 m 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. Health & safety For further information refer to appropriate Product Safety Data Sheet Fire
Important note
Fosroc Limited
www.fosroc.com
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FOSROC XR 90
General purpose fast-setting cementitious bedding and repair mortar.
and can be applied in thicknesses of 10mm to 75mm in one application. 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 Compressive Strength@ 20 C
o
Typical result 120mins: 20N/mm2 1 day: >30N/mm 2 28 days: >50N/mm2 0 3.5N/mm 2 5 -10 minutes* 10 -15 minutes* 120 minutes* 2200 Kg/m3
Total chloride ion content 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. FOSROC XR 90 can be used for emergency and general concrete repairs. Advantages Rapid strength gain will accept traffic in 120 minutes Pre-mixed and bagged material which only requires the addition of clean water 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 Tensile strength @ 28 days Working life Setting time Return to service Fresh wet density *dependant on temperature 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. 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. Mixing Mixing should be carried out using gloved hands. Fosroc XR90 should be added to clean water. Use enough water
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Standards compliance Conforms to Department of Transport Specification, HD27/04. Design Manual for Roads and Bridges, Vol. 7:Sec 2: 3.11. requirements for rapid repair. Description FOSROC XR 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
4
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 When ambient temperature is between 1C and 10C the use of warm water up to a maximum of 25C is recommended. Application 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 Cleaning FOSROC XR 90 should be removed from tools, equipment and mixers with clean water immediately after Limitations FOSROC XR 90 should not be used when the temperature is below 1C 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 5C and 35C. 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 Coverage and yield Approximately 12.0 litres / 25 kg bag (1.0 m 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. Health & safety For further information refer to appropriate Product Safety Data Sheet Fire FOSROC XR 90 is non-flammable.
Important note
Fosroc Limited
www.fosroc.com
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FOS/v04-May06/00
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FOSROC XR Cobbleset
High flow, shrinkage compensated rapid setting grout
return to service and is particularly useful when a fast reopening to pedestrians is required. 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 Property Compressive Strength @ 20oC (BS 1881, Part 116:1983) Working life Return to service Fresh wet density *dependant on temperature Instructions for use 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. Remove all free standing water prior to application. Mixing For quantities up to 50 kg a suitable drill and paddle is suitable. Larger quantities will require a mechanically powered grout mixer. 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. Application 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 Typical result 120 mins: 25N/mm 2 7 days: >35N/mm 2 28 days: >40N/mm 2 5 15 minutes* 30 minutes* 2.22 Kg/m
Uses 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. Recommended applications include: Pointing of granite setts Fixings bollards and street furniture Grouting beneath signpost base plates
Advantages Rapid strength gain will accept foot traffic in 30 minutes Pre-mixed and bagged material which only requires the addition of clean water Shrinkage compensated formulation Excellent bond strength Easy to mix Manufactured under an approved BS EN ISO 9001 Quality System
Description 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
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FOSROC XR Cobbleset
Cleaning Clean any mixing equipment with water immediately after mixing and prior to the initial set Cured material can only be removed mechanically Wash all tools frequently Health & safety Irritating to respiratory system and skin Risk of serious damage to eyes May cause sensitisation by skin contact 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 1C and falling. At 1C static temperature or at 1C and rising, the application may proceed. If in doubt contact the local Fosroc office. Never remix or add water. Storage Storage conditions Store in dry conditions in the original, unopened bags or tubs at between 5C and 35C. 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 Yield 25 kg bags 13 litres approx
Fire FOSROC XR Cobbleset is non-flammable.
Important note
Fosroc Limited
www.fosroc.com
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FOS/v03-Mar05/00
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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 Typical result 1 hour: 50N/mm 2 2 hours: >60N/mm2 28 days: >70N/mm 2
Property Compressive Strength @ 20oC
Tensile strength @ 20oC
28 days: 7 days:
9N/mm2 20Nmm2
Uses
For the rapid installation of manhole frames in Type 1 & 2 carriageways. For bedding and fixing kerbstones. Repairing and re-rpofiling precast units
Flexural strength @ 20 C Working life Setting tim Return to service Fresh wet density * dependant on temperature
5-10 minutes* 15 minutes* 60 minutes* 2140 K/m3
Advantages
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 Manufactured under an approved BS EN ISO 9001 Quality System Mixed by hand or mechanical mixing High flexural and tensile strengths
Instructions for use

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
Conforms to Department of Transport Specification, HD27/04. Design Manual for Roads and Bridges, Vol. 7:Sec 2: 3.11. requirements for rapid repair. 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.
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FOSROC XR PE20
Mixing 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.
Estimating
Supply Yield 15 kg poly tubs 7 litres approx
Application
For bedding applications: Apply the mixed material immediately after mixing Do not try to remix after initial hardening is evident Do not apply onto wet substrates
Storage
Store in dry conditions in original, unopened packs. Shelf life is 12 months if kept in a dry store in original, unopened packs. General information Do not apply to damp or wet surfaces in applications where the bond is critical. Do not expose to rainfall or moving water prior to the final set. Minimum application thickness 5mm. Health & safety For further information refer to appropriate Product Safety Data Sheet. Flashpoint : 29oC.
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 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 Do not apply when the concrete and/or air temperature is below freezing, or where the surface is contaminated with frost or ice
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.
Important note
Fosroc Limited
www.fosroc.com
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CI/SfB:12_Yq4 June 2008
FOSROC XR RSC
Rapid setting concrete. 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. 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 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. 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 Manufactured under an approved BS EN ISO 9001 Quality System Substrate priming 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. When ambient temperature is between 1C and 10C the use of warm water up to a maximum of 25C is recommended. 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. 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.
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. Properties Property Compressive strength: (BS1881, Pt 116:1983) @20OC Working life: Setting time: Traffic time: Fresh wet density: * dependent on temperature
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Typical result 1 hour: 20N/mm 2 7 days: >50N/mm 2 28 days: >60N/mm 2 5-10 minutes* 10-15 minutes* 60 minutes 2200 Kg/m3
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CI/SfB:12_Yq4 June 2008
FOSROC XR RSC
Low temperature working In cold conditions down to 1C, the use of warm water (up to 25C) 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 1C and falling. At 1C static temperature or at 1C and rising, the application may proceed. High temperature working At ambient temperatures above 30C, 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. Cleaning Clean any mixing equipment with water immediately after mixing and prior to the initial set. Cured material can only be removed mechanically. Limitations FOSROC XR RSC should not be used when the temperature is below 1C 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. For further information refer to appropriate Product Safety Data Sheet Fire FOSROC XR RSC is non-flammable
Estimating
Supply 25 kg bags Coverage and yield Approximately 12.0 litres / 25 kg bag (1.0 m at 12 mm thickness). 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.
Storage
Store in dry conditions in the original, unopened bags or tubs at between 5C and 35C. 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
Important note
Fosroc Limited
www.fosroc.com
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Fosroc Dekguard Clear

Clear protective coating system for exposed concrete and masonry Uses
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 Fosrocs Renderoc system of concrete reinstatement.
CI/SfB: Vu6 January 2009
Properties
The values obtained are for the Dekguard Clear system applied at the minimum recommended application rate. Volume solids Dekguard Clear:
35%
Carbon dioxide diffusion resistance (Taywood method). Equivalent thickness of air initial: 11 m per 18 m d.f.t. Equivalent thickness of 30 N/mm concrete cover (Taywood method): Water vapour diffusion resistance (Taywood method): Reduction in chloride ion penetration (Aston Page method): Freeze/thaw salt scaling ASTM C672 (50 cycles): Reduction in water absorption ASTM C642:
30 mm 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
SD 0.07 m @ 172 d.f.t.
> 90% Unaffected >84%
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. 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. 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.
All coating work to be carried out in accordance with the relevant sections of BS6160:2006, 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 gritblasting process. 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. 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. 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
Clear methacrylate protective / weather resistant surface coating. 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%.
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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. 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. Dekguard Clear Number of coats: As necessary to give required carbon dioxide diffusion resistance 0.316 litres/m/coat 60 microns per coat 6 hours
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. 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 20C.
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.
Theoretical application rate: Minimum dry film thickness: Overcoating time at 20C: Dekguard Primer Number of coats: Theoretical application rate: Theoretical dry film thickness: Overcoating time at 20C:
Estimating
Supply Renderoc FC: Renderoc RP252: Renderoc RP252 surface conditioner: 25 kg bags 20 kg bags 5 litre bottles 25 litre drums 25 litre drums 25 litre drums 5 and 25 litre tins
Flood coat 0.4 litre/m2 N/A 12 hours
Dekguard Primer: Nitoprime DG: Dekguard Clear: Fosroc Solvent 102: Coverage Renderoc FC: Renderoc RP252: Dekguard Primer: Nitoprime DG: Dekguard Clear:
Application should not commence if the temperature of the substrate is below 2C. 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. The primer should be allowed to dry for a minimum of 12 hours at 20C 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.
15 litre (5 m at 3 mm thick) 12 litre (2.4 m at 5 mm thick) 2.5 m per litre 2.5 m2 per litre 3.2 m 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 application of the Dekguard Clear System should not commence if the temperature of the substrate is below 2C.
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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 20C or 20 hours at 5C (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: Dekguard Primer: Nitoprime DG: Fosroc Solvent 102: 7C 38C 38C 33C
Dekguard is the trade mark of Fosroc International Limited

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Dekguard E2000

Crack-accommodating elastomeric protective coating for reinforced concrete structures 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.
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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 20C before failure when evaluated by the UK BRE method.
Properties
The values obtained are for the Dekguard E2000 system using Nitoprime DG applied at the minimum recommended application rate. Volume solids Dekguard E2000: Carbon dioxide diffusion resistance (Taywood method). Equivalent thickness of air Initial: After 2000 hours accelerated weathering: Water vapour diffusion resistance (Klopfer method): Chloride resistance (Taywood method): Static crack accommodation capability (UK BRE method): Dynamic crack accommodation (cyclic):
Advantages
Can accommodate substrate cracking up to 2mm and cyclic movement up to 0.3mm Excellent barrier to carbon dioxide, chloride ions, oxygen and water Special acrylic polymer minimises dirt retention Allows water vapour to escape from the structure Resistant to the effects of ultra-violet light Water-based Range of decorative colours
50%
> 50 metres > 50 metres SD 0.14 m, 200 dft No chloride ion diffusion after 100 days 2mm 0.3mm
Description
The Dekguard E2000 system comprises a single component penetrating primer and a single component elastomeric pigmented coating, both ready for immediate site use. 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. Nitobond AR may be used where chloride resistance is of secondary importance to carbonation resistance.
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. 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. 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
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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. 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
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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.
CI/SfB: CI/SfB:Vv9 Vu6 February 2005 June 2008
knapsack-type. A uniform surface appearance (sheen) should be achieved. If any matt porous patches remain, a further application of primer should be made. The primer should be allowed to dry for a minimum of 12 hours (at 20C), longer at lower temperatures, before continuing. Under no circumstances should the primer be overcoated with Dekguard E2000 until the surface is properly dry. 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. 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 20C. 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.
Application
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. 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: Theoretical application rate per coat: Theoretical wet film thickness per coat: Overcoating time: Nitobond AR Number of coats: Theoretical application rate per coat: Theoretical wet film thickness per coat: Overcoating time: Dekguard E2000 Number of coats: Theoretical application rate per coat: Theoretical wet film thickness per coat: 1 0.4 litres/m2 400 microns 1 or 2 0.15 litres/m2 150 microns 12 hours @ 20C Flood coat 0.4 litres/m2 N/A 12 hours @ 20C
Estimating
Supply Renderoc FC: Renderoc RP252: Nitoprime DG: Nitobond AR: Dekguard E2000: Fosroc Solvent 102: Coverage Renderoc FC: Renderoc RP252: thickness) Nitoprime DG: Nitobond AR: Dekguard E2000: 15 litres (5 m2 at 3mm thickness) 12 litres (2.4 m2 at 5mm 2.5 m2 / litre (total) 6 to 8m2 / litre 2.5m2 / litre (total) 25kg bags 20kg bags 25 litre drums 25 litre drums 10 litre drums 5 litre drums
Application of Nitoprime DG should not commence if the temperature of the substrate is below 2C. Application of Dekguard E2000 should not commence if the temperature of the substrate is below 5C. 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 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
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Limitations
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. Application of Nitoprime DG should not commence if the temperature of the substrate is below 2C. Application of Nitobond AR and Dekguard E2000 should not commence if the temperature of the substrate is below 5C. 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 20C or 20 hours at 5C (up to 80% RH). It should not be applied when the prevailing relative humidity exceeds 90%. 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.
CI/SfB: CI/SfB:Vv9 Vu6 February 2005 June 2008
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 Renderoc FC, Renderoc RP252, Nitobond AR and Dekguard E2000 are non-flammable. 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 Nitoprime DG: Fosroc Solvent 102: 38C 33C
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

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Dekguard Elastic

High performance crack-accommodating elastomeric acrylic protective and decorative coating for concrete and masonry 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 Fosrocs Renderoc system of concrete reinstatement.
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.
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). It must exhibit a water vapour transmission resistance (SD) of not more than 0.11 metres (by the Klopfer method) at a dry film thickness of 400 microns. The coating must be capable of withstanding 20,000 0mm 1mm 0mm cycles at 20C without failure. In static testing, it must be capable of bridging an 6 mm incipient crack @ 20C before failure and a 4 mm incipient crack @ 0C 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.
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 Excellent barrier to carbon dioxide, chloride ions, oxygen and water 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 Wide range of decorative colours
Description
The Dekguard Elastic system comprises a single component penetrating primer and a single component elastomeric pigmented coating, both ready for immediate site use. 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.
Properties
The values obtained are for the Dekguard Elastic system applied at the minimum recommended application rate. Volume solids Dekguard Elastic: Carbon dioxide diffusion resistance (BRE method). Equivalent thickness of air Initial: After 2000 hours QUV: Equivalent thickness of 30 N/mm2 concrete cover (Taywood method): Water vapour diffusion resistance (Klopfer method): Reduction in chloride ion penetration (Aston University Diffusion Cell method): 49%
> 100 metres > 100 metres
> 125 mm SD 0.11 m @ 400 microns dft
> 99%
Dekguard Elastic has been approved by the British Board of Agrment under Certificate No. 98/3461.
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Incipient crack spanning capability @ 400 microns dft static test (ASTM C836-84modified) 20C: 0C: 15C: Dynamic crack bridging capability 0 mm - 1 mm - 0 mm cycling 20C: 20,000 cycles 0C: 15,000 cycles 5C: 4,000 cycles Tear resistance (ASTM D624-84): Fire testing (BS 476, Pt 7: 1987) Spread of flame: Fire testing (BS 476, Pt 6: 1989) Propagation index I: Sub index i1: Building Regulations rating:
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 Nitoprime DG Number of coats: Flood coat Theoretical application rate per coat: 0.4 litres/m2 (no failure) (no failure) (no failure) 12 N/mm2 Class 1 0.0 0.0 Class 0 Theoretical wet film thickness per coat: Overcoating time: N/A Dekguard Elastic 2 0.4 litres/m2 400 microns
12 hours @ 20C when firm to the touch
Application of Nitoprime DG should not commence if the temperature of the substrate is below 2C. Application of Dekguard Elastic should not commence if the temperature of the substrate is below 5C. 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. Allow the primer to dry for a minimum of 12 hours (at 20C), 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. 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 20C. 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. Cleaning Renderoc FC and Dekguard Elastic should be removed from tools and equipment with clean water immediately
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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. 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. 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. 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.

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. 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. Dekguard Elastic should not be used on soffits subject to possible water ingress. In these cases use Dekguard S or W. 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: Renderoc RP252: Nitoprime DG: Dekguard Elastic: Fosroc Solvent 102: Coverage Renderoc FC: Renderoc RP252: Nitoprime DG: Dekguard Elastic: 15 litres (5 m2 at 3 mm thickness) 12 litres (4 m2 at 3 mm thickness) 2.5 m2 per litre 2.5 m2 per litre per coat 25kg bags 25kg bags 25 litre drums 10 litre drums 5 litre drums
Storage
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. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced.
Limitations
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 2C. Application of Dekguard Elastic should not commence if the temperature of the substrate is below 5C. 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 20C or 20 hours at 5C (up to 80% RH). It should not be applied when the prevailing relative humidity exceeds 90%. Dekguard Elastic should not be considered for areas
Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Renderoc FC, Renderoc RP252 and Dekguard Elastic are non-flammable. 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 Nitoprime DG: Fosroc Solvent 102: 38C 33C

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Dekguard S
High performance aliphatic acrylic protective and decorative coating for concrete and masonry Uses
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 Fosrocs 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
Excellent barrier to carbon dioxide, chloride ions, sulphates, oxygen and water Allows water vapour to escape from the structure Highly UV-resistant aliphatic acrylic gives exceptional resistance to the effects of long-term weathering Highly durable in all climatic conditions Wide range of decorative colours Excellent resistance to dirt pick-up
Properties
The values obtained are for the Dekguard S system applied at the minimum recommended application rate. Volume solids Dekguard S: Carbon dioxide diffusion resistance (Taywood method). Equivalent thickness of air Initial: 2,000 hours QUV weathered: Equivalent thickness of 30 N/mm2 concrete cover (Taywood method): Water vapour diffusion resistance (Taywood method):
43%
>250 metres >250 metres
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. 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.
>650 mm SD 0.98 m @ 150 microns dft
Reduction in chloride ion penetration (Aston University Diffusion Cell method) : >99% Chloride ion diffusion coefficient (Taywood method): 2,000 hours QUV weathered Freeze/thaw salt scaling (50 cycles) (ASTM C672-84): Good quality concrete (control): Fire testing (BS 476, Pt 7 : 1987) Spread of flame: Fire testing (BS 476, Pt 6 : 1989) Propagation index I: Sub index i1: Building Regulations rating: No chloride ion diffusion after 600 days immersion Unaffected Severe scaling Class 1 1.5 1.3 Class 0
Dekguard S has been approved by the British Board of Agrment under Certificate No. 98/3461. Fire tested to BS 476, Pt 7:1987. Spread of flame - Class 1. Fire tested to BS 476, Pt 6:1989. Propagation index I - 1.5. Sub index i1 - 1.3. Building Regulations rating - Class 0.
Protective/decorative surface coating The protective coating shall comprise a penetrating silane-siloxane primer and Dekguard S, a single
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Fosroc Dekguard S
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 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. 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 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. 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. 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 Number of coats: Flood coat Theoretical application rate per coat: 0.4 litres/m2 Theoretical wet film thickness per coat: Overcoating time @ 20C: N/A 12 hours Dekguard S 2 0.175 litres m2 175 microns 6 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, contact Fosroc Technical Department. The primer should be allowed to dry for a minimum of 12 hours (at 20C), longer at lower temperature, before application of Dekguard S. Under no circumstances should the primer be overcoated until the surface is properly dry. 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. 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.
Estimating
Supply Dekguard S: Dekguard Primer: Nitoprime DG: Nitobond AR: Fosroc Solvent 102: Coverage Dekguard S: Dekguard Primer: Nitoprime DG: Nitobond AR: 6 m2 per litre per coat 2.5 m2 per litre 2.5 m2 per litre 6 m2 per litre 10 litre drums 25 litre drums 25 litre drums 5 and 25 litre drums 5 and 25 litre tins
Application should not commence if the temperature of the substrate is below 2C.
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Fosroc Dekguard S
Limitations
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. Application of Dekguard S, Dekguard Primer or Nitoprime DG should not commence if the temperature of the substrate is below 2C. Nitobond AR application should not commence if the temperature of the substrate is below 5C. 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.
Precautions
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. Flash points Dekguard Primer: Nitoprime DG: Dekguard S: Fosroc Solvent 102: 38C 38C 42C 33C
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.

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Dekguard Textured

Textured weather-resistant coating system for exposed concrete and masonry Uses
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.
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. 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. 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.
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 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
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. 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. 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.
Application
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 Primer Number of coats: Theoretical application rate per coat Thoretical wet film thickness per coat: Overcoating time @ 20C: Flood coat 0.4 litres/m N/A 12 hours Dekguard Textured 1 0.5 litres/m 500 microns N/A
Specification Clauses
Protective/decorative surface coatings 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.
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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. The primer should be allowed to dry for a minimum of 12 hours (at 20C) longer at lower temperature, before application of Dekguard Textured. Under no circumstances should the primer be overcoated until the surface is properly dry. 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 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. Estimating Supply Renderoc FC: Renderoc RP252: Dekguard Primer Nitoprime DG: 25 kg bags 20 kg bags 25 litre drums 25 litre drums
Limitations
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 application of Dekguard Textured should not commence if the temperature of the substrate is below 5C. 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 20C or 20 hours at 5C (up to 80% RH). Dekguard Textured should not be applied when the prevailing relative humidity exceeds 90%. Dekguard Textured should not be considered for areas subjected to exposure to ponded water. Use Dekguard S where occasional ponded water is anticipated. 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.
Storage
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. 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.
Dekguard Textured: 10 litre drums Fosroc Solvent 102: 5 litre drums Coverage Renderoc FC: Nitoprime DG: 15 litres (5 m2 at 3 mm thickness) 2.5 m per litre (total) Renderoc RP252 : 12 litres (4 m2 at 3 mm thickness) Dekguard Textured: 2 m 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.
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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
Important note
Fosroc Limited
Coleshill Road, Tamworth, Staffordshire B78 3TL. UK telephone: +44 0 (1827) 262222 fax: +44 0 (1827) 262444 email: uk@fosroc.com
www.fosroc.com
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Fosroc Dekguard W
Water-based acrylic copolymer protective and decorative coating for concrete and masonry 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 Fosrocs Renderoc system of concrete reinstatement.
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.
The values obtained are for the Dekguard W system applied in two coats at the minimum recommended application rate. Volume solids Dekguard W: Carbon dioxide diffusion resistance (Taywood method). Equivalent thickness of air Initial: After 2000 hours QUV: Equivalent thickness of 30 N/mm concrete cover (Taywood method): Water vapour diffusion resistance (Taywood method): Reduction in chloride ion penetration when primer is used (Aston University Diffusion Cell method): Fire testing (BS 476, Pt 7: 1987) Spread of flame:
41%
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
133 metres 91 metres
279 mm SD 0.066 m @ 50 microns dft
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.
> 84% 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.
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 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 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.
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.
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Fosroc Dekguard W
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. Application 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. 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 Number of coats: Theoretical application rate per coat: Theoretical wet film thickness per coat: Flood coat Dekguard W 2 Cleaning Dekguard W should be removed from tools and equipment with clean water immediately after use. Semi protected surfaces 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.
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 2C. Application of Dekguard W should not commence if the temperature of the substrate is below 5C. 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 20C or 20 hours at 5C (up to 80% RH) or when the prevailing relative humidity exceeds 90%. 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.
0.4 litres/m2 0.18 litres/m2 N/A 180 microns 16 hours
Overcoating time @ 20C: 12 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. 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 20C. 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.
Estimating
Supply Dekguard W: Dekguard Primer: Nitoprime DG: Renderoc FC: Renderoc RP252: Nitobond AR: Fosroc Solvent 102: 10 litre drums 25 litre drums 25 litre drums 25kg bags 20kg bags 5 and 25 litre drums 5 litre drums
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Fosroc Dekguard W
Coverage Dekguard W: Dekguard Primer: Nitoprime DG: Renderoc FC: Renderoc RP252: Nitobond AR: 5.5 m2 per litre per coat 2.5 m2 per litre 2.5 m2 per litre 15 litres (5 m at 3mm thickness) 12 litres (2.4 m2 at 5mm thickness) 6 m2 per litre Fire Dekguard W is non-flammable. The coverage figures given are theoretical due to wastage factors and the variety and nature of possible substrates, practical coverage figures will be reduced. 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. Flash points Dekguard Primer: Nitoprime DG: 38C 38C
2
Precautions
Storage
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. If stored at high temperatures and/or high humidity conditions the shelf life may be reduced. Dekguard W should be protected from frost.
Fosroc Solvent 102: 33C For further information, refer to the Product Safety Data Sheet.
Important note
Fosroc Limited
www.fosroc.com
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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.
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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 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. 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 grit blasted to remove all foreign matter and open up all blow-holes, and provide a suitable key for Nitocote EP403. All blow-holes and imperfections should be filled with Nitomortar FC. Consult the data sheet for pot life and overcoating time. 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. Mixing 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. Application Number of coats: Theoretical application rate per coat: Theoretical wet film thickness per coat: Overcoating times @ 5C: @ 20C: @ 30C: Fully cured @ 5C: @ 20C: @ 30C:
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Advantages
High build application Can be applied directly to mild steel and concrete 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.
Description
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.
Corrosion, chemical and abrasion resistant lining 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.
Properties
Volume solids: Viscosity: Pot life @ 20C: @ 35C: The fully cured film is resistant to: 100% Pourable, spreadable liquid 30 to 40 minutes 10 to 15 minutes Distilled water Petrol Xylene 25% sulphuric acid Saturated sodium chloride 50% sodium hydroxide
2 0.2 litres per m2 200 microns 18 to 48 hours 6 to 18 hours 3 to 9 hours 14 days 7 days 7 days
The local Fosroc office should be consulted for resistance to specific chemicals, or operating temperatures greater than 20oC.

The minimum application temperature is 5C. All surfaces should be treated with two coats of Nitocote EP403. 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 20C. The second coat should be applied exactly as above, again achieving a wet film thickness not less than 200 microns. 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. Cleaning Nitocote EP403 should be removed from tools and equipment with Fosroc Solvent 102 immediately after use. Cured material can only be removed mechanically.
Although Nitocote EP403 may be applied to damp concrete, there must be no standing or running water. 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.
Storage
Store in dry conditions at temperatures between 5C and 30C 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. If stored at high temperatures the shelf life may be reduced.
Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Nitocote EP403 is non-flammable. 2.5 kg packs (1.5 litres) 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. Flash point Fosroc Solvent 102: 33C
Estimating
Supply Nitocote EP403: Fosroc Solvent 102: Coverage Nitocote EP403: 3 m2 per kg per coat (5 m2 per litre)
The coverage figure is theoretical due to wastage factors and the variety and nature of substrates, practical coverage figures may be substantially reduced.
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 5C, or is 5C and falling, nor when the prevailing relative humidity exceeds 90%.
Important note
Fosroc Limited
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Solvent-free epoxy resin coating for water retaining structures Uses
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.)
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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. All blow holes and imperfections should be filled with Nitomortar FC. Consult the local data sheet for pot life and overcoating time. 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
High build application Can be applied directly to mild steel and concrete Smooth, glossy, easy to clean surface Corrosion, chemical and abrasion resistant Can be applied to damp surfaces Water Regulations Advisory Service - approved product
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. Mixing 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.
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
Number of coats: Theoretical application rate per coat: Theoretical wet film thickness per coat: Overcoating times @ 5C: @ 20C: @ 30C: Fully cured * @ 5C: @ 20C: @ 30C: * see Limitations The minimum application temperature is 5C. 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. 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 2 0.2 litres per m 200 microns 18 to 48 hours 6 to 18 hours 3 to 9 hours 14 days 7 days 7 days
Nitocote EP405 meets the requirements of BS 6920, the Water Regulations Advisory Service, tests of effect on water quality.
Properties
Volume solids: Viscosity: Pot life @ 20C: @ 35C: 100% Pourable, spreadable liquid 30 to 40 minutes 10 to 15 minutes
The local Fosroc office should be consulted for resistance to specific chemicals.
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 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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be allowed to dry for not less than 6 hours and not more than 18 hours at 20C. The second coat should be applied exactly as above, again achieving a wet film thickness not less than 200 microns. For ease of overcoating, it is recommended that the first coat be white and the second coat blue, or vice-versa. 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. Cleaning Nitocote EP405 should be removed from tools and equipment with Fosroc Solvent 102 immediately after use. Cured material can only be removed mechanically.
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requirements of BS 6920 the United Kingdom Water Regulations Advisery Scheme but not Regulation 31 of the Water Supply (Water Quality) Regulations 2000. In accordance with WRAS listing, when Nitocote EP405 is used in contact with potable water, curing conditions are 21 days at 7oC. Storage All products have a shelf life of 12 months if kept in a dry store between 5C and 30C in the original, unopened containers. Material from different batches shall be stored separately. If stored at high temperatures the shelf life may be reduced.
Precautions
Health and safety For further information refer to appropriate Product Safety Datasheet. 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. Fire Nitocote EP405 is non-flammable. For further information, refer to Product Safety Data Sheet. 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. Flash point Fosroc Solvent 102: 33C
Estimating
Nitocote EP405 is supplied in 2.5 kg packs (1.5 litres) each yielding 3 m per kg per coat (5 m per litre). The coverage figure is theoretical due to wastage factors and the variety and nature of substrates, practical coverage figures may be substantially reduced.
Limitations
Nitocote EP405 should not be applied over existing coatings. Application should not be undertaken if the temperature is below 5C, or is 5C and falling, nor when the prevailing relative humidity exceeds 90%. 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. * 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 Limited
www.fosroc.com
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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.
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The minimum application temperature is 5C. 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 20C.
Advantages
Excellent chemical resistance Excellent adhesion to concrete and steel Excellent abrasion resistance
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 20C or no more than 18 hours at 35C 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 20C or no more than 18 hours at 35C 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
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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.
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.
Properties
Volume solids: Viscosity: Pot life @ 20C: Pot life @ 35C: Number of coats: Theoretical application rate per coat: Theoretical wet film thickness per coat: Overcoating times @ 5C: @ 20C: @ 35C: Fully cured @ 5C: @ 20C: @ 35C: 100% Pourable, spreadable liquid 90 minutes 35 minutes 1 0.25 litres/0.36kg per m 250 microns 16 to 72 hours 16 to 24 hours 6 to 18 hours 14 days 7 days 6 days

weather, materials should be stored between 15C and 20C for 24 hours before use. 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. 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 20C and no more than 18 hours at 35C between coats, and again achieving a wet film thickness not less than 250 microns.Suitable cloth is open weave 110 g/m glass cloth. Cleaning Nitocote EP410 should be removed from tools and equipment with Fosroc Solvent 102 immediately after use. Cured material can only be removed mechanically.
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 5C or is 5C and falling, nor when the prevailing relative humidity exceeds 90%. 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 5C and 30C in the original, unopened containers. Material from different batches shall be stored separately. Storage at higher temperatures may reduce shelf life.
Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet. Disposal 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
Supply Nitocote EP410: Nitoprime 25: Nitoprime 28: Fosroc Solvent 102: Coverage Nitocote EP410: Nitoprime 25: Nitoprime 28: 15.68m2/5.6kg pack 5m /0.95kg Handy pack 26m2/5kg Industrial pack 2.4m2/0.45kg Handy pack 20m2/4.2kg Industrialpack
2
5.6kg packs 0.95kg Handy packs 5kg Industrial packs 0.45kg Handy packs 4.2kg Industrialpacks 5 and 25 litre tins
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. Flash points Fosroc Solvent 102: Nitoprime 25: Nitoprime 28: 33 oC 55 oC 27 oC
For further information, consult the Product Safety Data Sheet.

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Nitocote SN502

Penetrating, hydrophobic silane-siloxane treatment for concrete and masonry Uses
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.
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. Application
Advantages
Penetrates into substrates Non-staining Reduces water and chloride intrusion Increases freeze thaw resistance Minimises efflorescence Allows water vapour to escape from the structure Chemically resistant to ice melting compounds, fuels, oils and atmospheric contaminants
In order to obtain the penetrating properties of Nitocote SN502, it is important that the correct rates of application and overcoating times are observed. Number of coats: Theoretical application rate per coat: Overcoating time: 2 flood coats 0.2 litres/m2 2 hours @ 20C
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 does not discolour most substrates and has excellent resistance to weathering.
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. Nitocote SN502 should be allowed to dry for a minimum of 2 hours (at 20C) before continuing. Cleaning Nitocote SN502 should be removed from tools and equipment using Fosroc Solvent 102 immediately after use.
Silane-siloxane penetrating treatment 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.
Limitations
Nitocote SN502 should not be contaminated with water. The application of Nitocote SN502 should not commence if the temperature of the substrate is below 2C. Nitocote SN502 may darken some polymer modified substrates and white cement. A trial area is recommended.
Properties
The values obtained are for Nitocote SN502 applied at the minimum recommended application rate. Reduction in chloride ion penetration To NCHRP 244 Standard: Australian C.T.I. method: Reduction in water absorption To NCHRP 244 Standard: Australian C.T.I. method:
Estimating
Supply
92% 98% 85% 94%
Nitocote SN502: Fosroc Solvent 102: Coverage and yield Nitocote SN502:
25 and 200 litre containers 5 and 25 litre tins
5 m2 per litre per coat
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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: Fosroc Solvent 102: 38C 33 oC

Important note
Fosroc Limited
www.fosroc.com
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Monomeric silane water repellant penetrant Uses
A penetrating treatment designed to protect concrete from both water and chloride ingress whilst still permitting water vapour transmission (breatheability). Application
CI/SfB: January 2006
In order to obtain the penetrating properties of Nitocote SN511, it is important that the correct rates of application and overcoating times are observed. Number of coats: Theoretical application rate per coat: Overcoating time at 20C: 2 flood coats 0.3 litres/m Minimum 6 hours
Advantages
Markedly reduces water and chloride ingress Deep penetration into substrates Non-staining Increases freeze thaw resistance Minimises efflorescence Chemically resistant to de-icing compounds and atmospheric contaminants
Nitocote SN511 should be applied by a continuously circulating pumped system at a nozzle pressure of 0.06 to 0.07 N/mm (8 to 10 lbf/in). 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/m. The interval between applications shall be a minimum of 6 hours (at 20C) before continuing. Surfaces should be protected from rain and spray during application and for at least 6 hours after completion. 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.
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. This treatment markedly reduces absorption of water and water-borne salts, but still permits passage of water vapour. The treatment is not affected by UV light and does not produce any discolouration of the substrate.
Estimating
Packaging Nitocote SN511: Fosroc Solvent 102: Coverage and yield Nitocote SN511: 0.3 litres/m per coat (minimum) 25 litre container 5 and 25 litre tins
Conforms to DTp Specification BD43/03 and BD43/90 and BA33/90.
Properties
Specific gravity: Purity: Refractive index Approximately 0.9 Minimum 95% 1.396 +/- 0.004
Limitations
The application of Nitocote SN511 should not commence if temperatures are below 5C and falling or if the concrete surface temperature is above 25C. Nitocote SN511 hydrolises with atmospheric moisture. Material from opened containers should be used within 48 hours or discarded. There is a possibility of colour change on some types of polymer modified facing materials and white cement. A trial area is recommended.
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. Protect plants, glass, asphalt, bitumen, plastics and all painted surfaces prior to application.
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Storage
Shelf life 12 months when stored in original unopened containers. Storage conditions Nitocote SN511 and Fosroc Solvent 102 should be stored in a cool dry place away from sources of heat or naked flames.
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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: Fosroc Solvent 102: 39C 33C
(Abel closed cup method IP33)

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Galvafroid
Zinc rich cold galvanising coating Uses
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.
contents are stirred periodically during application to avoid settlement. 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.
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 5C. 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. 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.
Properties
Volume solids: Solids by weight: Zinc content by volume on dry film: Zinc content by weight on dry film: Drying times at 20C touch dry: hard dry: recoating time: 40% 80% 61% 90% 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
Galvafroid should be removed from tools and equipment with Fosroc Thinner/Cleaner immediately after use. Dried material can only be removed mechanically.
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. Mixing Galvafroid must be thoroughly stirred to give a uniform product prior to application. It is recommended that the
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Estimating
Supply Galvafroid: Pack of 6 x 400 ml tins Pack of 4 x 800 ml tins 1.9 litre tin 0.5 litre tins
Fosroc Thinner/Cleaner: Coverage Galvafroid:
16 m2/litre when used as a primer 8 m2/litre when used as a self-finish
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Fosroc Galvafroid
Limitations
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. Galvafroid should not be used on surfaces exposed to soft water at temperatures above 60C. Galvafroid should not be used on surfaces treated with phosphoric acid based rust removers. Galvafroid should not be overcoated with materials containing strong solvents such as chlorinated and aromatic hydrocarbons, esters and ethers.
Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire 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. Flash points Galvafroid: Fosroc Thinner/Cleaner: 41C 41C
Storage
Galvafroid has a shelf life of 12 months if kept in a dry store between 5C and 20C in the original, unopened container.
Galvafroid is a trade mark of Fosroc International Limited

Important note
Fosroc Limited
www.fosroc.com
146
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Cemtop
Polymer modified, cement based, floor levelling compounds 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. Cemtop GP30: A general purpose floor levelling compound/underlayment for the preparation of floor surfaces before the application of tiles, carpet, vinyl, etc. 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. Cemtop XD: A heavy duty, highly abrasion resistant floor surfacing system for the reinstatement of industrial floor surfaces. See also Uses table on page 3.
Floor areas so designated should be covered with the Cemtop product as manufactured by Fosroc. The product should be applied in accordance with the manufacturers application instructions.
Properties
See Physical properties table on the third page of this datasheet.
Although the products have been designed for application by pump, they can also be applied by hand. 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. Installation by hand Typically, in areas of less than 100 m it will be more practical to install Cemtop by hand. Surface preparation it is essential that both new and old concrete floors are correctly prepared prior to the appplication of Cemtop. 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. 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. For recommendations or additional information regarding substrate preparation, please contact Fosroc. Application procedure
Advantages
Very fast application, enables large areas of floor to be completed in a working day Can be applied directly onto concrete floors, eliminates traditional sand-cement screeds 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. The products are supplied as a grey powder which requires only the addition of water to produce self smoothing, free flowing material.
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. BS 476, Part 6: 1989. Method of Test for Fire Propagation for Products Fire Propagation Index, I = 0.0. BS 476, Part 7: 1987. Surface Spread of Flame Test for Materials Class 1 Surface Spread of Flame.
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Thoroughly prepare the floor surface as above. 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 to the required thickness onto the dry, primed surface.
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Cemtop
Priming The objective of priming is to seal the substrate to prevent release of air from the substrate. Mixing 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. Ensure that sufficient labour is available to enable continuous mixing and pouring. Place the Cemtop within 2 minutes of completion of mixing. Pour the mixed material on to the dry primed surface, spread with trowel and allow to level. Roll surface with a spiked roller to aid air release and levelling properties. Do not over-roll. To reduce the formation of seam lines, freshly mixed Cemtop should be placed within 5 minutes of the previous adjacent batch being laid. Note: If the mix stiffens it should be discarded, do not attempt to re-mix with water. again prior to the application of Cemtop XD or Cemtop GP12 (both at 1: 3 primer to water ratio by volume).
Limitations
Concrete slabs onto which the Cemtop is to be applied must have a surface temperature of at least +5C with air temperature maintained at +10C or more during application. For temperatures in excess of 25C during application refer to Fosroc Customer Services Department. 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. If the substrate onto which Cemtop is applied moves or cracks, reflective cracking may occur. Cemtop should not be applied to asphalt substrates. Cemtop should not be applied to external surfaces or surfaces subject to wetting.
Estimating See Estimating table overleaf.
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
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Cemtop
Uses
Cemtop S 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: Cemtop GP30 Cemtop GP12 Cemtop XD
Physical properties
Cemtop S Compressive strength at 28 days (40 mm cubes cured at 20C, 65% RH): Flexural strength at 28 days (rectangular prisms cured at 20C, 65% RH): C + CA accelerated wear tests at 28 days* Category: BRE impact resistance at 28 days (BS 8204, Part 1: 1987) Category: TRRL slip resistance test 4S rubber slider: TRRL rubber slider: 20 N/mm 4.5 N/mm A N/A N/A Cemtop GP30 20 N/mm 4.5 N/mm A Dry: excellent Wet: satisfactory Dry: excellent Wet: satisfactory Cemtop GP12 25 N/mm 7.0 N/mm Normal A N/A N/A Cemtop XD 30 N/mm 8.0 N/mm Good A Dry: excellent Wet: satisfactory Dry: excellent Wet: satisfactory
Traffic time at 20C Foot traffic: Light traffic: Heavy traffic:
4 hours 24 hours
4 hours 24 hours
4 hours 48 hours
4 hours 36 hours 7 days
* Refer to Concrete Society Technical Report No. 34.
Category A is the highest rating.
Estimating
Cemtop S Application thickness: Application method: Theoretical coverage: Supply: Water addition per 25 kg bag: * Can be taken down to a chamfered edge. Nitoprime 33: 5 m/litre of concentrate per 2 priming coats 4 m/litre of concentrate per 3 priming coats 3 m/litre of concentrate per 4 priming coats 25 litre containers Featheredge to 10 mm Pump/hand 1.7 kg/mm/m 25 kg bags 5.0 litres Cemtop GP30 5 to 30 mm Pump/hand 1.7 kg/mm/m 25 kg bags 4.0 litres Cemtop GP12 6 to 12 mm* Pump/hand 1.7 kg/mm/m 25 kg bags 4.5 litres Cemtop XD 6 to 12 mm* Pump/hand 1.7 kg/mm/m 25 kg bags 4.5 litres
Supply:
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Cemtop
Storage
Store in unopened bags in cool dry internal conditions. 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. Nitoprime 33 has a shelf life of 12 months if stored at 20C. Protect from frost and extreme heat. Nitoflor FC140 If additional chemical resistance is required, Nitoflor FC140 can be applied over a single coat of Nitoflor FC130. It is recommended that Fosrocs technical department should be consulted prior to the installation of a combined product system such as the systems described in this data sheet.
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 Limited
Drayton Manor Business Park Coleshill Road, Tamworth, Staffordshire B78 3TL. UK telephone: +44 (0) 1827 262222 fax: +44 (0) 1827 262444 150 Page 4 email: uk@fosroc.com
www.fosroc.com
Fosroc Nitoflor FC130 & FC140

High performance epoxy resin floor coatings Uses
Nitoflor FC130 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. 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. 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.
CI/SfB: (43) Pr4 June 2008
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. Nitoflor FC130 and Nitoflor FC140 comply with BS 476, Part 7 : 1971 Class 1 spread of flame.
Properties
The values given below are average figures achieved in laboratory tests at 20C and 35C. Actual values obtained on site may show minor variations from those quoted. Physical properties Nitoflor FC130 Pot life*: Time between coats: hours Initial hardness: Full cure: @ 20C 2 hours @ 35C 1 hour
6 to 24 hours 4 to 16 24 hours 7 days 16 hours 7 days
Dry film thickness (2 coats): 100 microns (approximate) Nitoflor FC140 Pot life*: Tack-free time: Time between coats: hours Initial hardness: Full cure: @ 20C 4 hours 4 to 6 hours 6 to 24 hours 24 hours 7 days @ 35C 1.5 hours 2 to 4 hours 4 to 16 18 hours 5 days
Advantages
Hard wearing durable, low maintenance costs High resistance to a wide range of industrial chemicals Hygienic impervious finish provides easily cleaned surface Attractive available in a range of colours to improve the working environment
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. 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.
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. 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. Nitoflor FC130 and Nitoflor FC140 are available in a range of standard colours and are also available in a clear grade.
All coating work to be carried out in accordance with the relevant sections of BS6150:2006, Painting of Buildings Code of Practice. Surface preparation It is essential that Nitoflor FC130 and Nitoflor FC140 are applied to sound, clean, dry substrates in order to achieve
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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. 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. Old concrete floors 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. When using Nitoflor FC140 on very porous surfaces or surfaces which are damp prime with a single coat of Nitoprime 25. 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. Mixing 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. Coating 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. 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.
Good drying conditions are required to allow complete evaporation of the water as the resin cures. Adequate ventilation and air movement is necessary. 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. 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 Nitoflor FC130 should be removed from tools and equipment with clean water immediately after use. Nitoflor FC140 should be removed from tools and equipment with Fosroc Solvent 102 immediately after use. Hardened material can only be removed mechanically. Maintenance The service life of a floor can be considerably extended 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.
Estimating
Supply Nitoflor FC130: Nitoflor FC140: Nitoprime 25: Fosroc Solvent 102: Nitoflor anti-slip grains: Coverage Nitoflor FC130 and FC140: Nitoflor FC130 and FC140 with Anti-slip Grains: Nitoprime 25: 35 to 40 m/pack (per coat) 24 to 30 m/pack (per coat) 25 m/pack 5 kg packs 5 kg packs 5 kg packs 5 and 25 litre tins 0.9 kg
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Limitations
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. 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. 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. Nitoflor FC130 should not be applied at temperatures below 10C or where ambient relative humidity exceeds 85%. Nitoflor FC140 should not be installed at temperatures below 5C. 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.
Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Nitoflor FC130 is non-flammable. 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. Flash points Nitoflor FC140: Fosroc Solvent 102 Disposal 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. For further information, refer to the Product Safety Data Sheet. 23C 33C
Storage
Nitoflor FC130 should be stored in dry conditions between 10C and 30C, 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 Limited
www.fosroc.com
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Fosroc Nitoflor Hardtop S

Dry shake floor hardener for new concrete floors 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.
CI/SfB: (13) pq4 January 2009
Properties
Abrasion resistance Nitoflor Hardtop S application rate per m2 concrete 3Kg 5Kg First app. Kg/m2 2 3 Second app. Kg/m2 1 2 BS8204 classification ARI Special
Average wear of 0.02mm for special class. 20 time increase on 40N/mm2 concrete ( concrete society technical report no.34, 2nd edition) Hardness (Mohs scale) The selected aggregates contained within Nitoflor Hardtop S have a hardness value of 7 on the Mohs original scale.
Advantages
Supplied ready to use no additives required 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. 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. 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. 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. On large floors it will be necessary to work progressively behind the laying team to ensure application at the correct time.
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. Nitoflor Hardtop S is available in natural (concrete grey) colour as standard.
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%. 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 manufacturers instructions. Special attention shall be paid to bay edges in accordance with the manufacturers written requirements.
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Nitoflor Hardtop S is applied in two stages. (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. (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. Bay edges 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: (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. (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. 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. 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. 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. Cleaning 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. 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. Surface treatments Subsequent surface treatments are not normally necessary with Nitoflor Hardtop S because of the high density, low porosity finish.
Estimating
Supply Nitoflor Hardtop S: Concure WB: Coverage Nitoflor Hardtop S: Concure WB: 5 kg/m2 / 3 kg/m2 3.5 to 5 m2/litre 25 kg bags 20 litre container
Applications should comply with the recommended rate to obtain the published performance characteristics. Any reduction may have a detrimental effect on the finished floors abrasion resistance and, in the case of pigmented floors, the quality and consistency of the finish.
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. 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.
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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.
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 Limited
www.fosroc.com
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Fosroc Nitoflor Lithurin

Permanent hardening and dustproofing compound for concrete surfaces Uses
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. 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
CI/SfB: Yu5 May 2009
Preparation 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). 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. 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 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. 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 m using a soft broom or brush. Ensure that the surface is thoroughly saturated with the solution and well brushed out to prevent ponding. 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.
Description
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.
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
Chemical resistance:
Estimating
Nitoflor Lithurin is supplied in 15 kg buckets. One coat applications require approximately one bucket to cover approximately 200 m . Two coat applications require approximately one bucket per 150 m. 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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Fosroc Nitoflor Lithurin

Limitations
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. 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.
CI/SfB: Yu5 May 2009
2 kg of lime for neutralisation. The pH of the solution must always be checked to ensure that complete neutralisation has occurred. 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. 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 Limited
www.fosroc.com
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CI/SfB: July 2009
Fosroc Polyurea FLM

Fast setting, pure polyurea elastomeric floor coating
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. 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 Protective coating for flooring applications in a wide range of environmental conditions. Typical applications include: Industrial floors Processing plants Food processing areas Stadia Workshops & production facilities Manufacturing plants 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. Advantages Environment friendly - zero VOC Excellent chemical resistance, thermal stability and UV Resistance * Very fast turn-around time. The coated substrate can be put into service within an hour Excellent impact, abrasion and puncture resistance Seamless and monolithic, including day joints Significantly enhances the durability of reinforced concrete Low permeability values Designed for service temperatures from -30 C to +135 oC *See Limitations Specification The protective and/or wateproofing coating shall be Fosroc Polyurea FLM, a 100% solids, flexible, two component,
o
rapid curing pure Polyurea coating system providing high corrosion, abrasion and thermal shock resistance. It shall meet the values under the section Properties.
Typical Physical properties at 23oC Solids by Volume Volatile organic compounds Viscosity Density at 23oC Tensile strength ASTM D412 Modulus 100%/ 200%/ 300% ASTM D412 Elongation ASTM D412 Shore D ASTM D2240 Abrasion (1kg,H22 wheels) ASTM D4060 Abrasion (1kg,CS17 wheels) DIN EN ISO 5470 Service temperature ASTM D4060 : 100% : 0 g/litre : A ISO =1000 mPas : B AMINE <1500 mPas : 1.01 g/ml : >16 Nmm-2 : >9/ 12/ 15 Nmm-2 : >300% : 47 : 29 mg /1000 cycles : < 0.02mg /1000 cycles : -30oC to +135oC
Tear Resistance ASTM D624C : 85 5 N/mm
Colour : RAL 7005 Grey Other colours available to order Chemical Resistance (ASTM D3912, 72 hours immersion) Chemical Hydraulic Oil Motor Oil Diesel Fuel Petrol Skydrol Sodium Hydroxide (50%) Ammonia (0.880) 33% Sugar solution conc. Bleach (5%) Butanol Lactic Acid (20%) Phosphoric Acid (10%) Hydrochloric Acid (20%) Nitric Acid (30%) R R R R-C R R R-C R-C Result Max service temp. R R 50 oC 25 oC NR 50 oC 25 oC 50 oC 25 oC 50 oC 50 oC 50 oC 25 oC R-DIS 50 oC R-DIS 25 oC
R-DIS 50 oC
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
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Fosroc Polyurea FLM

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. Clarification of property values 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 Hose Temperature Volume ratio Pressure Gel Time Walkable Trafficable (light duty) Trafficable (medium duty) Trafficable (heavy duty) : +70o C to +80oC : +70o C to +80oC : 1:1 : 120 - 150 bar : 5 - 10 sec : 2 mins : 15 - 20 minutes : 24 hours : 7 days 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. 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. 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. 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. 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. A list of appropriate equipment is provided in the Fosroc Polyurea Method Statement. 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. Following correct preparation, the substrate must be primed. Fosroc Primer 195 should be used. of BS EN ISO 8501-1:2007. Any laminations must be removed. Blast cleaning to Sa 2. (ISO 8501-1:2007). Roughness: using abrasives suitable to achieve a coarse surface of Grade Medium G (50-85m, Ry5) (BS EN ISO 85032:2001). 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.

Refer to Application section below and Fosroc Polyurea Method Statement for further detail. Surface preparation All surfaces must be clean, dry and free from contamination. 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. 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. Steel The steel must be of first class quality and must not have been allowed to rust more than corresponding to grade B
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Fosroc Polyurea FLM

Application Method 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. If pigmented material is stored it should be mixed with a bunghole mixer for 20 minutes prior to use. Avoid moisture contamination of bulk material, seal drums for storage. Do not add solvent. Heat the spray lines to 70 80 C. 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. If non slip surfaces are required consult Fosroc Polyurea Method Statement. 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. Due to the fast cure rate of Fosroc Polyurea FLM overspray can only be removed mechanically.
o
Coverage: Fosroc Polyurea FLM : 1.5 3.0 ltrs per m2 (1.5 - 3.0 mm) depending on specification
Fosroc Primer 195

Storage
: Concrete : 2.5 - 4 m2 / litre : Steel : 6.5m2 / litre
Fosroc Polyurea FLM and Primer 195 have a shelf life of 12 months if kept in a dry, air conditioned store between +5C and +30C in the original unopened containers.
Limitations
Fosroc Polyurea FLM should not be applied over existing coatings. 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. 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.
Estimating
Supply: Fosroc Polyurea FLM Part A ISO component
Precautions
: 200 ltr drums Health and Safety 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 Polyurea FLM Part B AMINE component : 200 ltr drums : 195 ltr drums + separate colour pack Fosroc Primer 195 Part A Base Fosroc Primer 195 Part B Hardener : 12.5kg in 25 litre pail : 7.5kg in 10 litre pail
Fosroc Equipment Cleaner: 5 litre
Important note
Fosroc Limited
www.fosroc.com
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Fosroc Concure WB
Water based concrete curing compound 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
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. 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. Coverage rate The recommended coverage rate is between 3.5 and 5.0 m/litre (0.200 to 0.285 litres/m). 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. Equipment 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. 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. Overcoating and removal 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.
Advantages
Improved curing of concrete enhances cement hydration and provides a more durable concrete Control of moisture loss improves surface quality, reducing permeability, producing a hard wearing, dustfree surface and minimising potential for surface cracking and shrinkage Fugitive colour provides visual guide during application Water based, therefore, non-flammable Spray application reduces labour costs and eliminates the need for alternative curing systems
Concure WB gives 75% or greater curing efficiency when tested to BS 7542 and complies with ASTM C309 and AASHTO M148 as Type 1.
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. 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.
Minimum application temperature: 5C 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.
Limitations
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. In extreme drying conditions additional curing using polythene or wet muslin may be required.
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Fosroc Concure WB
Estimating
Supply Concure WB is supplied in 200 litre and 20 litre drums.
Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Concure WB is water based and non-flammable.
Storage
Concure WB has a minimum shelf life of 12 months provided the temperature is kept within the range of 4C to 35C. 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. Containers should be kept sealed and airtight to prevent loss of moisture by evaporation.
Concure is the trade mark of Fosroc International Limited
Important note
Fosroc Limited
www.fosroc.com
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Fosroc Acid Etch

Concrete remover, cleaning and etching agent Uses
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.
Cleaning large items of equipment (Examples are readymix trucks, concrete mixers or barrows.) 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. Cleaning small tools 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. Cleaning concrete floors 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. 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. 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.
Advantages
Rapid concrete etching action No corrosive action with glass, plastic and rubber Cleans hardened concrete from tools and mechanical equipment
Description
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.
Properties
Specific gravity: Typically 1.08 at 20C
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.
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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 Limited
www.fosroc.com
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CI/SfB: Yt4 February 2006
Fosroc Nitoseal 12
Biodegradation resistant sealant Uses
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. The principal applications for Nitoseal 12 are: Sludge digestion tanks Filtration and aeration tanks Culverts Raw water reservoirs Sea walls 1 Nitoseal 12 2 Hydrocell XL* 3 Water face
Design criteria
Example of an expansion joint in a reservoir wall is shown below
1 2 4 2 5 6
4 Supercast Hydrofoil* 5 Thioflex 600* 6 External face
* Also available from Fosroc
Advantages
Resistant to aerobic and anaerobic bacteriological attack Excellent adhesion under immersed conditions Abrasion resistant Separate component for accelerating the initial cure
Properties
Technical data Nitoseal 12 Form: Two-part compound Base: White paste Curing agent: Dark-grey paste 12 months in original containers in cool, dry conditions 100% 1.44 kg/litre Grey
Storage life: Solids content: Density: Colour:
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. 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 10C the seal can be subjected to tidal immersion approximately 60 minutes after application, without adverse effect.
Physical/chemical change: Chemical cure Application temperature: Pot life: Cure rate: Cure time: 5C to 50C 2 to 3 hours at 25C With accelerator 20 minutes at 25C 48 hours at 25C With accelerator 24 hours at 25C 48 hours at 25C 96 hours at 10C Permanent immersion in water should not occur until full cure has taken place
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 manufacturers printed instructions.
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 10C prior to immersion. Hardness shore A at 25C: 35 to 40
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Fosroc Nitoseal 12
Flammability: Biological: resistance Movement accommodation factor: Burns but does not readily support combustion Good resistance to both aerobic and anaerobic conditions normally occurring in sewage treatment works 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. Finishing 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
20% in butt joints
Technical data Nitoseal 12 accelerator Flash point: Storage life: Pack size: Over 65C 12 months in original containers in cool, dry conditions 50 ml
Joint preparation 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. Ensure that expansion joint fillers are tightly packed and that no voids are left at the base of the sealing slot. 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. Non-porous surfaces: Fosroc Primer 4. NB: Avoid using too much primer resulting in pools in the base of the joint. 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. 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.
Clean equipment immediately after use with Fosroc Equipment Cleaner.
Estimating
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. Guide to Nitoseal 12 quantities Joint size in mm (w x d) 5x5 10 x 5 20 x 10 25 x 15 30 x 15 40 x 20 50 x 25 Litres per metre run 0.025 0.050 0.200 0.375 0.450 0.800 1.300 Metre run per 2 litre 80.0 40.0 10.0 5.3 4.4 2.5 1.6
Guide to primer quantities 1 litre of Fosroc Primer 7 to 30 litres of Nitoseal 12. 1 litre of Fosroc Primer 4 to 150 litres of Nitoseal 12.
Storage
Fosroc Primer 4 and Fosroc Primer 7 must be stored in accordance with the Highly Flammable Liquids and Liquefied Petroleum Gases Regulations 1972.
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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 Flash point: Coverage: Application temperature: Drying time: Pack size: 14C 60 m/litre 5C to 50C 2 to 15 minutes minutes 250 ml
Fosroc Primer 7 23C 12 to 15 m/litre 5C to 50C 20 to 60 500 ml 5 litres
Fosroc Equipment Cleaner Flash point: Storage life: Pack size: 44C Indefinite 5 litres
Nitoseal is a trade mark of Fosroc International Limited

Important note
Fosroc Limited
www.fosroc.com
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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
CI/SfB: Yt4 July 2009
Advantages
Approved for use in contact with potable water 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 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 Isocyanate free technology
Design criteria
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. 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. To calculate the theoretical minimum joint width knowing the expected maximum working movement of the joint: W= M __ + M MAF/100
Description
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.
W = Joint width
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.
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M = Expected maximum working movement of joint MAF = Movement Accommodation Factor of that sealant
Properties
Form: Colour: Smooth, non-slumping paste Grey For special colours contact Fosroc for further Information 25% butt joints 50% lap joints 30 minutes 24 hours: 48 hours: 72 hours: 5C to 50C Dry 30C to +80C Wet up to 40C 32 Resistant to occasional spillage of many chemicals: see limitations Nitoseal MS600 has been evaluated in microbiologically active situations and has been shown to have resistance to aerobic and anaerobic conditions Excellent 3mm 6mm 8mm
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. 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: Skinning time at 20 C / 50% RH: Cure rate at 20 C / 50% RH: Application Service temperature: Hardness shore A 20C: Chemical resistance: Biological resistance:
Priming
Fosroc Primer MS2 is required for all joints. 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. 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. 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.
UV resistance:
Water immersion: Nitoseal MS600 must be fully cured before permanent immersion in water
Cleaning 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. Removal can be achieved by rigorous wire brushing, grinding or grit blasting. Joints in concrete should preferably be sawn. After sawing, all saw slurry must be flushed away and the joint allowed to dry. 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. 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 Clean tools immediately after use with Fosroc Equipment Cleaner.
Estimating
Guide to quantities Joint 6 x 10 12 x 10 20 x 20 25 x 12 30 x 15 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
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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 Limited
www.fosroc.com
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CI/SfB: Yt4 December 2005
Fosroc Plastijoint
Hand applied flexible bituminous putty Uses
Plastijoint is recommended for sealing joints, particularly vertical and inclined joints, in most types of water retaining structures. Sewage disposal works Culverts Sea walls Retaining walls (brickwork and concrete) Subways and basement structures
Properties
Form: Colour: Movement accommodation factor BS 6093: Application temperature: Chemical resistance to occasional spillage: Biological resistance: Solids content: Stiff putty Black
10% for butt joints 5C to 50C (Plastijoint heated to 45C to 55C) Dilute acids Dilute alkalis Petroleum solvents Mineral oils Vegetable oils resistant resistant non resistant non resistant non resistant
Advantages
Designed for permanent immersion in water Tough, weather resistant seal Excellent slump resistance Easily applied by hand Suitable for joints up to 40 mm wide Resistant to bacteriological attack
Plastijoint is resistant to the aerobic and anaerobic conditions normally occurring in sewage treatment works 100%
Preparation Plastijoint is applied by hand after it has been heated to 45C to 55C 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. 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. 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.
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. 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.
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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. Finishing 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. Cleaning Clean equipment immediately after use with Fosroc Equipment Cleaner.
Storage
Shelf life 2 years stored in cool dry conditions in unopened original containers.
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.
Estimating
Guide to Plastijoint quantities Joint size in mm 20 x 20 25 30 25 x 20 25 30 40 30 x 25 40 Litre per metre 0.40 0.50 0.60 0.50 0.63 0.75 1.00 0.75 1.20 Metre per 5 litre 13.0 10.0 8.3 10.0 8.0 6.7 5.0 6.7 4.2 Joint size in mm 30 x 50 35 x 25 30 40 50 40 x 25 30 50 Litre per metre 1.50 0.88 1.10 1.40 1.80 1.00 1.20 2.00 Metre per 5 litre 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 Limited
www.fosroc.com
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Fosroc Colpor 200PF

Cold applied, high performance, pitch free, pavement joint sealant Uses
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. Hardness shore A at 25C: Chemical resistance to occasional spillage:
Application temperature:
To avoid unacceptably prolonged cure times, do not apply at temperatures below 5C 15 5 Aviation fuels Hydraulic fluids Skydrol Kerosene Petrol Diesel fuels 100% Over 65C Burns but does not readily support combustion Synthetic oils Mineral oils White spirit Mild alkalis Dilute acids
Advantages
Pitch free Cold applied no heating equipment required Fuel, oil and hydraulic fluid resistance High durability and long service life High movement accommodation Solids content: Flash point: Flammability:
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 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. 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. Priming Concrete joint faces should be primed with Fosroc Primer 20 or Primer 19. 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. 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. Primer 19 Empty the entire contents of the Primer 19 hardener tin into the base tin, and replace base tin lid. Mix thoroughly
British Standard 5212 : 1990 types N, F and FB. 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. 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. The width/depth ratio of the Colpor 200PF seal should be 1 : 1 to 1 : 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).
Properties
Form: Two part compound Base compound: viscous liquid Curing agent: liquid Black Butt joints 25% Chemical cure 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 25C
Colour: MAF (BS 6093): Physical or chemical change: Setting time:
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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. 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. In cold weather, Colpor 200PF mixes more easily if stored overnight at room temperature. 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. Cleaning Clean equipment immediately after use with Fosroc Equipment Cleaner. Remove mixed material from the hands with Swarfega or similar industrial hand cleanser. Guide to Colpor 200PF quantities Joint size in mm 10 x 10 13 x 13 15 x 15 20 x 15 20 x 20 25 x 20 25 x 25 30 x 25 Litre per metre 0.100 0.169 0.225 0.300 0.400 0.500 0.625 0.750 Metre per 5.0 litre pack 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.
Limitations
For the sealing of industrial floor joints, higher modulus sealants such as Thioflex 600* or Expoflex 800* (see separate data sheets) are recommended. 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.
Storage
Store Colpor 200PF in original containers in cool, dry conditions i.e. not exceeding 25C. Storage life in these conditions is 12 months. Storage above this temperature may reduce storage life.
Estimating
Packaging 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.
Precautions
Colpor is the trade mark of Fosroc International Limited

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Nitoseal 333

Hot poured N1 polymer modified bitumen sealant Uses
For the sealing and maintenance of joints in concrete roads and asphalt surfacing
Properties
Form: Colour: Movement accommodation factor (BS 6093): Application temperature: Safe heating temperature: Pouring temperature: Chemical resistance: Solids content: Density: Flash point: Plastic solid Black
Butt joints 25% Over 5C 185C 165C to 175C Not resistant to petrol, diesel, lubricating oils or greases 100% 1.15 0.05 Over 65C
Advantages
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. 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. 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.
Applications instructions
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. 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. Application 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. 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 165C to 175C. 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
BS 2499 : 1993 Type N1. Nitoseal 333 has been independently tested to BS 2499 : N1 in accordance with the Department of Transport Specification for Highway Works.
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. 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.
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temperature range. Frost may give concrete a deceptively dry appearance. Nitoseal 333 should be poured to a level 5 to 7 mm below the traffic surface, or to the level specified. Nitoseal 333 which has been heated and then allowed to cool below 95C must be discarded. Cleaning Equipment should be emptied immediately after use. Nitoseal 333 which has been heated and allowed to cool completely must be discarded. Ancillary materials Fosroc Primer B2 Fosroc Fibreboard Fosroc Equipment Cleaner
Storage
Nitoseal 333 must be stacked flat not more than six high and covered if stored outside. Fosroc Primer B2 should be stored in accordance with the Highly Flammable Liquids and Liquefied Petroleum Gases Regulations 1972.
Limitations
Nitoseal 333 is not suitable for use in contact with tar or pitch based materials. Nitoseal 333 should not be used in contact with potable water.
Precautions
Estimating
Packaging Nitoseal 333 is supplied in 15 kg packs. Guide to Nitoseal 333 quantities Joint size in mm 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 Kg per metre 0.12 0.15 0.18 0.24 0.23 0.26 0.36 0.43 0.48 0.58 0.72 0.86 Metres per 15 kg pack 120 100 83 62 65 57 40 35 31 26 21 17
Fire
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.
Technical data ancillary materials Fosroc Primer B2 Flash point: Specific gravity: Coverage: Application temperature: Pack size: 0C 0.9 12 m/litre 5C to 50C 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.

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Nitoseal 878

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. Chemical resistance to occasional spillage:
Aviation fuels Hydraulic fluids Skydrol Kerosene Petrol Diesel fuels 100% Over 65C
Synthetic oils Mineral oils White spirit Mild alkalis Dilute acids De-icing salts Urea
Solids content: Flash point: Flammability:
Burns but does not readily support combustion
Advantages
Fuel, oil and hydraulic fluid resistance High durability and long service life High movement accommodation
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. 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. Priming Concrete joint faces should be primed with Fosroc Primer 20. Decant sufficient primer into a clean dry tin for the days 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. 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. The mixed Fosroc Primer 19 should be applied within one working day. Do not split packs of Fosroc Primer 19.
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Standards
British Standard 5212:1990 - types N, F and FB.
Description
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. 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. The width/depth ratio of the Nitoseal 878 seal should be 1:1 to 1:1 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: Colour: MAF (BS 6093): Cure process: Application temperatures: Setting Time: 5C - 35C 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 Two component product comprising liquid base and curative Grey Butt joints 25% Chemical cure
Shore A Hardness: 20
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Fosroc Nitoseal 878

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. In cold weather, Nitoseal 878 mixes more easily if stored overnight at room temperature. 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. Cleaning Clean equipment immediately after use with Fosroc Equipment Cleaner. Remove mixed material from hands with Swarfega or similar industrial hand cleanser. 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.
Limitations
Apply at temperatures of 5C and rising. Do not warm material above 35C. 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. For the sealing of industrial floor joints, higher modulus sealants such as Nitoseal MS300* or Expoflex 800* are recommended. *See seperate data sheet
Storage
Nitoseal 878: 12 months in original containers stored in cool, dry conditions i.e. not exceeding 25C. Higher temperatures may reduce storage life.
Precautions
Estimating
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 10 x 10 13 x 13 15 x 15 20 x 15 20 x 20 25 x 20 25 x 25 30 x 25 Litre per metre 0.100 0.169 0.225 0.300 0.400 0.500 0.625 0.750 Metre per 20.0 litre pack 200 118 89 67 50 40 32 26
Important note
Fosroc Limited
www.fosroc.com
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Fosroc Pliastic
Hot-poured rubber bitumen horizontal joint sealant Uses
For sealing movement and construction joints in pavements, floor slabs, water retaining and water excluding structures
Water excluding structures All joints which extend below the high water table level should contain a waterstop in addition to the Pliastic seal. Services and internal finishes 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. Ensure the joint is recessed 3 to 5 mm below the traffic surface.
Advantages
An economic sealant for horizontal and inclined joints up to 1 in 20 Resists dirt and ingress of grit associated with trafficked pavements Good adhesion to concrete and asphalt surfaces
Properties
Form: Flash point: Solids contents: Density: Colour: Application temperature: Product pouring temperature range: Safe heating temperature: Chemical resistance to occasional spillage: Plastic solid Over 65C 100% 1.02 kg/litre Black Over 5C Pliastic N2: 175C to 185C Pliastic 77: 180C to 190C Pliastic N2: 190C Pliastic 77: 195C Dilute acids: resistant Dilute alkalis: resistant Petroleum solvents: not resistant Mineral oils: not resistant Vegetable oils: not resistant Greases: not resistant Total joint range, butt joints: Pliastic N2: 12% Pliastic 77: 10%
BS 2499 : 1993 Pliastic N2.
Description
Pliastic sealants are available in a choice of two grades: Pliastic N2 Complies with BS 2499 : 1993. A low extension grade 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. 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 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. 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.
Movement accommodation factor:
Maintenance
No special requirement, damage should be repaired if and when it occurs.
Joint preparation Ensure that the joint surfaces are completely dry, clean and frost free. Remove all contamination preferably by grit blasting or by rigorous wire brushing. Immediately prior to priming blow out all remaining loose dust with dry, oil-free compressed air. Where applicable, care must be taken to ensure that compressible filler, such as Fosroc Fibreboard, will provide adequate support for the Pliastic compound.
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Priming porous surfaces Use Fosroc Primer B2 on concrete, stone and brick paving. Allow primer to become touch dry before sealing, normally 1 to 4 hours. 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. 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. Heating The use of a heating vessel with an oil jacket and fitted with stirrer and thermometer is essential. 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. Pouring temperatures: Pliastic N2: 175C to 185C. Pliastic 77: 180C to 190C. Do not overheat. Use as soon as possible after heating, preferably within 2 hours. Safe heating temperatures: Pliastic N2: 190C. Pliastic 77: 195C. 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 95C 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. Application 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.
Cleaning
Equipment should be emptied immediately after use. Compound which has been heated and allowed to cool completely must be scrapped.
Estimating
Packaging 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. Fosroc Primer B2 is supplied in 5 or 25 litre cans. Guide to primer quantities 5 litres Fosroc Primer B2 for 250 kg of Pliastic.
Guide to Pliastic quantities Joint size in mm 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 Kg per metre run 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 Metre per 15 kg sack 76 61 51 38 51 41 34 26 20 38 31 26 19 20 17 13 10 15 10 8 Metre per 50 kg drum 255 204 170 127 170 136 113 85 68 128 102 85 64 68 57 43 34 51 32 26
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Limitations
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.
Precautions
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 Limited
www.fosroc.com
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Fosroc Expoflex 800

Heavy duty epoxy urethane joint sealant
Chemical resistance to occasional spillage:
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. UV resistance: Solids content: Density: Flash point:
Resistant to alcohols, alkalis, mineral oil, hot detergent solution, 60% live steam, 25% mineral acids, vegetable oils and kerosene Some surface discolouration and slight surface hardening 100% 1.4 g/cm Over 65C
Advantages
Cures to a tough seal Abrasion resistant High modulus Resistant to chemical, fuel and oil spillage Easily installed to give a flush finish
Joint Design Joints should be designed so that joint changes do not exceed the 10% MAF of Expoflex 800. 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. 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
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.
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.
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. Priming
Properties
Expoflex 800 Form: Two-part compound Base: White paste Curing agent: Grey paste Light grey 10% for butt joints Chemical cure 1 hour at 25C 24 hours at 20C: light traffic 48 hours at 20C: heavy traffic To avoid prolonged cure time apply Expoflex 800 above 5C 65 to 80 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. Mixing 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
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Colour: MAF (BS 6093): Cure: Pot life: Trafficking time: Application temperature: Hardness Shore A:
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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. Finishing
Storage
Storage life of 12 months in original containers when kept in dry conditions between 5C and 27C.
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. Cleaning Clean equipment immediately after use with Fosroc Equipment Cleaner. Health and safety For further information refer to appropriate Product Safety Data Sheet.
Estimating
Expoflex 800 is supplied in 2 litre tins in cartons of two. Guide to quantities Joint size w x d in mm 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 Litres per metre run 0.075 0.100 0.200 0.500 0.625 0.750 0.900 1.000 1.600 1.250 2.500 Metre run per 2.0 litre pack 26.67 20.00 10.00 4.00 3.20 2.67 2.22 2.00 1.25 1.60 0.80
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
Important note
Fosroc Limited
www.fosroc.com
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Fosroc Hilastic LM
One-part, low modulus neutral cure silicone sealant
Uses For sealing joints in building structures, uPVC windows and door frames. Advantages
Preparation 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. 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. Where a particularly neat finish is required, cover face edges with a masking tape and remove immediately after sealing work is completed. Application 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. Cleaning Clean tools immediately after use with Fosroc Equipment Cleaner. Clean hands with a proprietary hand cleaner.
Neutral cure system appropriate for porous and

non-porous surfaces
Elastic low modulus seal Good adhesion to a variety of substrates including

uPVC
Good application properties Description

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. 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: Colours: Cure: Skinning time @ 23C: Thixotropic paste White, brown, grey, buff, brick red, portland, black, dark grey Chemically cures to a solid rubber 30 minutes
Should not be used on substrates which bleed oils, plasticisers or solvents. Not to be used with bitumen compounds. Cure may be retarded in conditions of very low humidity and temperature. Hilastic LM should not be overcoated or painted even when fully cured. Like most silicone sealants, Hilastic LM should not be used on natural stone.
Cure rate @ 20C / 65% RH: 1 mm / day Application temperature: Typical hardness shore @ 20C / 60% RH: Movement accommodation factor (MAF): 5C to 40C
Estimating
30 Packaging 380 ml plastic cartridges with separate screw-on nozzles, packed in cartons of 20. Total contents approximately 7.6 litres.
50%
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Fosroc Hilastic LM
Guide to sealant quantities Joint size in mm 5x5 5 x 10 10 x 10 15 x 10 20 x 10 25 x 12 Litre per metre run 0.025 0.050 0.100 0.150 0.200 0.300 Metre per 380 ml cartridge 15.20 7.60 3.80 2.53 1.90 1.27
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
Hilastic is the trademark of Fosroc International Limited

Important note
Fosroc Limited
www.fosroc.com
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One part, general purpose building sealant Uses
Nitoseal MS50 is suitable for sealing joints in Concrete, Brickwork, Blockwork, Perimeter sealing around doors and windows, Non-trafficked floor joints.
Joints in concrete should preferably be sawn. After sawing all saw slurry must be flushed away and the joint allowed to dry. 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. 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. 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. Where a particularly neat finish is required, mask the face edges of the joint before sealing and remove immediately after tooling is completed. Priming 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. Prime the joint face using a clean, dry brush. Avoid over application of primer causing puddles in the bottom of 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. Application and finishing Sachets Cut the end off the sachet and place in the Fosroc GX gun. Fit the nozzle and cut at 45 degrees at a suitable size for sealing the joint. Cartridges Cut end off threaded stub on cartridge, Fit the nozzle and cut at 45 degrees at a suitable size for sealing the joint. 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. Cleaning Clean tools immediately after use with Fosroc Equipment Cleaner.
Advantages
Excellent adhesion to most common building materials Single component with fast rate of cure Easy to apply at low temperature Can be applied to damp substrates Environmentally friendly Primer-less for most applications (see Priming) Available in a range of colours (see Properties) Isocyanate free technology Acts as an acoustic sealant
Description
Nitoseal MS50 is a one part, medium modulus sealant based on hybrid silyl modified polyether technology.
Properties
Form Colour Smooth, non-slumping paste White, Grey, Black, Magnolia, Buff, Portland,Rustic Red, Brown, Anthracite > 65oC 30 minutes 24 hours 48 hours 72 hours 5oC to 50oC 28 3mm 6mm 8mm
Flash point Skinning time at 20 C / 50%RH Cure rate at 20 C, 50% RH Application temperature Typical hardness Shore A at 20 C
Movement accommodation 20% factor (MAF) UV resistance Good Service temperature range -30oC to 70oC
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.
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Estimating
Guide to sealant quantities Joint size Litres/ mm metre run 6 x 10 12 x 10 20 x 10 25 x 12 30 x 15 0.06 0.12 0.20 0.30 0.45 Metres/ 380ml crtdge 6.33 3.17 1.90 1.27 0.84 Metres/ 600ml sachets 10.00 5.00 1.00 2.00 1.33
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 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.

Important note
Fosroc Limited
www.fosroc.com
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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.
CI/SfB: Yt4 January 2006
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. Good adhesion to silicone, polysulphide or polyurethane contaminant. * Refer to Priming section. Cured sealant: Form: Colour: Typical hardnesss Shore 'A' @ 20oC: Modulus classification: U.V. resistance: Service temperature range: MAF: Elastic solid White, Grey, Black, Portland, Buff, Rustic Red 20 Low Excellent -40oC to 70oC Butt joints Lap joints 25% 50% 50% 100% unprimed primed unprimed primed
Standard compliance
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. 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.
Application Instructions Preparation
Properties
Uncured sealant: Form: Flash point: Solids content: Application temperature range: Skinning time: Cure rate: Smooth, non slump paste >65oC 100% approximately 5oC to 50oC 25 mins, 20oC/50% RH 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.
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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. Guide to sealant quantities Joint size in mm 3x5 3 x 10 5x5 5 x 10 10 x 5 10 x 10 15 x 10 20 x 10 25 x 15 Litre per metre run 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
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. 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.
These are theoretical yields. No allowance has been made for variation in joint dimensions or wastage.
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.
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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 perimeter joint of plastic or metal frame
2
Example of sealed movement joint in external joint panels 1
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.
1
With structural glazing or floor joints. With pipes or in other applications where it may be
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.
Example of brickwork expansion joint
Where timber or wood based products have been

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 2 Hydrocell 3 DPM
Health and safety

No significant hazard. For additional information see appropriate Product Safety Data Sheet.
Important note
Fosroc Limited
www.fosroc.com
191

One part, floor joint sealant Uses
Nitoseal MS300 is suitable for sealing saw-cut and movement joints in internal floors, and external joints where abrasion resistance is required. Factory floors Sports stadia terracing Shopping centres Warehouse and distribution depots Concrete hardstanding areas
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CI/SfB:Yt4 June 2008
Cure rate at 20C, 50% RH 24 hours 3 mm 48 hours 6 mm 72 hours 8 mm Application temperature Typical hardness Shore "A" at 20C Trafficking time at 20C Light traffic Heavy traffic Modulus UV resistance 5C to 50C 45 24 hours 4 days High Excellent
Advantages
Suitable for forklift truck traffic Suitable for saw cut and perimeter joints Cures to a tough seal Abrasion resistant Withstands vehicular traffic Single component Fast rate of cure Easy to apply at low temperature Can be applied to damp substrates Primer-less for most applications (see "Priming" section)
Service temperature range -20C to 70C
Preparation Joints in concrete should preferably be sawn. After sawing all saw slurry must be flushed away and the joint allowed to dry. 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. 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. 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. 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). 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 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.
Description
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.
Properties
Nitoseal MS300 Form Flash point Colour Paste >65C Grey For special colours contact Fosroc for further Information Butt joints 25% Lap joints 50% 25 minutes
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Movement accommodation factor Skinning time at 20C/50% RH
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Do not split packs of Fosroc Primer MS2. Application and finishing Cut end off sachet and place in Fosroc GX Gun. Fit nozzle and cut at 45 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. Cleaning Clean tools immediately after use with Fosroc Equipment Cleaner.
CI/SfB:Yt4 June 2008
Limitations
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. In large joints ensure sealant is sufficiently cured before trafficking. In 40 mm joints this could be up to 10 days.
Estimating
Guide to sealant quantities in traffic joints Joint size in mm 6 x 10 12 x 12 20 x 20 25 x 20 30 x 20 40 x 25 Litre per metre run 0.06 0.144 0.40 0.50 0.60 1.00 Metre per 600 ml sachet 10 4.17 1.50 1.2 1.00 0.60
Storage
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. Fosroc Primer MS2 is highly flammable, see Product Safety Data Sheet for details.
0.75 litres of Fosroc Primer MS2 will be sufficient for 90m of joint. No allowance has been made for joint size or wastage. Packaging Nitoseal MS300 - 600 ml sachets. 10 no. sachets per box. Fosroc Primer MS2 0.75 litre packs

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Plastiseal
Rubber-bitumen gun applied sealant Uses
For sealing joints in flashings, guttering and sheet laps An integral part of the Proofex waterproofing system
Example of a sealed roof perimeter joint is show below
Advantages
Firm flexible weather resistant seal 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
1
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.
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. 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. The use of Fosroc Primer 3 is always recommended on porous surfaces.
Example of sealed joint in guttering is shown below

2
1 Plastiseal 2 Gutter
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Fosroc Plastiseal
Properties
Form: Colour: Movement accommodation factor (BS 6093): Physical or chemical change: Application temperature: Chemical resistance to occasional spillage: Semi-stiff paste Black 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. Priming porous surfaces 10% for butt joints, 20% for lap joints Solvent release 5C to 50C Dilute acids Dilute alkalis Solvents Petroleum Lubricants resistant resistant not resistant not resistant not resistant 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 Not normally required. Ferrous metals should be treated with an anti-corrosion primer. 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: Flash point: 90% minimum 61C
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. Guide to Plastiseal quantities These are theoretical yields without allowance for joint size variation or wastage. Joint size in mm wxd 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 Litre per metre run 0.15 0.20 0.23 0.30 0.40 0.50 0.38 0.63 0.75 0.90 0.88 1.00 Metre per 0.38 litre cartridge 2.50 1.90 1.70 1.30 1.00 0.80 1.00 0.61 0.51 0.42 0.43 0.3 Metre per box (7.6 litre) 51.0 38.0 33.8 25.3 19.0 15.2 20.3 12.2 10.1 8.4 8.7 7.6
Maintenance
No special requirement, damage should be repaired if and when it occurs.
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 manufacturers current technical data sheet.
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 Cut conical tip off cartridge and thread, screw on nozzle, cut at 45 degrees to required size and fit into a Fosroc W Gun. Expansion joints Plastiseal must always be supported by a firm backing to
Coverage
Fosroc Primer 3: 12.5m2 per litre
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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.
Storage
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 Limited
www.fosroc.com
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Fosroc Silicone Sealant 33HM

One-part, high modulus, silicone acetoxy cure, sealant - specification grade Uses
Silicone Sealant 33HM is ideal for sealing joints on glass and ceramic surfaces. Principal applications include: Glazing (not structural glazing) Hygienic areas Hospitals Kitchens Showers Baths and basins Sanitary ware In-situ draughtproofing to casement windows and doors
33
2
Design criteria
Example of capped beading glazing system
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. Fast rate of cure Robust elastic seal Excellent adhesion Example of sealed stress relief and expansion joint in ceramic tiled finishes
1 1
1 Silicone Sealant 33HM 2 Glazing Strip 3 Butyl glazing and bedding compound
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. 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.
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.
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Properties
Form: Colours: Movement accommodation factor (BS 6093): Cure: Cure rate 20C, 65% RH: Application temperature: Typical hardness shore A at 25C: 100% modulus: Chemical resistance to occasional spillage: Thixotropic paste White, translucent
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. 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. resistant resistant resistant resistant not resistant resistant not resistant resistant Priming 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 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. Cleaning Clean tools immediately after use with Fosroc Equipment Cleaner. Clean hands with a proprietary hand cleaner.
15% butt joints 30% lap joints Chemically cures to a solid rubber
Skinning time, 20C: 10 to 45 minutes 96 hours to 5 mm depth 5C to 50C 24 4.0 kg/cm Sulphuric acid 25% Hydrochloric acid 10% Acetic acid 10% Lactic acid 2% Caustic soda 10% Ammonia 10% Kerosene Mineral oil Continuous service temperature range: 40C to 120C Solids content: Flash point: Flammability: 100% Over 65C Burns
Maintenance
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. White Silicone Sealant 33HM contains a fungicide and is unsuitable for use in the assembly of aquaria.
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 manufacturers current data sheet.
Estimating
Packaging 310 ml plastic cartridges with separate screw-on nozzles, packed in cartons of 20. Total contents approximately 6.2 litres.
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Guide to sealant quantities Joint size in mm 3x5 3 x 10 5x5 5 x 10 10 x 5 10 x 10 15 x 10 20 x 10 Litre per metre run 0.015 0.030 0.025 0.050 0.050 0.100 0.150 0.200 Metre per 0.31 litre cartridge 20.7 10.3 12.4 6.2 6.2 3.2 2.1 1.6
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 Limited
www.fosroc.com
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CI/SfB:Yt4 February 2007
Fosroc Thioflex 600

Multi-component, gun and pouring grade, polysulfide sealant Uses
Sealing movement joints in building and civil engineering structures, including superstructures, floors, basements and subways.
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.
British Standard BS 4254 : 1983. U.S. Federal Specification TT-S-00227E November 1969 (amended 1970). DTp specification for Highway Works December 1991 series 1000 clause 1017. ASTM C920-87: Type M, Grade NS, Class 25.
Advantages
Meets key international standards Forms a tough, elastic, rubber-like seal Accommodates continuous and pronounced cyclic movement Excellent adhesion to most common substrates, including primed concrete, glass, aluminium and stainless steel High resistance to ageing reduces physical damage due to climatic extremes
Properties
Form: Colours: Movement accommodation factor (BS 6093): Physical or chemical change: Pot life: Setting time: Multi-part, paste compound Gun grade: grey Pouring grade: grey 25% butt joints 50% lap joints Chemical cure 2 hours @ 25C 72 hours at 5C 36 hours at 15C 18 hours at 25C 4 weeks at 5C 2 weeks at 15C 1 week at 25C 5C to 50C 20C to +60C
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.
Cure time:
Application temperature: Operating temperature:
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.
Hardness shore Gun grade grey: 20 to 25 A 25C: Pouring grade: 15 to 23 Water immersion: Thioflex 600 must be fully cured before permanent immersion in water Chemical resistance to occasional spillage: 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
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Fosroc Thioflex 600

Biological resistance: Thioflex 600 has been evaluated in microbiologically active situations and has been shown to have resistance to aerobic conditions 100% 1.62 kg/litre Over 65C Burns but does not readily support combustion Iron and steel must be protected with an anti-corrosion primer prior to sealing. 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. 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. Cleaning Clean equipment immediately after use with Fosroc Equipment Cleaner. 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. Maintenance No special requirements, any damage identified during normal building inspections should be repaired or replaced as appropriate.
Solids content: Density: Flash point: Flammability:
Joint preparation 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. 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. Priming When Fosroc Primers 4 or 7 are required, these should be used as follows: 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. 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.
Estimating
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.
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Fosroc Thioflex 600

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 Litres per metre run 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 Metre run per 2.5 litre pack 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 Metre run per 5 litre pack 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
Limitations
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.
Storage
Precautions
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 Limited
www.fosroc.com
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Fosroc Flamex Fire Protection

Flexible intumescent sealants Uses
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.
CI/SfB:Zt4 (K2) June 2009
Sealant was assessed in terms of insulation and integrity. Insulation is defined as the ability to restrict excessive heat transfer through the joint, preventing ignition from conduction on the cold side. Integrity is the ability to remain intact during the test, thereby withstanding the pressures and stresses developed during a fire situation. Results summary Flamex One intumescent sealant Joint size Backing material w x d (mm) Wall joints 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 Lightweight blocks sealed both sides: 10 x 15 Expandafoam > 4 hrs 20 x 15 Expandafoam > 4 hrs 20 x 20 Expandafoam > 5 hrs 3 hrs > 2.5 hrs > 2 hrs > 4 hrs > 4 hrs > 5 hrs > 5 hrs Insulation Integrity
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
Standard complance
Tested in accordance with BS 476 Pt. 20: 1987.
Description
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. 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. 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.
Lightweight blocks to concrete lintel sealed both sides: 15 x 15 Expandafoam 3.5 hrs > 4 hrs 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 Conduit wall penetration 20 mm conduit in nominal 50 mm hole: 15 x 15 Expandafoam > 2.5 hrs 25 mm conduit in nominal 50 mm hole: 12 x 15 Expandafoam 3.5 hrs
> 4 hrs > 4 hrs
Flamex Two polysulphide intumescent sealant Joint size Backing material w x d (mm) Wall joints Single seal in lightweight blocks: 10 x 12 Expandafoam > 15 mins 20 x 12 Ceramic strip > 2 hrs > 1.5 hrs > 4 hrs Insulation Integrity
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).
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
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Flamex Two polysulphide intumescent sealant contd. Joint size Backing material w x d (mm) 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 Insulation Integrity Application temperature: Hardness Shore A at 25C: Density: Flash point: Chemical resistance:
5C to 30C 20 to 30 (7 days cure at 25C, 50% RH) 1.61 kg/litre Over 65C 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: Colours: MAF: Physical change: Skinning time: Cure time (typical rates): Paste White and grey as standard colours Butt joints 10% Cures by loss of water 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 25C, 50% RH. Smaller joints will cure more quickly. A fairly advanced state of cure is reached at 7 days 5C to 40C 30 to 50, typical 45 (28 days cure at 25C, 50% RH) 85% 1.48 kg/litre
Joint preparation 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. 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. 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. 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.
Application temperature: Hardness Shore A at 25C: Solids content: Density: Flamex Two Form: Colour: MAF: Physical or chemical change: Pot life: Setting time (typical rates): Full cure (typical rates):
Multi-component paste in one tin; requires mixing Mid grey 25% butt joints 50% lap joints Chemical cure 2 hours at 25C 96 hours at 5C 48 hours at 15C 24 hours at 25C 4 weeks at 5C 2 weeks at 15C 1 week at 25C
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Flamex Two Fosroc Primer 4 and Fosroc Primer 7 are required and should be used as follows: Fosroc Primer 4: For all non-porous surfaces. The sealant should be applied after the primer has dried, approximately 5 minutes and within 3 hours. Iron and steel must be treated with an anti-corrosion primer prior to sealing. Fosroc Primer 7: For all porous surfaces such as concrete, stone, brickwork, blockwork and timber. Apply by brush, working in well, ensuring complete coverage. Avoid over priming resulting in an excess of primer in the base of the joint or beyond the joint faces. 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. Excessively porous surfaces may need a second coat, applied over the first coat which must be thoroughly dry. Mixing Flamex Two base component and curing agent 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. 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. 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. 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.
Uncured Flamex Two should be cleaned from equipment using Fosroc Equipment Cleaner. 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.
Limitations
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. Over-painting of Flamex sealants is not recommended. 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. 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.
Estimating
Packaging 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 Litres per metre run 0.150 0.225 0.300 Metre run per 380 ml cartridge 2.5 1.7 1.2
Guide to Flamex Two quantities Joint size in mm 10 x 12 15 x 12 20 x 12 25 x 12 30 x 15 40 x 20 50 x 25 Litres per metre run 0.12 0.18 0.24 0.30 0.45 0.80 1.25 Metre run per 2.5 litre pack 20.80 13.80 10.40 8.3 5.5 3.10 2.00
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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 5C and 25C.
Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet. * See separate data sheet.
Important note
Fosroc Limited
www.fosroc.com
206
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CI/SfB: (18) (4-) (D6)
October 2005
Fosroc Flamex S
One-part low modulus neutral cure fire rated silicone sealant Uses
For fire protection of curtain walling, building faades, expansion joints and penetration seals, where pipes and cables pass through fire rated structures. Movement accommodation factor (MAF): Physical or chemical cure: Skinning time (23C at 50% RH): Cure rate (23C at 50% RH): Application temperature:
50% butt joints 100% lap joints Chemical cure 2 hours 2 mm per day 5C to 30C
Advantages
Tested to BS 476 Part 22:1987 (ISO 834) Up to a 4 hour fire rating in specified joint and penetration configurations Excellent adhesion 50% MAF allowing structural movement Meets BS 5889 Type A Prevents the passage of smoke through joints in fire conditions Acts as an acoustic sealant
Typical Shore A hardness: 20
Fire ratings
The fire rating tables give times for insulation and integrity ratings, These are defined as: Insulation: The ability to restrict excessive heat transfer through the joint, preventing ignition from conduction on the cold side. Integrity: The ability to remain intact during the test, thereby withstanding the pressures and stresses developed during a fire situation. Fire rating table A Method: BS 476 Part 22 : 1987 Joint size width x depth Joint configuration Integrity mins Insulation mins
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). 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). ISO 834 achieving over 1 hour (A - 60) fire resistance in joints, pipe and power cable penetrations (fire rating table C). Centre Scientifique que du Btiment (CSTB) Test achieving 1 hour fire rating in pipe and power cable penetrations (fire rating table D).
Polyethylene backed seal single sided - on fire side of test furnace 10 x 10 mm 15 x 10 mm 20 x 10 mm 25 x 20 mm A A A A 120 90 60 120 n/a 30 30 60
Description
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. Attainment of a specific fire rating is dependent on the joint configuration. For detailed information see fire rating table A. Attainment of a specific fire rating is dependent on penetration configurations. For detailed information see fire rating tables B, C and D.
Polyethylene backed seal single sided - on non-fire side of test furnace 10 x 10 mm 15 x 15 mm 20 x 20 mm 25 x 25 mm A A A A 240 240 240 240 240 240 240 240
Polyethylene backed seal double sided 10 x 10 mm 15 x 10 mm 25 x 20 mm B B B 240 240 240 240 240 240
Properties
Form: Colour: Thixotropic paste White/Grey
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CI/SfB: (18) (4-) (D6)
October 2005
Fosroc Flamex S
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 25 x 10 mm A 240 30 20 mm Flamex S and 25 mm mineral wool 50 mm penetration 25 mm cable 4 hrs None 4 hrs
4 hrs 4 hrs
240 Fire rating table C Method: ISO 834
Rock fibre backed seal double sided 25 x 10 mm A 240 240
Penetration size
Penetrant
Backing Fire material rating
Example of test joint configurations

Joint type A 1 Joint type B
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 mm steel 0.8 mm thick 1KV Cu Core Gypsum board, lightweight wall: Flamex S depth of 2 x 12 mm, ceramic fibre backing Tested fireside and non-fireside of test furnace
Depth
Sleeve 160 mm 2 cables EKKJ diameter galvanised 3 x 10 x 10 mm steel 0.8 mm thick 1KV Cu Core 450 mm diameter
102 mm 60 mins
2 Width
1 Flamex S 2 Backing material Fire rating table B Method: BS 476 Part 22 : 1987 Services
Ventilation duct 98 mm 400 mm diameter galvanised steel 0.8 mm thick Penetrant
60 mins
Penetration size
Backing Fire material rating
Insulation Integrity rating rating
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 Concrete floor: Flamex S depth of 12 mm, ceramic fibre backing Tested non-fireside of test furnace 400 x 400 mm 48.3 mm o.d. mild steel pipe 2.6 mm thick 138 mm 60 mins
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 20 mm Flamex S and 25 mm mineral wool 150 x 150 mm penetration 25 mm diameter cable 1 hr 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 20 mm Flamex S and 50 mm mineral wool 150 x 150 mm penetration None 1.5 hrs
4 4 4 4
hrs hrs hrs hrs
2 hrs
4 hrs 4 hrs
4 hrs
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CI/SfB: (18) (4-) (D6)
October 2005
Fosroc Flamex S
Fire rating table D Method: Centre Scientifique que du Btiment Penetration size Penetrant Insulation Integrity rating rating 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. Priming On cement and concrete, priming with Flamex S Primer is recommended. 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 5C to 30C. 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 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.
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
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.
Limitations
Flamex S should not be applied to surfaces that are below 5C. Flamex S should not be used against substrates that bleed oils, plasticisers or solvent. Flamex S is not intended for use as the structural seal in any application.
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. Application Flamex S should be backed or supported with a closed cell polyethylene foam of nominal density 35 kg/m, a ceramic fibre blanket of nominal density 128 kg/m, or mineral wool of nominal density 100 kg/m. The choice is dependent upon the performance level required and the type of joint being sealed. Contact the local Fosroc office for details. 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. Extrude sealant firmly into the joint ensuring complete contact with joint faces.
Estimating
Guide to Flamex S quantities Joint size in mm 10 x 15 15 x 15 20 x 15 Litres per metre run 0.150 0.225 0.300 Metre run per 380 ml cartridge 2.5 1.7 1.3
Packaging Flamex S is supplied in 380 ml plastic cartridges packed in cartons of 20.
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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 5C and 25C. 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 Limited
www.fosroc.com
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CI/SfB: Hn7:Rn7 September 2008
Fosroc Expandafoam
Closed-cell polyethylene joint filler, back-up strips and cord Uses
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. 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 Colour: Temperature stability: Density: Grey
40C to +60C 30 +/- 5 kg/m
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.
Joint sealing slots
Advantages
Readily compressible Low load transfer Excellent recovery after compression Non-absorbent Rot-proof CFC-free
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. 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. Where Expandafoam is used as the joint filler no additional bond breaker is necessary. 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. 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.
BS 5628 Part 3 Use of Masonry paragraph 20.4. DTp Specification for Highway Works, December 1991 series 1000. Clause 1015.
Description
Expandafoam is a flexible, readily compressible, closedcell polyethylene joint filler supplied in sheet form and as rectangular strips or circular section cords.
Properties
Technical data (sheets and strips) Form: Weathering test: Recovery: Water absorption: Effects of fire: Cross-linked, compressible, closedcell foamed sections and sheet No disintegration Greater than 70% Negligible Being a thermoplastic material, Expandafoam will melt. It is combustible but rate of flame spread will be reduced when confined within a joint
Estimating
Sheet size: Sheet thickness: Strip sizes: Strip dimensions: 1.0 x 2 metres 10, 12, 15, 20 and 25 mm 15 metres long 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
Technical data (cord) Form: Storage life: Water absorption: Compressible closed-cell foam circular cords Indefinite Negligible
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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.
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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
Storage
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 Limited
www.fosroc.com
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CI/SfB: Rj3 October 2005
Fosroc Fibreboard
Impregnated fibreboard filler
Uses 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. Forming structural expansion and separation joints in: Concrete pavements and floors Roads, ramps and runways Pedestrian areas Concrete retaining walls Concrete basement structures and subways
* Also available from Fosroc.
Design criteria
Typical sealed expansion joints in roads, runways and other trafficked surfaces
1 2 3
1 Pliastic* or Colpor 200PF* 3 Fosroc Fibreboard 2 Bond breaker tape 4 Recessed seal
Advantages Easy to handle, cut and tamp Resilient Will not extrude under compression
Example of a sealed subway expansion joint is shown below.

1
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.
DTp Specification for Highway Works, May 2005 series 1000 Clause 1015 (joint filler boards). American Association of State Highway Officials, Standard Specification M 153-54. US Federal Specification HH-F-341a: Type 1, Class B.
1 Thioflex 600* 2 Bond breaking tape 3 Supercast Rearguard S waterstop*

4 Blinding concrete 5 Proofex Engage* 6 Fosroc Fibreboard
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: Solids content: Recovery: Weathering test: Compressible sheet 100% Greater than 70% No disintegration
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CI/SfB: Rj3 October 2005
Fosroc Fibreboard
Slabs 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. 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.
1 2 3
Estimating
Nominal sheet thicknesses: 10mm Sheet sizes: 12.5 mm 20 mm 25 mm
1200 x 2440 mm
Fibreboard Strips 12.5mm thick 20mm thick Pack of 10 Pack of 10 Pack of 5 Pack of 10 100mm x 2.44m 150mm x 2.44m 200mm x 2.44m 150mm x 2.44m
Storage
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.
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 Limited
www.fosroc.com
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CI/SfB: Rn6 June 2008
Fosroc Hydrocell XL
Cross linked, non-absorbent, closed cell, polyethylene joint filler Uses
Hydrocell XL is a cross linked, non-absorbent, semi-rigid, cellular polyethylene joint filler used for forming 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. Potable water reservoirs Culverts and canals Sewage tanks Roadways and hardstandings Retaining walls Basement structures and subways Runways, taxiways and aprons Compressive strength: Water absorption:
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/mm 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.
Properties
Property Recovery: Test method ASTM D3575 Typical values 98% after 50% compression 0.15 N/mm Less than 0.05% by volume
ASTM D3575 ASTM D3575
Advantages
Cross linked to resist lateral and hydrostatic pressure High density support of sealant to prevent adhesion failure Non-absorbent closed cell structure High compression recovery Non-extruding Low load transfer to joint edges Non-tainting and rot proof Chemically resistant Bitumen free Natural bond breaker
Weathering test: Chemical resistance:
DTp Clause 1015 No disintegration Excellent resistance to acids, alkalis, oxidising agents and biological degradation
Compression loading The load compression curve shown below gives typical compression values achieved in accordance with ASTM D3575. Typical load/compression curve
Description
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.
0.3
Load N/mm
0.2
0.1
DTp Specification for Highway Works, December 1991, Series 1000, Clause 1015. BS 5628, Part 3: Code of Practice for the Use of Masonry. The compressive strength of Hydrocell XL prevents 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
0 0 10 20 30 40 50 60
% compression
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CI/SfB: Rn6 June 2008
Fosroc Hydrocell XL
Joint sealing slots 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. 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.
Storage
Hydrocell XL should be stored in original unopened packaging, in cool dry conditions, away from sunlight.
Precautions
Health and safety There are no known health hazards associated with Hydrocell XL in normal use.
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 -70C or above 100C.
Important note
Hydrocell is the trademark of Fosroc International Limited
Fosroc Limited
www.fosroc.com
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CI/SfB: Yn7 January 2006
Fosroc Secofoam
Multi purpose expanding polyurethane foam gap filler
One-part foam gap filler, insulant and fixative, supplied in a disposable aerosol canister for easy application.
Properties
Form: Storage: Shelf life: Density: Tensile strength: (BS 5241) Compressive strength at 10% compression: (BS 4370) Water absorption by volume: Foam structure: Colour: Physical or chemical change: Thermal conductivity: (ASTM C518.76) Application temperature: Service temperature: Tack free time: Flammability: P.U. foam Cool place out of sunlight 9 months 20 to 25 kg/m 9 N/cm
Uses
Secofoam is used for fixing and filling gaps around the following: New and replacement windows and door frames Pipe and duct work entries Thresholds and sills Wall chases Roof eaves and ridges Foam insulation slabs
3 N/cm
0.3% on cured foam Fine homogeneous cells Pale green Chemical cure by reaction with moisture 0.023 W/m/K
Advantages
Highly flowable fills irregular gaps Provides a barrier to draughts and water penetration High thermal insulation properties prevents heat loss through gaps Easy and quick to apply Fast curing Good adhesion Ozone friendly contains no CFCs Non shrinking
+5C to +35C 40C to +90C 6 to 10 minutes at 20C Class B3 DIN 4102 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. Toxicity:
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.
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Fosroc Secofoam
Pipe and duct entries
4 2 1
6 7
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.
3 7 5
1 2 3 4 5 6 7
Secofoam Frame Glass Brick Putty Window Sealant

1 4 2
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
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.
1 2
1 2 3 4 5
Secofoam Frame Brick Door Sealant
1 Secofoam 2 Concrete 3 Insulation board
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constructive solutions Page 2
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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. Others 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. Operating instructions 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. 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. 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. 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. 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. 4. Contents should always be fluid enough to shake, if not stand in warm water for a few minutes prior to use. Cleaning Once cured Secofoam can only be removed mechanically.
Estimating
Pack size: Foam, free expansion: 750 ml x 12 45 times initial volume
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.
Precautions
Health and safety Secofoam contains isocyanates. For further information please consult product Safety Data Sheet.
Secofoam is a trade mark of Fosroc International Limited
Important note
Fosroc Limited
www.fosroc.com
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Fosroc Supercast Butyl-Nek

Flexible sealing compound for Precast Concrete Units Uses
Provides a permanent watertight joint for precast concrete units regardless of their shape or size. Easily compressible and designed to completely seal and fill the annular space between pre-cast units. Specific Gravity @ 25oC Ductility @ 25oC Softening Point @ 25oC Penetration @ 25 C Flash Point Application Temp Range Not affected by rainwater, allowing for delays between application and jacking Resistant to chemicals Cost-effective installation Service Temp Range
o
CI/SfB: (52)t4 December 2005
Properties
Physical Properties ASTM D 4-801.331 D 113-85 D 36-86 D 217-82 D 92-85 5oC min -20oC min 6.0cm 325 min 75 62 oC 50oC max 50oC max
Advantages
Chemical Properties Immersed for 30 days, FS SS-S-2120A section 4.5/ASTM C 990 5% Solution of Caustic Potash Complies Complies Complies Complies
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 Hydrochloric Acid 5% solution of Sulphuric Acid Saturated Hydrogen Sulphide Solution
Standard Compliance
Supercast Butyl-Nek meets the requirements of: 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 Sag or Flow Resistance 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. 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. 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
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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. 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 Fosrocs current application instructions.
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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. Horizontal Application 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.
CI/SfB: (52)t4 December 2005
Storage
Supercast Butyl-Nek has a shelf life of 12 months. Store in original boxes in cool, dry conditions, away from sunlight.
Precautions
Health and Safety For further information refer to appropriate Product Safety Data Sheet.
Estimating
Pack sizes for Supercast Butyl-Nek Supercast Butyl-Nek 12mm x 60mm Supercast Butyl-Nek 12mm x 80mm Supercast Butyl-Nek 12mm x 120mm Supercast Butyl-Nek 18mm x 18mm Supercast Butyl-Nek 22mm x 22mm Supercast Butyl-Nek 25mm x 40mm Supercast Butyl-Nek Primer: Box of 4 x 6mm rolls 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 5 litre can
Important note
Fosroc Limited
www.fosroc.com
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Fosroc Supercast PVC waterstops range

Centrally and externally placed PVC waterstops Uses
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: Water retaining Reservoirs, water towers and sewage tanks Dams, culverts, canals and spillways Swimming pools Bunded areas surrounding liquid retaining tanks Water excluding Basements and underground car parks Tunnels and subways Abutments and retaining walls
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CI/SfB: Hn6 October 2009
All centrally placed Supercast waterstops incorporate an eyeletted, reinforced edge flange. This enables them to be easily positioned by wiring to surrounding reinforcement. Hydrofoil sections
16 24 250mm 12 20 200mm
Heavy duty sections 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. XHD Hydrofoil section
Roof decks and podium areas

30
Advantages
250mm
Range of profiles to suit every need Fully continuous 4 bulb network Reinforced eyeletted edge flanges for positive fixing Simple on-site jointing Full range of moulded and fabricated intersection pieces WRc approval for use in contact with potable water The range consists of centrally placed profiles; Supercast Hydrofoil and Supercast XHD Hydrofoil; and externally placed profiles; Supercast Rearguard S. All dimensions are approximate and subject to Fosroc manufacturing tolerances. Supercast Rearguard S 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. Supercast Rearguard S can also be used in contraction and construction joints. All Rearguard sections incorporate a nailing flange with a reinforced edge to provide a secure fixing that will resist tearing. 25
22 250mm 22 20 200mm
Description
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. Supercast Hydrofoil 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.
Rearguard S sections
22
20 All dimensions are approximate and subject to Fosroc manufacturing tolerances. 150mm
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Design criteria
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. 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. 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. Externally placed waterstop 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. 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.
specification CRD-C 572-74. It shall have a tensile strength in excess of 14 MN/m and an elongation at break in excess of 300%
Properties
Profiles Form: Colour: Hydrostatic head: Joint movement: Compound Typical figures: Tensile strength: Hardness: Extruded thermoplastic sections Blue Up to 10 m Up to 10 mm
To BS 2782 at 25C Minimum 14 MN/m Shore A 80-90
Elongation at break: Minimum 300%
Installation instructions
Supercast Hydrofoil 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. 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. 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
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.
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
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Site jointing instructions 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 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. Factory welded Supercast Rearguard S to Hydrofoil and Rearguard S XHD Hydrofoil
T-piece on edge on edge (T-PCE)
90 mitre (M-O-E INT)
Factory welded intersections for Supercast Hydrofoil and Supercast XHD Hydrofoil.
Factory welded intersections for Supercast Rearguard S
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)
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Estimating
Section Wt/roll Minimum radii Roll width in in on flat on edge length mm kg m m m 250 200 150 250 200 250 27.1 27.3 21.3 33.4 24.0 42.9 15 14 12 10 9 15 0.15 0.15 0.075 5.0 5.0 0.23 12 15 15 12 12 10
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.
Supercast Hydrofoil
Rearguard S XHD Hydrofoil
Storage
Application at low temperatures 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 Limited
www.fosroc.com
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Fosroc Supercast SW
Swellable waterstops for in-situ concrete
Uses Integral sealing for construction joints in concrete cast in-situ. Convenient and problem solving in situations where a conventional waterstop would require complex shuttering. 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. They can be linked to Supercast PVC waterstops to give an appropriate effective combination of waterstops which maintain network continuity. Advantages Easy to install by adhesive bonding, or casting into joint faces 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 Swelling properties unaffected by long term wet/dry cycling Tolerant of salts in concrete and groundwater Sustains effective seal in wet conditions Highly adaptable to accommodate complex joint shapes Description The Supercast SW range consists of swellable waterstops; Supercast SW formed sections, Supercast SWX gun-applied paste and Supercast SW adhesive. 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.
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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.
Design criteria
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. Swelling of Supercast SW in fresh concrete is minimal therefore maximising the positive pressure seal provided by the hydrophilic to the protected joint. 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. Both Supercast SW10 and SW20 have a delayed swell action which helps prevent pre-swell during wet site conditions (see limitations). 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. Standard compliance Supercast SW10 and Supercast SW20 are suitable for use in contact with potable water and are Water Regulations Advisory Service approved products. Drinking Water Inspectorate Regulation 25(1)b of the Water Supply (Water Quality) Regulations 1989.
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 manufacturers current application instructions.
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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 manufacturers current data sheet.
Supercast SW waterstop
Properties
Form: Size: Supercast SW10: Supercast SW20: Solids content: Colour: Supercast SW10: Supercast SW20: Unrestrained volumetric expansion ratio: Application temperature range: Service temperature range: Hydrostatic pressure resistance*: Rectangular section elastomeric strips 5 mm x 20 mm 10 mm x 20 mm 100% Black Red Up to 300% 5C to 50C 30C to 70C SW10: 30 metres SW20: 50 metres
Supercast Rearguard waterstop Secant piled wall Supercast SW waterstop Supercast SWX gunned between bulbs to form seal
Pile cap detail using Supercast SW waterstop
*(In concrete construction joint with no movement)

Unrestrained volume swell
Swollen
Dry 0 Number of wet/dry cycles 10 20 30
Supercast SW, Supercast SWX and Supercast Rearguard waterstops at secant pile wall and floor slab junction
Graphic showing reproducibility of volume swell with wet/dry cycling
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.
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Fosroc Supercast SW
Estimating
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
SW Details with 2 cages of reinforcement
Minimum wall height above kicker is 1m Minimum wall thickness 190mm with SW 10 200mm with SW20 Minimum concrete cover to SW 75mm with SW10 80mm with SW20
Supercast SW Adhesive: 380 ml cartridge packed in cartons of 20
Coverage
Supercast SW10 /SW20: Usually single run of strip per joint Supercast SWX: (per cartridge) 6 mm diameter bead - 11 metres run 12mm diameter bead - 2.7 metres run
Note: assuming 20mm diameter rebar.
SW Details with 1 cage of reinforcement placed centrally
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. See diagram opposite.
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: 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
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Fosroc Supercast SW
Ancillary materials Supercast SWX Form: Colour: Tack-free time: Cure rate: Volume swell ratio: Concrete pour: Supercast SW Adhesive Form: Application temperature: Maximum open time: Concrete pour: Grey paste 5C to 30C 30 minutes 2 to 8 hours Elastomeric water swellable paste Grey Approximately 1 hour (20C / 50% RH) 3mm in 24 hours 200% 2 to 8 hours Supercast SW Adhesive
Precautions
Health and safety Supercast SW There are no known health hazards associated with Supercast SW10 and SW20 in normal use. Supercast SWX 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.
No significant hazard. For additional information see relevant product safety data sheet.
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.
Important note
Fosroc Limited
www.fosroc.com
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Fosroc Supercast Synkoflex and Synkoflex FR

General purpose non swelling preformed plastic adhesive waterstops for concrete joints Uses
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. 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 Resistant to chemicals Fuel resistant (Supercast Synkoflex FR only) Cost effective installation. Supercast Synkoflex FR Form Form Nominal size Colour Specific gravity Resistance to Hydrostatic head Application Temp. Range Service Temp. Range
CI/SfB:(1-)Zt4 May 2008
be applied in accordance with Fosrocs current data sheet Supercast Synkoflex FR 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 Fosrocs current data sheet.
Properties
: Square section flexible waterstop : 25mm x 25mm x 4m roll : Black : 1.20 to 1.35 : 50m of water : 5oC min : -20oC min 50oC max 50oC max
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. Nominal size Colour Specific gravity Resistance to hydrostatic head
: Rectangular section flexible waterstop : 30mm x 12mm x 5m strips : Blue : 1.60 : 30m of water 50oC max 50oC max
Application Temp. Range : 5oC min Service Temp. Range : -20oC min
Specification Clauses
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. 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
230
Supercast Synkoflex 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. Freshly poured concrete Lay the Supercast Synkoflex onto the fresh concrete and overlap strips by 25mm.
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Fosroc Supercast Synkoflex & Synkoflex FR

Supercast Synkoflex FR 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. Freshly poured concrete Lay the Supercast Synkoflex FR onto the fresh concrete and overlap strips by 25mm. Estimating Supercast Synkoflex 25mm x 25mm Supercast Synkoflex FR 12mm x 30mm Supercast Synkoflex Primer: Supastik E10 Adhesive : 50 - 60m per can @ 50mm wide 10 - 13m per pack @ 75mm wide : Box of 6 x 5m rolls : Box of 6 x 4m rolls
CI/SfB:(1-)Zt4 May 2008
Health & Safety

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
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
Important note
Fosroc Limited
www.fosroc.com
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Fosroc Supercast Twinstop

Composite PVC and hydrophilic waterstop system for dual watertight security 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.
CI/SfB: Hn6 February 2006
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.
Technical support
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.
Advantages
Hydrophilic elements are treated with a delay swell coating to avoid problems associatd with hydrophilic pre-swell 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 Cost-effective alternative to co-extruded waterstops Range of fabricated intersection pieces Hydrophilic elements have been designed into the system in the optimum position 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
Design criteria
Supercast Rearguard TS 250 mm
1 2
1 Supercast SW TS hydrophilic elements 2 Supercast PVC waterstop Supercast Hydrofoil TS 250 mm
Supercast Twinstop is suitable for use in contact with potable water and is a Water Regulations Advisory Service approved product. 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 25C, it has a tensile strength in excess of 14 MN/m and an elongation at break in excess of 300%.
1 Supercast SW TS hydrophilic elements 2 Supercast PVC waterstop
Properties
Form: Colour: Tensile strength at 25C: BS 2782 Elongation at break at 25C: BS 2782 Composite PVC hydrophilic waterstop Blue/red Minimum 14 MN/m Minimum 300%
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
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Fosroc Supercast Twinstop

Installation 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. Supercast Rearguard TS 250 mm 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. 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. Concrete should never be poured onto a pre-activated hydrophilic strip. Example of Supercast Twinstop System
CI/SfB: Hn6 February 2006
1 3
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.
Storage
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.
Important not
Supercast Twinstop is the trade mark of Fosroc International Limited
Fosroc Limited
www.fosroc.com
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235
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CI/SfB: Y9 October 2005
Fosroc Integra
Crystalline capillary waterproofing system for concrete substrates Uses
Integra is an economical cementitious coating system for waterproofing concrete against positive and negative hydrostatic heads of water. Its uses include: sewage treatment and water treatment tanks, pipes, tunnels, manholes and below grade basements including retaining walls.
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. 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. 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/m 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. 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. 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. Cleaning Prior to curing, Integra may be cleaned from tools and other surfaces with water.
Advantages
Penetrates concrete, seals capillary tracts and hairline cracks Cost effective Effective waterproofing treatment for hydrostatic conditions Contains no chlorides Easy to apply 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.
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.
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CI/SfB: Y9 October 2005
Fosroc Integra
Estimating
Supply
25kg bags.
Coverage Two coat application By brush: By trowel: 1-1.5kg/m per coat 2-2.5kg/m per coat
Actual coverage rates will depend on the profile and porosity of the substrate.
Limitations
Not recommended for application temperatures below 5C. Full activation and effectiveness may occur 2-3 weeks after application.
Storage
Precautions
Integra is the trade mark of Fosroc International Limited

Important note
Fosroc Limited
www.fosroc.com
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CI/SfB: Vs1 March 2006
Fosroc Mulseal DP
Bitumen / rubber latex waterproofing emulsion
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. Coverage:
Typically 1.1 - 1.4 m/litre per coat, but will depend upon the nature of the surface being treated
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. Application 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. 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. 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: 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.
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Advantages
Excellent adhesion to most common building materials Low water vapour permeability Can be applied to green concrete 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.
DTp Specification for Highway Works May 2005 series 2000 clause 2004.
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.
Properties
Form: Solids content: Density: Application temperature: Drying time: Thixotropic liquid 60% 1.00 kg/litre 5 to 50C 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
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CI/SfB: Vs1 March 2006
Fosroc Mulseal DP
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 Splashes of Mulseal DP on paintwork, etc, should be wiped off at once with a damp cloth. Ancillary materials Fosroc Primer 3.
Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire 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. Flash points Fosroc Primer 3 -7oC
Estimating
Supply Mulseal DP: Fosroc Primer 3: Yield Mulseal DP 1.1 to 1.4 m/litre per coat Mulseal in 1.1 priming coat 2.0 to 2.5 m/litre. Fosroc Primer 3 12 to 15 m/litre. 5 litre tins, 25 and 200 litre drums 5 litre tins
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 Limited
www.fosroc.com
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Fosroc Nitocote CM210

Flexible cementitious waterproof coating Uses
Nitocote CM210 is a flexible cementitious coating, used for waterproofing water retaining structures and water excluding structures. Nitocote CM210 provides a flexible waterproof coating suitable for use in potable water tanks, reservoirs, canals and culverts. The material can be used on concrete, brick and blockwork substrates.
CI/SfB: Vr4 December 2006
Properties of cured coating (21 days cure at 23C followed by 28 days immersion at 23C). The values obtained are for Nitocote CM210 when applied in two coats each of 1mm wet film thickness: Resistance to positive water pressure (DIN 1048): Resistance to negative water pressure (DIN 1048): Static crack accommodation: Abrasion resistance: 7 bar (70m head of water) 3 bar (30m head of water) >1.0mm Wear Index 1 (ASTM D 4060) equivalent to 40 N/mm2 concrete
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
Chloride ion diffusion No penetration after resistance (Taywood method): 12 months continuous testing 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.
All coating work to be carried out in accordance with the relevant sections of BS6160:2006, Painting of Buildings Code of Practice. Surface preparation 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 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. 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).
BS 6920: 2000 Effect on Water Quality. Water Regulations Advisory Scheme approved. DWI Regulation 31 approved. Fire Tested to BS 476: 1987 Parts 6 and 7.
Description
Nitocote CM210 two-component polymer 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.
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.
Properties
Typical properties of mixed material: Pot life at 20C: Colour: Mixed density: Minimum application temperature: 1 hour Grey or white 1850 kg/m 5C
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Mixing The liquid component should be poured into a plastic or metal drum having a volume of at least 25 litres. 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. Note: The preferred drill speed is between 250 and 750 rpm. Mixing warning 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. Pre-wetting of substrate 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. 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. 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. 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.
All the mixed material should be used within 1 hour of mixing. 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. 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. 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. 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. Brush application 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. For floor application, a soft bristled broom is recommended. Pour the material on to the substrate and then spread to the required thickness. 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. 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.
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Finishing tools 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. Spray application 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. 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. 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. 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. 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. Sealed joints 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.
Apply debonding tape over the sealant. After application of the Nitocote CM210 remove the tape and overlaying coating. Curing For contracts not requiring UK potable water approvals, allow a minimum cure time of equivalent to 7 days at 7oC (3 days at 20oC and above). Nitocote CM210 should be dry cured. This is to ensure the full physical properties are developed. UK potable water approvals 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. Tanks with a surface area less than 250m2 should be flushed with water prior to filling. 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.
Estimating
Supply Powder component (grey or white): Proofex LM mesh: Coverage Coverage rate at 1mm wet film thickness: 12.5m2 per pack 0.54m2 /kg 18.2kg bag 100mm x 50m
Liquid polymer component: 5.0kg plastic container
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.
Limitations
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.
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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.
Precautions

Important note
Fosroc Limited
www.fosroc.com
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CI/SfB: July 2009
Fosroc Polyurea WPE

Fast setting, pure polyurea elastomeric waterproof coating General Information
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.
Properties
Typical Physical properties at 23oC Solids by Volume Volatile organic compounds Viscosity Density at 23oC Gel time Tensile strength ASTM D412 Modulus 100%/ 200%/ 300% ASTM D412 Elongation ASTM D412 Shore D ASTM D2240 Abrasion (1kg,H22 wheels) ASTM D4060 Service temperature Colour (Others colours available to order) : 100% : 0 g/litre : A ISO =1000 mPas : B AMINE <1500 mPas : 1.01 g/ml : 5 - 10 seconds : >19 N mm-2 : > 9/ 13/ 16 N mm-2 : >300% : 46 : 36 mg /1000 cycles : -30oC to +135oC : RAL 7005 Grey : Unpigmented
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 Tank coating Waste water tank lining Roof waterproofing Aquarium lining Stadia Landscape & water containment
Chemical Resistance (ASTM D3912, 72 hours immersion) Chemical Hydraulic Oil Motor Oil Diesel Fuel Petrol Skydrol Sodium hydroxide (50%) Ammonia (0.880) 33% Sugar solution conc. Bleach (5%) Butanol Lactic Acid (20%) Phosphoric Acid (10%) Hydrochloric acid (20%) Nitric acid (30%) Sulphuric Acid (10%) Result Max service temp. R R NR R R R R-C R R R-C R-C R 50 oC 25oC 50 oC 25 oC 50 oC 50 oC 50 oC 25 oC 50oC 50 oC 25 oC R-DIS 50 oC R-DIS 25 oC
Advantages
Environment friendly - zero VOC Excellent chemical resistance, thermal stability and UV Resistance * Very fast turn-around time. The coated substrate can be put into service within an hour Excellent impact, abrasion and puncture resistance Seamless and monolithic, including day joints Significantly enhances the durability of reinforced concrete Low permeability values Designed for service temperatures from -30oC to +135 oC Non slip finish easily achievable * See Limitations
R-DIS 50 oC
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.
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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 Note: The chemical resistance recommendations given above apply to spillage and secondary containment applications up to 72 hours contact duration; for any
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CI/SfB: July 2009
Fosroc Polyurea WPE

other requirements/chemicals contact Fosroc for further advice. Clarification of property values 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 Hose Temperature Volume ratio Pressure Gel Time Walkable Trafficable (light duty) Fully Serviceable : +70oC to +80oC : +70oC to +80oC : 1:1 : 120 - 150 bar : 5 - 10 sec : 2 minutes : 15 - 20 minutes : 24 hours 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. 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. 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. 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. 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 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. 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. Following correct preparation, the substrate must be primed. Fosroc Primer 195 should be used. Blast clean to Sa 2. (BS EN ISO 8501-1:2007). Roughness: using abrasives suitable to achieve a coarse surface of Grade Medium G (50-85m, Ry5) (BS EN ISO 8503-2:2001). 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.

Refer to Application section below and Fosroc Polyurea Method Statement for further detail. Surface preparation All surfaces must be clean, dry and free from contamination. 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. 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. 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.
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CI/SfB: July 2009
Fosroc Polyurea WPE

Application Method 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. If pigmented material is stored it should be mixed with a bunghole mixer for 20 minutes prior to use. Avoid moisture contamination of bulk material, seal drums for storage. Do not add solvent. Heat the spray lines to 70 80oC. Apply the Fosroc Polyurea WPE at the specified thickness (1.5 3.0 mm ) to the primed substrate in a cross hatch pattern with a minimum of two alternate directional passes. If non slip surfaces are required consult Fosroc Polyurea Method Statement. 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. Due to the fast cure rate of Fosroc Polyurea WPE overspray can only be removed mechanically. Coverage: Fosroc Polyurea WPE : 1.5 3.0 ltrs per m2 (1.5 - 3.0 mm) depending on specification : Concrete : 2.5 - 4 m2 /litre : Steel : 6.5 m2 /litre
Fosroc Primer 195
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.
Limitations
Fosroc Polyurea WPE should not be applied over existing coatings. 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.
Estimating
Supply: Fosroc Polyurea WPE Part A ISO component
Precautions
Health and Safety : 200 ltr drums For further information refer to appropriate Product Safety Data Sheet. Flash Point Fosroc Polyurea WPE and Primer 195 are nonflammable. Flash Point Fosroc Equipment Cleaner: 44oC
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 : 12.5kg in 25 litre pail : 7.5kg in 10 litre pail
Fosroc Equipment Cleaner : 5litre
Important note
Fosroc Limited
www.fosroc.com
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CI/SfB: Ln2 July 2009
Fosroc Proofex 3000

High performance waterproofing membrane for basements and structures Uses
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.
Surface preparation All concrete surfaces must be a wood float or shutter finish and free from cavities or projections. Masonry surfaces must be flush pointed. All surfaces must be clean, dry and free from contamination, ice and frost. Priming
Advantages Cross-laminated HDPE film for protection against damage Dimensionally stable Combines toughness with flexibility for detailing
around corners
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. Angle and corner details Where possible, a 25mm chamfer should be provided to all external angles prior to application of the reinforcing strip. Use Proofex Angle Fillet strips fixed using 6 mm beads of Plastiseal at all wall to floor junctions. All internal and external angles should be reinforced with Proofex Engage Detail Strip or a 300 mm wide strip of Proofex 3000. Application Application temperature range 5C to 35C. 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. 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. 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. 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.
Self adhesive layer system makes installation quick,

simple and reliable
Resistant to ground water, soluble sulphates and

chlorides
Suitable for waterproofing basements grades 2, 3 and

4 as defined in BS 8102 : 1990, Protection Of Structures Against Water From The Ground
Description
Proofex 3000 is a cold applied, flexible, waterproof, high performance membrane incorporating a cross laminated HDPE carrier film with a polymer modified bitumen compound. Proofex 3000 should be laid in accordance with the provisions of BS 8102 : 1990. 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.
Typical properties
Membrane thickness: Adhesion to primed concrete (ASTM D1000): Tensile strength (BS EN 12311-1) Longitudinal: Transverse: Elongation (BS EN 12311-1) Longitudinal: Transverse Water vapour permeability (BS EN 1931): Hydrostatic test (BS EN 1928): 215 N/50mm 220 N/50mm 324% 238% 1.5 mm 4.9 N/mm
Impermeable to ISO 12572 >60 kPa
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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 Protection 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. Proofex 3000 can also be covered with Proofex Sheetdrain to give both protection and a drainage layer. Roll area: Edge laps: End laps: Weight: Proofex Primer Coverage: Minimum installation temperature: Drying time @ 20 C: Pack size:
o
20 m 50 mm minimum 150 mm minimum 32kg
6 to 8 m/litre +5C rising 1 to 2 hours 5 ltr and 25 ltr drums
Proofex Engage Detail Strip Thickness: Roll size: 1.5 mm 200 mm x 10 m
Proofex Protection Board 3 mm Thickness: Coverage: 1000 mm x 2000 mm 2.0 m2
Ancillary Products Storage

Proofex Protection Board Bitumen impregnated board, designed to protect membranes from damage through backfilling and trafficking. 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 Top Hat MDPE sheathing, which encapsulates an aluminium foil layer. For use at service penetrations through Proofex 3000. Proofex Angle Fillet Strips fixed at all floor and wall junctions with a 6mm bead of Plastiseal. Proofex 3000 has a shelf life of 12 months and must be stored in an upright position at a temperature between 5C and 40C. 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. 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. Flash Point Proofex Primer: >39oC
Estimating
Proofex 3000 Roll size: 1 m x 20 m
Proofex is the trade mark of Fosroc International Limited

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Proofex Cavitydrain

High density polyethylene drained cavity former for waterpoofing of sub-structures
CI/SfB:(16.9)Ln6 October 2009
Ensure drainage system is free from obstructions. 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. 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. 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. 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. Use fixings at 1000 mm centres in the conical voids adjacent to the formed edge lap. 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. Flash around pipes and column bases using Proofex 3000 membrane to provide continuity of water proofing (see detail). Example of Proofex Cavitydrain at floor slab /column base joint
5 3 4
Uses
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. 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. 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.
Advantages
Internal application in a controlled environment increases security against waterproofing failure Provides a continuous drainage former and damp proof barrier High compressive strength Conical voids enable high load transfer to structural elements Chemically resistant Easily fixed and installed using mechanical fixings
Description
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. Mortar is poured into the conical voids on the internal face of the drainage former allowing high load transfer to structural elements.
Properties
Void height: Vertical drainage capacity (H.G. = 1.0): * Horizontal drainage capacity (H.G. = 0.01): * Compressive load at 10% compression: Mass/unit area: Chemical resistance: 20 mm 12 l/s/m 0.34 l/s/m 90 kN/m 1.0 kg/m Resistant to most acids, alkalis, oils and fuels 1 Proofex Cavitydrain 4 Floor screed 2 *Proofex Angle Fillet 5 *Proofex 3000 membrane 3 Insulation if required * Also available from Fosroc 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. 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).
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* BS 6906, Part 7. ASTM D1621.
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Fosroc Proofex Cavitydrain

Example of Proofex Cavitydrain at joint between wall and floor
1
CI/SfB:(16.9)Ln6 October 2009
4 Floor screed 5 Butt joint 6 Supercast Rearguard S Waterstop* * 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.
3 4 1
Estimating
1 Proofex Cavitydrain 2 Floor screed 3 Supercast Rearguard S Waterstop* 4 Channel connected to site drainage system * 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). Proofex Cavitydrain HC comes in rolls: 0.97 m x 50 m. Approximately 60 fixings are required per roll of Proofex Cavitydrain.
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. 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
Storage
Precautions
Health and safety Each Proofex Cavitydrain roll should be lifted by a minimum of two site operatives.
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 Limited
www.fosroc.com
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Fosroc Proofex Engage

Pre-applied waterproofing membrane which mechanically bonds to poured concrete, remaining in place if settlement of substrate occurs 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.
CI/SfB: 19Ln6 January 2009
Typical properties
Membrane properties Peel adhesion to concrete: BS4254 mod* Shear strength of joints: MOAT 27:5.2.2 Selvedge: Proofex Engage Detail Strip: Puncture resistance: ASTM E154 Methane permeability: BS903 Part A30:1996 CO2 permeability: Rilem Report 12 Typical value 74N per 50mm
377N 506N 600N 1.33E-17m2/sec/Pa <5.12E-13m2/sec/Pa
Advantages
Unique mesh system bonds permanently to concrete, remaining in place even if settlement takes place Basement waterproofing protection to grades 2, 3 and 4 as defined in BS8102:1990 Methane, radon and CO2 protection as defined in BRE Report 212 BBA certification Protects concrete from attack from chemicals and aggressive ground salts Simple application - requires no primer or protection Inert product - no risk of a reaction with ponded water prior to concrete being poured Standard compliance Independently certified performance, BBA certificate (No. 03/4042). British Standard 8102:1990 - Code of Practice for 'Protection Of Structures Against Water From the Ground'.
* Concrete cast against grid and cured for 7 days. Peel adhesion tested at 50mm/minute at 20C.
Substrate preparation Horizontal application - the membrane must be applied to smooth prepared substrate. 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. Standing water must be removed to prevent contamination of overlaps and subsequent compromise of waterproof properties. Vertical application - the membrane is applied to formwork or adjoining structures. Membrane installation Cut the membrane to a convenient length for installation. Carefully align the membrane and roll it out with the ribbed surface uppermost. Lay adjacent sheets accurately so they overlap the previous sheet 75mm along the adhesive selvedge. When laying adjacent full rolls there should be a stagger of half a roll length to avoid a build up of end joints in one area. End joints and cut edges - butt join the Proofex Engage sheets onto Proofex Engage L Section. The top surface of the join can be further sealed with Proofex LM reinforced with Proofex LM Mesh. This overseal should extend 75mm either side of the formed joint. All overlaps and joints should be firmly rolled to ensure complete adhesion between layers. If cold or damp conditions prevail the selvedge adhesive may be tackified by wiping with Fosroc Solvent 102.
The waterproof tanking membrane shall consist of a polyethylene membrane incorporating a complex cell mesh, enabling the membrane to mechanically bond with the concrete. The membrane shall be supplied with one selvedge to provide sealed laps and comply with British Standard 8102 1990 - code of practice for Protection of Structures Against Water from the Ground to provide basement waterproofing protection to grades 2, 3 and 4. The product shall have a current British Board of Agrment Certificate.
Description
Proofex Engage is a unique patented system comprising a complex cell mesh bonded to a poyethylene membrane which allows poured concrete to interlock with the membrane forming a tenacious mechanical bond. Proofex Engage is supplied with a selvedge on one side to provide sealaed laps.
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Fosroc Proofex Engage

Removal of formwork Where the membrane has been applied to removable shuttering it is recommended that a minimum concrete compressive strength of 10N/mm is reached before the formwork is stripped. Penetrations Penetrations e.g., pipe entries through Proofex Engage, require special attention to detail. Proofex Top Hat units used in conjunction with Proofex Total Tape and Nitoseal MS50 is recommended.Refer to Fosroc for more information on details.
CI/SfB: 19Ln6 January 2009
Estimating
Proofex Engage Roll size: Coverage: 1.27 m x 30 m x 5mm, 38.10 m2
Proofex Engage Detail Strip Roll size: Proofex LM Pack size: Coverage: Proofex LM Mesh Dimensions: Proofex Top Hat Diameter: 110 mm 330 mm x 330mm 160 mm 380 mm x 380mm 100 mm x 50 m (nominal ) 28 kg 7 m2 (at 4 mm thick) 200 mm x 10 m x 1.5 mm
Ancillary products
Proofex LM A two component trowelable membrane for sealing around intricate details such as pipe entries, penetrations, pile caps, etc. Proofex corner pieces 125mm Internal and external corner pieces made from polyethylene membrane with a 100mm butyl selvedge. Proofex L section This 5m long x 250mm wide section of polyethylene has 2 butyl selvedge strips. It is used by bending at 90o along its length for application between horizontal and vertical membrane to provide waterproofing continuity it also connects with internal and external corner pieces. Proofex "L" section is suppied with a butyl "closure" strip at each end, if the "L" section is cut this strip must be replaced with Proofex Engage Detail Strip. Proofex Engage Detail Strip A reinforced, double sided waterproof adhesive tape for sealing and jointing roll ends, cut edges and corner pieces. 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 LM Mesh A reinforced mesh used in conjunction with Proofex LM for areas of extreme loading (covings, edges and pipe penetrations). Proofex Top Hat Waterproof pipe entry consisting of MDPE sheathing, which encapsulates an aluminium foil layer.
Proofex Total Tape Dimensions: Nitoseal MS 50 Supply: 380 ml cartridge in boxes of 20 50 mm x 30 m
Storage
Store in original unopened packaging, in cool dry conditions, away from sunlight, in a flat position. Proofex L section should be stored vertically as supplied, in cool dry conditions. Do not distort or crush the coil.
Precautions
Health and safety Proofex Engage weighs approximately 60kg and should be lifted by a minimum of three site operatives. For further information refer to appropriate Product Safety Data Sheet.

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Proofex Hydromat

Pre or post- applied bentonite waterproofing membrane with unique surface bentonite impregnation for impermeable lap joints Uses
Basement waterproofing protection to grades 2, 3 and 4 as defined in BS8102:1990. Provides a vapour and waterproof membrane in building and civil engineering structures and protection to the structure from attack by aggressive chemical substances in the ground.
CI/SfB: (1-)Lg9 May 2009
British Standard 8102:1990 code of practice for Protection of Structures Against Water From the Ground.
Properties
Membrane properties Tensile strength MD/CD DIN EN ISO 10319 Puncture force DIN EN ISO 12236 Peel strength ASTM D6496 Montmorillonite Content (Sodium Bentonite) XRD Typical value 20kN/m / 11kN/m 2500N >360N/m Approx. 90%
Advantages
Unique impermeable lap joints derived from surface bentonite impregnation of the non-woven geotextile layer during manufacture 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. Installation below floor slabs 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. 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. 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
Description
Proofex Hydromat consists of two elements Natural sodium bentonite as the sealing material. Two layers of geotextile to encapsulate and contain the bentonite.
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 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.
17

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. Installation on cast vertical walls 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. Backfill must be free from any angular material or debris which could damage the membrane and should not contain rocks larger than 50mm. 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. Installation for sealing vertical walls against retaining structures 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.
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. 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. 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. Sealing around penetrations must be carried out in accordance with Fosrocs 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. 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.
Ancillary products
Proofex Hydromat Powder 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
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Hydromat Powder, either in dry condition or mixed 1 part powder:4 parts water in the form of a paste. A typical area of use is around piles. See Fosroc standard details.
Precautions
Health & Safety Proofex Hydromat 2.42m x 15m weighs approximately 210kg in the dry state and should be lifted by mechanical equipment. Proofex Hydromat Powder weighs 25kg and should be lifted by two operatives. For further information refer to appropriate Product Safety Data Sheet.
Estimating
Proofex Hydromat Thickness: Roll sizes: Weights: 7mm (dry) 1.2 m x 2.42 m 2.42 m x 15 m 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 Limited
www.fosroc.com
256
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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 Uses and advantages
For the waterproofing of intricate details e.g. pipe entries, covings etc 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 Compatible with Proofex waterproofing systems Standard compliance Materialprfanstalt Nordrhein-Westfalen; tested in accordance with DIN 18195, parts 4 to 6. General test certificate No. P-22 1356 8 96-1, MPA Dortmund Description Two component bituminous rubber emulsion with special hydraulically hardening fillers.
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. 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. 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. It is recommended that, where required, each full first coat of Proofex LM is left to dry overnight before applying a second coat. Mixing 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. 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 +20C and normal humidity. Higher temperatures shorten while lower temperatures lengthen the pot life. 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.
Properties
Consistency: Density: Pot life: Application temperature: Primer: Curing: Paste-like (mixture) Approximately 1.2 g/cm (mixture) while fresh Approximately 90 minutes at +20C Approximately: minimum +5C up to +35C ambient temperature Mixed material diluted with water 1:10 1 to 3 days depending on temperature, relative humidity, substrate and layer thickness. Typical cure time at 20C, 60% relative humidity, 3.3 mm coating, is approximately 24 hours. Resistant to rain after 3 hours at +20C/65% relative humidity To numerous salt solutions, weak acids and aggressive substances normally existing in soil
Resistance:
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CI/SfB: November 2005
Fosroc Proofex LM
Fire The completed installation may be protected as required with Proofex Protection Board. 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. Suitable noise, heat and mechanical insulation materials such as styrene and mineral foam may be glued to Proofex LM. Normal application Proofex LM primer: Dilute Proofex LM with water in a mixing ratio of 1:10. Damp conditions with no water pressure present Waterproofing (one layer) Layer thickness (wet): Coverage: Approximately 3.3 mm Approximately 4 kg/m
Estimating
Supply 28 kg pack. Coverage and yield Proofex LM: Approximately 4 to 6 kg/m at normal loadings. Approximately 8 kg/m where standing water and pressurised water occur. Coverage per m/mm dry film thickness equals approximately 1.65 kg Proofex LM. Proofex LM primer: Approximately 50 to 80 g/m unthinned material, depending on the porosity of the substrate.
Storage
Positive water pressure: Up to 1 bar (10 metre head of water) Waterproofing (one or two layers) Layer thickness (wet): Coverage: Approximately 4.0 mm Approximately 5 kg/m. 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 6.7 mm Approximately 8 kg/m. With or without incorporating reinforcement mesh

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Proofex Sheetdrain

Geocomposite HDPE drainage sheet with thermobonded polypropylene filter 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. Proofex Sheetdrain can also be used as protection to a sheet membrane against physical damage from backfill operations.
1 4
CI/SfB: (1-)Lng September 2008
Example of external tanking with drained protection is shown below
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. Proofex Sheetdrain provides filtered drainage and enhanced protection when used with Proofex waterproof membranes on reservoirs, podia and elevated slabs.
5 7
Advantages
Maintains high rate of flow (water and gas) while under stress thanks to its symmetrical, impervious structure Maintains an air layer along walls High impact resistant, high density polyethylene core with a crush strength of up to 450 kPa/m provides drainage void around structures under backfill and long term loadings Cost effective alternative to French drains Easily fixed on site 1 2 3 4 5 6 7
3 2 6
*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.
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Properties
8mm Geospacer: Raw material Profile Crush resistance (NF EN 964-1) Filter: Raw material Flow rate at 10cm head (BS6906-3) 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 Compression strength: 16mm
100% virgin HDPE 100% virgin HDPE Double cuspated symmetrical and watertight >150 kPa >450 kPa
Polypropylene non woven heat bonded 80 litres/m2/s 1.1m 25m 0.85 l/m/s (under 20 kPa) 0.7 l/m/s (under 50 kPa) 1.1m 25m 2.3 l/m/s (under 20 kPa) 1.6 l/m/s (under 100 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 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
3 Specification depth up to 6m 4 1 2 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 manufacturers technical data sheet. 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 manufacturers technical data sheet.
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Fixing 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. 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. 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. Top closure
Limitations
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 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. 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.
Estimating
Product Proofex Sheetdrain: Packaging 1.1 m x 25 m roll Quantity 1
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. Backfilling 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. Ancillary materials *Proofex Detail Strip Hilti IZ 8x70 fixings * Available from Fosroc. The product is supplied in a roll and must not be exposed directly to UV radiation for over two months.
Precautions
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.
Proofex is the trademark of Fosroc International Limited

Important note
Fosroc Limited
www.fosroc.com
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CI/SfB: 19n6 October 2005
Fosroc Proofex WG
High performance Epoxy resin waterproof grout Uses
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.
Properties
The following results are typical for the hardened grout at 20C. Test method for Density: Compressive strength (B 6319, Part 2: 1983) 6 hours (24C): 1 day: 3 days: 7 days: Tensile strength (BS 6319, Part 7: 1985) 7 days: Flexural strength (BS 6319, Part 3: 1990) 7 days: Secant modulus (BS 6319, Part 6: 1984) Chemical resistance Proofex WG is resistant to oil, grease, fats, most chemicals, mild acids and alkalis, fresh and sea water. Consult Fosrocs Customer Service Department when exposure to solvents or concentrated chemicals is anticipated. Pot life 36 N/mm 89 N/mm 93 N/mm 100 N/mm Typical results 2025 kg/m
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
14 N/mm
Description
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.
32 N/mm 13 kN/mm
Design criteria
Example of Proofex WG applied to circular pile-caps
1 2
Ambient temperature affects the time for which bulk material will remain fluid. Typical values in minutes are: 10C 20C 30C Proofex WG: Exotherm 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. 60 30 15
1 2 3
Proofex WG *Proofex Engage *Proofex LM *Also available from Fosroc.
Supplier specification 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 manufacturers data sheet. Performance specification 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
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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.
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.
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CI/SfB: 19n6 October 2005
Fosroc Proofex WG
hardened grout must have a compressive strength which exceeds 99 N/mm at 7 days, a tensile strength which exceeds 13 N/mm at 7 days and a flexural strength which exceeds 31 N/mm at 7 days. The storage, handling and placement of the grout must be in strict accordance with the manufacturers instructions. Cleaning 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.
Limitations
Temperature
Preparation 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. 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. Formwork The formwork should be constructed to be leakproof as Proofex WG is a free-flowing grout. Mixing Pour all the contents of the hardener pack into the base container. Mix using a slow speed power drill and paddle until homogeneous. 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. Placing The mixed grout should be poured steadily from one side only to eliminate the entrapment of air. Continuous grout flow is essential. Sufficient grout must be available prior to starting. The time taken to pour a batch should be regulated to the time taken to prepare the next batch.
During application The cure rate will be slower near 5C, and application should not be attempted when the temperature is 5C and falling. Where application temperature exceeds 20C note the pot life given previously. In service The cured grout, which is completely resistant to frost and sub-zero temperatures, is suitable for use up to 45C.
Estimating
Supply Proofex WG: 16 litre packs containing liquid base and hardener
Storage
Proofex WG has a shelf life of 12 months if kept in dry conditions at 20C.
Precautions
Health and safety Fire Fosroc Solvent 102 is flammable. In the event of fire extinguish with CO2 or foam. Flash point Fosroc Solvent 102: 33C
For additional information see relevant Product Safety Data Sheet.
Proofex is the trademark of Fosroc International

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Expoband H45

Flexible expansion joint membrane
CI/SfB: Ly June 2008
Example of Reservoir Wall
Uses
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.
(sealed internally with Expoband H45)
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 5
Description
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. Example of a reservoir roof joint (sealed internally with Expoband H45)
6
1. Expoband H45 2. *Supastik E10 Adhesive 3. *Supercast Waterstop * Also available from Fosroc
4. *Hydrocell 5. *Nitoseal MS600
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 manufacturers printed instructions.
Properties
Expoband H45 Hypalon membrane
4 3 1 5 7 1 2
Form: Colour: Density: Tensile Strength:
Elastomeric Strips Dark Grey 1.7 approximate 7.0 N/mm2 400% >tensile strength of substrate
8 9 7
Elongation at break: Adhesion to concrete (with Supastik E10): 5. Supastik E10 adhesive* 6. Earth Overlay 7. Nitoseal MS600* 8. Supercast waterstop* 9. Hydrocell*
1 Expoband H45 2 Proofex Sheetdrain* 3 Proofex or Famguard GS100* 4 Famguard GS100* strap laid loose but spot bonded along each edge
* Also available from Fosroc

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Fosroc Expoband H45

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. 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. 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. 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. 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. If the primer has been left longer than 8 hours or has become contaminated with dust, the surface must be reprimed.
The rate of cure of Fosroc Primer 13X is temperature dependent. Ideally the substrate should be above 10C to ensure a reasonable cure rate, however this primer can be applied when substrate temperatures are 5C and rising. 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. 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. 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. Jointing the Expoband H45 membrane The surfaces to be jointed must be clean and wiped with Fosroc Solvent 105 prior to jointing. For heat welded joints, a 50 mm overlap should be used. Welding is carried out using a proprietary hot air welding tool. The tool should be set to the correct heat output by trial to achieve a satisfactory weld. 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.
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Fosroc Expoband H45

Water applications After application the Expoband H45 system should be allowed to cure for 28 days at 7C before permanent contact with water. Ancillary materials and equipment Supastik E10 adhesive. Fosroc Solvent 105. Fosroc Primer 13X. Slow speed drill and Fosroc sealant mixing paddle. Adhesive spreader with 2 to 3 mm serrations. Hot air welding gun and roller.
Fosroc Primer 13X should be stored in accordance with the Highly Flammable Liquids and Liquefied Petroleum Gases Regulations 1972.
Precautions
Health and safety Expoband H45 There are no known hazards associated with this product in normal use. Supastik E10, Fosroc Primer 13X, Fosroc Solvent 105 For further information refer to appropriate Product Safety Data Sheet.
Estimating
Supply Expoband H45: 1mm thick x 100mm wide, 25metre roll 1mm thick x 200mm wide, 25metre roll
Fire 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: membrane) 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 10m2/litre (based on a 2mm spread of adhesive above and below the
Technical data ancillary materials Fosroc Solvent 105 Flash Point: Storage Life: Pack Size: 43C Indefinite 5 litre
Supastik E10 Form: Storage Life: Base: Off-white viscous paste Curing agent: Grey viscous paste 12 months in originally sealed containers sotred below 25C in cool dry conditions Above 65C 1.2 kg/litre 3 to 4 hours 1 to 2 hours 50 to 60 minutes 20 to 30 minutes 100%
The coverage figures are theoretical due to wastage factors and the variety and nature of substrates, practical coverage figures may be substantially reduced.
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. Flash Point: Mixed density: Pot Life: 5C: 10C: 20C: 40C: Solids content:
Storage
Expoband H45 should be stored in original unopened packaging, in cool dry conditions, away from sunlight.
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Fosroc Expoband H45

Cure duration: Before trafficking: Application temperature: Mixed Colour: Over 15C: 48 hours 7 days
5C to 15C: 96 hours
Before immersion: >7C: 5C to 50C Grey
Fosroc Primer 13X Flash Point: Density: Storage Life: Pot Life: Application temperature: Tack-free time at 20C: Pack size: Base: -7C Curing Agent: -7C 1.0 kg/litre 12months in originally sealed containers 30 minutes 5C to 35C 10 to 60 minutes 200ml
Expoband is the trade mark of Fosroc International Limited

Important note
Fosroc Limited
www.fosroc.com
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Proofex 3000MR
High performance methane, radon and CO2 resisting waterproof membrane for basements and structures
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. Advantages 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. Self adhesive layer system makes installation quick, simple and reliable Resistant to ground water, soluble sulphates and chlorides Suitable for waterproofing basements grades 2, 3 and 4 as defined in BS 8102 : 1990, Protection Of Structures Against Water From The Ground Description 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. 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. Proofex 3000MR should be laid in accordance with the provisions of BS 8102 : 1990. Typical properties Membrane thickness: Methane gas resistance: Radon permeability (SP Sweden): Adhesion to primed concrete (ASTM D1000): Tensile strength (BS EN 12311-1): Longitudinal: Transverse: Elongation (BS EN 12311-1) Longitudinal: Transverse: Hydrostatic test (BS EN 1928): Water vapour permeability (BS EN 1931): 1.2 mm <5cm3/m2 24h bar 0.56 10-12m2/s 4.9 N/mm
Surface preparation All concrete surfaces must be a wood float or shutter finish and free from cavities or projections. Masonry surfaces must be flush pointed. All surfaces must be clean, dry and free from contamination, ice and frost. Priming 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. Angle and corner details Use Proofex Angle Fillet strips fixed using 6 mm beads of Plastiseal at all wall to floor junctions. 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. Application Application temperature range 5C to 35C. 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. 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. In cold weather temporary batten support of the Proofex 3000MR membrane is recommended. Horizontal application: Completely unroll the Proofex 3000MR 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 3000MR membrane and progressively removed from the mid point out to the end of the roll. This process should be repeated on the other half of the roll. The Proofex 3000MR membrane should be brushed onto the surface to ensure good bonding.
230 N/50mm 235 N/50mm 33 % 37 % >60 kPa
Impermeable to ISO 12572

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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. Penetrations 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 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. Proofex 3000MR can also be covered with Proofex Sheetdrain to give both protection and a drainage layer.
Estimating
Proofex 3000MR Roll size: Roll area: Edge laps: End laps: Roll weight: Proofex Primer Storage life: Coverage: Minimum installation temperature: Drying time @ 20oC: Pack size: 1 m x 20 m 20 m 50 mm minimum 150 mm minimum 25 kg
2 years 6 to 8 m/litre +4C rising 1 to 2 hours 5 ltr and 25 ltr drums
Proofex Engage Detail Strip Thickness: 1.5 mm Roll size: 200 mm x 10 m
Ancillary products
Proofex Protection Board Bitumen impregnated board, designed to protect membranes from damage through backfilling and trafficking. 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 Top Hat MDPE sheathing, which encapsulates an aluminium foil layer. Proofex Angle Fillet Strips fixed at all floor and wall junctions with a 6mm bead of Plastiseal.
Proofex Protection Board 3 mm Thickness: Coverage: Storage Proofex 3000MR must be stored in dry conditions, away from sunlight, in an upright position at a temperature between 5C and 40C. 1000 mm x 2000 mm 2.0 m2
Precautions
Health and safety 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. Flash Point Proofex Primer: >39oC

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Proofex Radon Barrier

High performance, gas-impervious, reinforced membrane Uses
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.
CI/SfB: (13.9)Ln6
July 2007
Preparation Underslab ground membranes The hard-core bed should be blinded with soft sand and consolidated to provide a smooth bed free of sharp projections. 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. Laying The membrane should be laid neatly and tucked well into angles to prevent bridging. At corners in upstands folded welts should be formed. Lapping and jointing 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 can also be heat welded by a specialist installer. 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. Penetrations 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.
Advantages
Virgin co-polymer product design for maximum gas protection. Loose-laid system for ease of application. Can be used on ground-bearing concrete floors or on suspended concrete or beam and block floors.
Description
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. 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). 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
Membrane thickness: Weight (DIN53104): Roll weights (4m x 20m): Radon gas transmission rate : Moisture vapour transmission: Tear resistance MD: CD: Tensile strength MD: CD: Elongation@ Max Load MD & CD: Colour 370 m 356g/m 2 28.48kg 4 x 10-12m2/s 0.16g/m2/day 248N/mm 303N/mm 21.5Mpa 29.4 Mpa >800% Yellow
Standard compliances
Independently certified performance, IAB Certificate (No. 03/0177).
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Fosroc Proofex Radon Barrier

Estimating
Proofex Radon Barrier Roll width: Roll length: Proofex TOTAL Tape Tape width: Tape length: 50mm 30m 4m 20m
CI/SfB: (13.9)Ln6
July 2007
Ancillary products Proofex TOTAL Tape Double-sided butyl tape for sealing of side and end laps and for use in detailing work. Typar SF56 80 g/m2 geotextile as protection for membrane against damage. Proofex Protection Board Proofex Protection BoardP Bitumen impregnated board designed to protect membranes from damage through backfilling and trafficking. Proofex 3000MR Methane and water resistant self-adhesive membrane. Proofex Top Hats MDPE sheathing, which encapsulates an aluminium foil layer.
Maintenance
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.
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.
Important note
Fosroc Limited
www.fosroc.com
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CI/SfB: (13.9)Ln6 September 2009
Fosroc Proofex Total

High performance, totally gas-impervious, reinforced membrane Uses
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.
Preparation Underslab ground membranes The hard-core bed should be blinded with soft sand and consolidated to provide a smooth bed free of sharp projections. 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. Laying 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. Lapping and jointing 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. Proofex Total can also be heat welded by a specialist installer.
Advantages
5-layer product design for maximum gas protection. Polyester reinforcing grid for puncture resistance during application. Loose-laid system for ease of application. Can be used on ground-bearing concrete floors or on suspended concrete or beam and block floors. Can be used to form a cavity tray, eradicating the need for a separate product.
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. Maintenance 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.
Protection
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. Penetrations Where possible services should be routed such that they do not pass through the membrane, thus reducing the number of 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
Properties
Membrane thickness Weight Roll weight (2m x 25m) Water vapour permeability (ISO 9932) Methane gas transmission rate (BR212) Bursting strength (ISO 2759) Radon permeability 0.45 mm 300 g/m2 17.5 kg 0.01 g/m2/24hr <0.01 mls/m2/24hr
Ancillary products
>900 kPa 2.3 (10 m /24hr)
-12 2
Proofex Total Tape Double-sided butyl tape for sealing of side and end laps and for use in detailing work. Proofex Top Hats MDPE sheathing, which encapsulates an aluminium foil layer.
Standard compliances
BRE Digest 211 Radon : Guidance on protective measures for new buildings BRE Digest 212: Construction of new buildings on gas contaminated land.
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Fosroc Proofex Total

Estimating
Proofex Total Roll width: Roll length: Proofex Total Tape Tape width: Tape length: 50mm 30m 2m 50m
Storage
Store in original unopened packaging, in cool dry conditions, away from direct sunlight.
Precautions
Important note
Fosroc Limited
www.fosroc.com
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Fosroc Conbextra BB
Non shrink cementitious bridge bearing grout
Uses Grouting beneath: Bridge bearings Parapet posts Flanged lighting columns Conbextra BB can be used in section thicknesses 10 mm to 100 mm.
Properties
All properties at a water : powder ratio of 0.19 Property Compressive strength (typical results): Expansion: Elastic stability (compressive strain): Total chloride ion content (as % of mass of cement): Test method BS 1881 : 1983 Part 116 ASTM C827-87 DTp SHW 1991 Clause 2601 (viii) 1 day: 28 N/mm 7 days: 58 N/mm 28 days: 67 N/mm 0.25% - 1.0% < 1%
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
< 0.1%
Total acid soluble sulphate SO3 (as % of mass of cement):
< 4%
Performance specification 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 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.
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. 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.
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.
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.
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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. 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. 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. 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. High temperature working At ambient temperatures above 35C the mixed grout should be stored in the shade. Cool water (below 20C) should be used for mixing the grout. 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 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 5C. For full cold weather working limitations, refer to Department of Transport Specification clause 2601 subclause 3
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.
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Precautions
Fire
Conbextra BB is non-flammable.
Conbextra is the trade mark of Fosroc International Limited

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Conbextra GP
General purpose non-shrink cementitious grout Uses
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.
Performance specification All grouting must be carried out with pre-packaged nonshrink cementitious grout manufactured and supplied by a BSi registered firm. 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. The compressive strength of the grout must reach 40 N/mm at 7 days and 60 N/mm at 28 days. The storage, handling and placement of the grout must be in strict accordance with the manufacturers instructions.
Advantages
Non-shrink Simply add correct quantity of water Can be used at flowable or trowellable consistency Chloride free Non-staining
Properties
The following results were obtained at flowable consistency (ie 4.5 litres of water per 25 kg bag) and at a temperature of 20C. Test method for Compressive strength (BS 1881, Part 116: 1983 - restrained): Typical result
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. 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. Typical detail of stanchion base plate Conbextra GP to underside of stanchion base plate (second stage)
16 N/mm @ 1 day 42 N/mm @ 7 days 60 N/mm @ 28 days 7.0 N/mm @ 7 days 13.0 N/mm @ 28 days 23 kN/mm 15 minutes 2 hours Approximately 2170 kg/ m depending on actual consistency used An expansion of up to 1% overcomes plastic settlement in the unset material
Flexural strength (BS 6319, Part 3: 1990): Youngs modulus (BS 6319, Part 6: 1984): Time for expansion Start: Finish: Fresh wet density:
Base plate
Expansion characteristics: Shims 50 mm max
Conbextra GP or Lokfix to bolt pocket (first stage)
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Preparation 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 and fixing pockets must be blown clean of any dirt or debris. 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. 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. 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. This can be achieved by using foam rubber strip or Silicone Sealant 33HM beneath the constructed formwork and between joints. In some cases it is practical to use a sacrificial semi-dry sand and cement formwork. The formwork should include outlets for pre-soaking. 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. Mixing 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. 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 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. Consistency of grout mix The quantity of clean water required to be added to a 25 kg bag to achieve the desired consistency is given below. Trowellable: Flowable: Placing At 20C 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. Any bolt pockets must be grouted prior to grouting between the substrate and the base plate. 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. When the Conbextra GP has reached trowelable consistency, the unrestrained portion should be cut back to the baseplate/bearing plate. Typical hopper system 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.
Removable hopper: For larger pours the grout may be hand placed or pumped into a removable hopper (trough) Conbextra GP poured into removable hopper (second stage)
3.4 to 3.6 litres 4.0 to 4.5 litres
50 mm max
Conbextra GP or Lokfix (first stage)
75 mm max
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Curing On completion of the grouting operation, exposed areas should be thoroughly cured with Concure curing membrane, continuous application of water and/or wet hessian. Cleaning 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.
Storage
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.
Precautions
Estimating
Supply 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 Yield: Trowellable 12 litres Flowable 13.25 litres
Fire
Conbextra GP is non-flammable.
Limitations
Low temperature working When the air or contact surface temperatures are 5C or below on a falling thermometer, warm water (30C to 40C) is recommended to accelerate strength development. For ambient temperatures below 10C 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 35C cool water (below 20C) should be used for mixing the grout prior to placement.

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Conbextra HF
High flow non-shrink cementitious grout Uses
Conbextra HF is used for free flow, non-shrink, cementitious grouting of gap thicknesses 10 to 100 mm. Recommended applications include: Large stanchion 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 Youngs modulus (ASTM C-469-83): Flow characteristics (Efflux time) CRD-C Cone: Setting time (BS 4550, Part 3: 1978) Initial set: Final set: Time for expansion Plastic state Start: Finish: Fresh wet density: Flexural strength (BS 4551: 1980):
Properties
The following results were obtained at fluid consistency i.e. 4.8 litres of water per 25 kg bag. Test method for Compressive strength (BS 1881, Part 116: 1983 - restrained) Typical result 25 N/mm @ 1 day 44 N/mm @ 7 days 56 N/mm @ 14 days 64 N/mm @ 28 days 82 N/mm @ 180 days 2.5 N/mm @ 1 day 8.0 N/mm @ 7 days 9.5 N/mm @ 14 days 10.0 N/mm @ 28 days 11.0 N/mm @ 180 days 29 kN/mm 19 to 25 seconds
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.
5.5 hours 7.5 hours
15 minutes Initial set Approximately 2200 kg/m 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).
Expansion characteristics:
Performance specification 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. 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. The compressive strength of the grout must exceed 40 N/mm at 7 days and 60 N/mm at 28 days. 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 manufacturers instructions.
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Preparation 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. 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. Particular care should be taken to blow out all bolt holes and pockets. Where water soaking is impossible contact Fosroc Customer Service Department.
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Fosroc Conbextra HF
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. 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. 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 150 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 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. 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 total contents of the Conbextra HF bag, mix continuously for 5 minutes, ensuring a smooth, even consistency is obtained. Consistency of mixed grout To achieve the consistencies which are defined in CRD-C621-82A, the amount of clean water that is added to a 25 kg bag at 20C is: Flowable: Fluid: 4.5 litres 4.8 litres 1 Conbextra HF or Lokfix* (first stage) 2 Conbextra HF poured or pumped into removable hopper (second stage) * Also available from Fosroc. Sufficient grout must be available prior to starting and the time taken to pour a batch must be regulated to the time taken to prepare the next one. 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 Fluid: Grout consistency Flowable: Maximum flow distance in mm Gap depth 100 mm 250 mm mm head head 10 20 30 40 50 10 20 30 40 360 950 1500 2200 3000 900 1900 3000 3000+ 1200 2600 3000 3000+ 3000+ 2500 3000 3000+ 3000+
Placing Place the grout within 20 minutes of mixing to gain the full benefit of the expansion process. Conbextra HF can be placed in thicknesses up to 100 mm in a single pour. 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. Continuous grout flow is essential.
Example of a typical hopper system:
50 mm max
t t
100 mm
Maximum flow distance at 20C The flow distances given below are intended as a guide. Actual flow distances will vary depending on site conditions.
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head must be maintained at all times so that a continuous grout front is achieved. 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 Conbextra HF has reached trowelable consistency, the unrestained portion should be cut back to the baseplate/bearing plate. 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. Cleaning 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.
Limitations
Low temperature working When the air or contact surface temperatures are 5C or below on a falling thermometer, warm water (30C to 40C) is recommended to accelerate strength development. For ambient temperatures below 10C the grout consistency should be flowable and the formwork should be maintained 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 35C the mixed grout should be stored in the shade. Cool water (below 20C) should be used for mixing the grout.
Storage
Store unopened bags in cool dry internal conditions. Conbextra HF has a shelf life of 12 months if kept in a 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 Allowance should be made for wastage when estimating quantities required. The approximate yield per 25 kg bag for different consistencies is: Consistency Yield: Flowable 13.25 litres Fluid 13.5 litres
Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Conbextra HF is non-flammable.

Important note
Fosroc Limited
www.fosroc.com
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Fosroc Conbextra TS
Shrinkage compensated cementitious aggregate filled grout Uses
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. 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.
Performance specification 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. 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. Supplier specification
Advantages
Shrinkage compensated High compressive strength No need to site batch aggregates Highly flowable Extended workability Can be pumped or poured
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.
Preparation 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. 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. Baseplates 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. 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. 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
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. 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.
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
At a water powder ratio of 0.13 at 20C. Test method Compressive strength (BS1881 Part 116): - restrained Initial set (BS4550): Final set (BS4550): Expansion characteristics (ASTM C827-87): Typical result 32 N/mm2 @ 3 days 48 N/mm2 @ 7 days 64 N/mm2 @ 28 days 6.5 hours 9 hours Up to 2% at 24 hours
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Fosroc Conbextra TS
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. 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. Pour or pump Conbextra TS from one point only to eliminate the entrapment of air. Conbextra TS is formulated to give extended workability but must be placed within 20 minutes of mixing. If pumping Conbextra TS, use a piston pump (eg Putzmeizter P13) with a minimum pump line diameter of 50 mm. Curing 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.
Limitations
Low temperature working When air or contact surface temperatures are 5C or below on a falling thermometer warm water (30-40C) is recommended to accelerate strength gain. Normal precautions for winter working with cementitious materials should always be adopted. High temperature working At ambient temperatures above 35C the mixed grout should be kept in the shade prior to placement. Water less than 20C should be used for mixing.
Storage
Precautions
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 m).

Important note
Fosroc Limited
www.fosroc.com
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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. Expansion characteristics:
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

No risk of significant wash-out of cement phase when placed underwater 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 Chloride free Pre-packaged needing only on-site addition of water Preparation 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. 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. Formwork 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. Mixing and placing Mixing 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. 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.) Placing 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. Care must be taken at the start of the grouting operation to restrict the grout flow so that water is not entrapped.
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. 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.
Properties
The following results were obtained at a water : powder ratio of 0.22. Test method for Compressive strength (BS 4550, Part 3: 1978) 1 day: 3 days: 7 days: 28 days: Setting time (BS 5075, Part 1: 1982) Initial: Final: Density of hardened grout: Typical result 5C 6 N/mm 24 N/mm 36 N/mm 50 N/mm 5C 20C 25 38 44 53 N/mm N/mm N/mm N/mm
20C
13 hours 4.5 hours 16.5 hours 5.5 hours 2050 kg/m
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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. 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. 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. Curing 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. when mixed with 5.5 litres of water is 14.5 litres.
Storage
Precautions
Health and safety For further information refer to appropriate Product Safety Data Sheet. Fire Conbextra UW is non-flammable.
Limitations
Conbextra UW must not be applied below 5C.
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

Important note
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CI/SfB: 12_Yn6 October 2005
Fosroc Lokfix
Polyester resin anchoring grout
The material is tested in accordance with BS 5080, BS 7861 and BS 6319.
Properties
Gel time Temperature (C) 5 10 20 30 Gel time (minutes) 130 65 25 10 Minimum time before load (hours) 12 5 2 1
Uses
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.
The following test results were obtained at a temperature of 20C: Lokfix S25 Compressive strength: (BS 6319 Part 2: 1983) Tensile strength: (BS 6319 Part 7: 1985) Flexural strength: (BS 6319 Part 3: 1983) Compressive modulus: (BS 7861 Part 1: 1996) Density: 83 N/mm 11 N/mm 20 N/mm 13 GPa 1880 to 1920 kg/m Lokfix P25 87 N/mm 11 N/mm 19 N/mm 13 GPa 1880 to 1920 kg/m
Advantages
Easy to mix and apply Rapid strength gain Vibration resistant Corrosion resistant Non-expansive Can be placed underwater Increased flowability Chemical resistance
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.
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 20C): For use where the hole is 8 to 40 mm greater in diameter than the bar. Lokfix P25 (pumpable grade, 25 minute gel at 20C): 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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Fosroc Lokfix
Selection of grout version The version of Lokfix grout chosen will depend on anchor conditions (see Description). Parameters of anchor design The high strength of the cured resin permits strong anchors to be created. Ultimate strength is varied by: Strength of host material Length of resin bond to bar Hole preparation and formation Type and dimension of bar Typical loads attained Concrete: 20 N/mm unreinforced. Bar: Hole: Deformed rebar to BS 4449. Air-flushed rotary percussive drilled. Hole preparation and formation Optimum performance of Lokfix grouts requires rough sided, dust-free holes. Use of rotary percussive drills with air or water flushing is recommended. Diamond drilled holes should be under-reamed. Cast holes should preferably be of inverse dovetail configuration. If parallel sided holes are cast they should be rough to provide adequate keying. Bar preparation All bars should be deformed. They should preferably be degreased and all flaky rust removed. Mixing 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. Packs have been designed to produce practical and economic volumes of grout. DO NOT attempt to mix partial pack components.
40
30
Estimating
Refer to estimating guide table on the following page.
Load (tonnes)
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.
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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 2.5
therefore
= 9.84
10 packs required
NB: This example and the table below quotes net quantities and makes no allowance for overdrilling the hole or for 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 0.020 litre 0.038 litre 0.069 litre 16 mm 0.029 litre 0.060 litre 0.093 litre 20 mm 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 0.079 litre 0.124 litre 0.175 litre 0.241 litre 38 mm 0.046 litre 0.091 litre 0.142 litre 0.208 litre 0.340 litre 44.5 mm 0.100 litre 0.166 litre 0.298 litre 51 mm 0.117 litre 0.249 litre
Installation Lokfix S25 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. Lokfix P25 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. Cleaning Any mixing drums, pumps, etc., should be cleaned within
the pot life of the grout. Fosroc Solvent 105 is available for this purpose.
Supply
Lokfix S25 - Blue Lid 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 - Yellow Lid 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.
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Fosroc Lokfix
Storage
Store in accordance with the Highly Flammable Liquids and Liquefied Petroleum Gases Regulations 1972. Shelf life of 12 months at 20C will be reduced at higher temperatures. Flash points Lokfix S25: Lokfix P25: Fosroc Solvent 105: 29C 29C 43C
Limitations
Fire resistance and creep At operating temperatures above 40C, 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
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Fosroc Cebex 100

Expanding and plasticising grout admixture Uses
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.
Properties
Chloride content: Compressive Strength: Nil to BS 5075 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. Cebex 100 does not significantly affect the setting times of cement based grouts. 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. 15 minutes to 2 hours. Temperatures over 20oC may slightly reduce these times. Cebex 100 is compatible with all types of Portland cement. Cebex 100 may be used in mixes containing certain other Fosroc admixtures. Consult Fosroc for further information.
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.
Setting times:
Expansion Character:
Standard compliance
Cebex 100 is a suitable pre-stressing grout admixture when complying with BS 8110 Part 1, 1997, Annex A. Time for: expansion: Compatibility:
Description
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.

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.
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 manufacturers technical data sheet.
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Fosroc Cebex 100

Application 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. 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.
Storage
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.
Precautions
Estimating
Packaging Cebex 100 is supplied in packs containing 24 x 225g units. Dosage OPC 50 kg 50 kg Concreting sand -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
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Fosroc Cebex 250

Underwater grouting admixture Uses
stored, handled and placed strictly in accordance with manufacturers instructions.
Cebex 250 is an anti-washout grouting admixture. Mixing
Advantages
Minimises the risk of washout of cement from grouts during placing under water. 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. 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. 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. 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. Supply Cebex 250 is supplied in a 1 kg bag.
Description
Properties
Bulk density: Chloride content: 50 kg/m3 Nil to BS 5075
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 Compressive strength (BS 1881): Typical result 13.5 26.5 36.5 47.0 N/mm2 @ 1 day N/mm2 @ 3 days N/mm2 @ 7 days N/mm2 @ 28 days
Storage
Cebex 250 has a shelf life of 12 months if kept in dry store in its orginal packaging.
Limitations
Grout should not be applied below 3oC. Overdosing may lead to air entainment, result in a decrease in compressive strength.
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
Important note
Fosroc Limited
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Fosroc Cebex 653

Thixotropic stabiliser for cement grouts Uses
Stabilisation of cement grouts for pumping into cavities or fissures subject to water flow Tunnel annulus grouting in soft ground or rock Shaft grouting
Properties
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. Setting times
Advantages
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. Cebex 653 is a tunnel annulus grout admixture used to produce an instantaneous gelation and fast set behind tunnel linings.
Dosage One 0.27 kg plastic bag of Cebex 653 is required per 300 kg of cement. Overdosing 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. Application 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. 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.
Performance specification 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. 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. The admixture must be stored, handled and placed strictly in accordance with the manufacturers instructions.
Estimating
Pack size Cebex 653 is supplied in plastic bags containing 0.27 kg.
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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
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constructive solutions

Technical data sheet catalogue

Alphabetical index C Cebex 100

217 197 220 222 226 228 232 200

Product group index Concrete Repair & Remediation 1

117 120 123 126 129 132

135 137 139

141 143 245

147 151 154 157 159

107 109 111 113 115

Product group index Barriers

220 222 226 228 232

174 176 178 180

183 185 187 189 192 169 194 197 200

211 213 215 217

268 252 270 272

Cement & Concrete Technology

274 277 280 283 285

294 296 297

Fosroc Nitobond AR Nitobond HAR

CI/SfB: June 2008

Cost effective Curing aid

For further information refer to appropriate Product Safety Data Sheet.

Nitobond is the trade mark of Fosroc International Limited

5 and 25 litre tins

Nitobond is the trademark of Fosroc International Limited

Fosroc Nitobond SBR

CI/SfB: (4-) Vt3 August 2007

Typical result 62 N/mm2 3.3 N/mm2 9 N/mm2 53 N/mm2

Control 46 N/mm2 2.7 N/mm2 7.9 N/mm2 11 N/mm2

Reinforcing steel priming

Fosroc Nitobond SBR

CI/SfB: (4-) Vt3 August 2007

Fosroc Nitobond SBR

CI/SfB: (4-) Vt3 August 2007

Low temperature working

High temperature working

Overcoating with protective decorative finishes

Fosroc Nitobond SBR

CI/SfB: (4-) Vt3 August 2007

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

Nitobond is the trade mark of Fosroc International Limited

Fosroc Nitoprime Zincrich Plus

CI/SfB: October 2006

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

Fosroc Nitoprime Zincrich Plus

CI/SfB: October 2006

Additional information Limitations

Nitomortar is the trade mark of Fosroc International Limited

EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 EN 13295:2005 E N 13412 EN 13036-4 EN 13501-1 BS 4551 Pt14:1980 -

@ 10C 40 mi n @ 10C 3 hours 3 hours

@ 20C 20 mi n @ 20C 2 hours 2 hours

Nitoprime Zincrich Plus: Nitobond EP Renderoc Primer Concure WB

Initial set: 3.5 hours Final set: 5.0 hours

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

@ 2 0 oC 55 min @ 20C 12 hours 24 hours

@30oC 30min @ 30C 8 hours 16 hours

Nitoprime Zincrich Plus: Nitobond EP Concure WB

Method TI-B 52 E N 13057 -

Build Characteristics Minimum thickness: Vertical: Horiz ontal: 10mm Up to 150 mm Up to 90 mm

EN 12190:1999 EN 1542:1999 EN 1015-17:2000 EN 13687-1:2002 EN 13501-1 BS 4551 Pt 14:1980 -

Build Characteristics hand applied Minimum thickness: Overhead: Vertical:

Renderoc is the trade mark of Fosroc International Limited