DESCRIPTION

Acid-resistant, furan polymer concrete that provides excellent protection or structural replacement for old or new concrete. Forms can be stripped away as quickly as fifteen minutes after pouring if desired, with strengths up to 5,000 psi achieved in approximately one hour.

TYPICAL USE

Replacement or topping of concrete subjected to splash and spillage of aggressive acids in chemical plants; food, beverage, pharmaceutical processing areas; power plants; pulp and paper mills; and plating plants.

PRIMERS

Refer to Hortoncrete Guide Specification for details.

EXPANSION JOINTS

Hortoncrete Joint Compound. Refer to Hortoncrete Guide Specification for details.

PREPARATION FOR NEW SLABS

Prepare the sub-base as for standard Portland cement ready-mix slabs by filling the base area with clean, dry clay, shell or other material meeting the engineer’s approval. Unless using shell, compact base material to 100% Proctor density, cover the entire base area with plastic vapor barrier product meeting the engineer’s approval, and form according to stab configuration and thickness. Place steel reinforcing rebars or mesh according to the engineer’s load design and pour Hortoncrete following manufacturer’s procedures.

TOPCOATS

Optional use of Hortoncrete Carbon Glaze. Contact EMI, INTERNATIONAL for recommendations.

COLOR

Black

SOLIDS BY VOLUME

100% (Mixed); less than 0.1 % shrinkage.

COVERAGE

9 square feet per 1.5 cubic-foot unit, 2 inches thick.

THICKNESS

2 inches minimum

COMPRESSIVE STRENGTH

To 15,000 psi. (ASTM C 579-75)

FLEXURAL STRENGTH

To 3,500 psi. (ASTM C 580-74)

TENSILE STRENGTH

To 2,000 psi. (ASTM C 307-77)

ABRASION RESISTANCE

0.3 grams loss, average of 3 tests (ASTM C-944)

DENSITY

150 pounds per cubic foot, ± 2%.

POROSITY

0.10% to 0.30%

COEFFICIENT OF THERMAL EXPANSION

11-12 x 10 -⁶ per inch degree F.

TEMPERATURE RESISTANCE

(Wet or Dry) Continuous 250 F.

MIXING RATIO

Each 200-pound unit requires two bags of aggregate component mixed with two gallons of resin and an appropriate amount of catalyst. CAUTION: DO NOT MIX THE CATALYST AND RESIN TOGETHER DIRECTLY. A VIOLENT REACTION WILL OCCUR.

POT LIFE

30 to 45 minutes at 77 F. for standard mix. Can be regulated by catalyst adjustment, from 15 minutes to several hours, as might be needed. Consult EMI, INTERNATIONAL for detailed instructions.

CLEAN UP INSTRUCTIONS

Mixers and hand tools can be cleaned with water. Do not allow mixed material to set hard before cleaning.

CHEMICAL RESISTANCE

Contact EMI, INTERNATIONAL for detailed chemical resistance chart.

SPECIAL QUALIFICATIONS

Meets the requirements of the United States Department of Agriculture for use in federally inspected meat and poultry processing plants.

MIXING AND INSTALLATION

Use clean motorized mixers. Mixers previously contaminated with Portland cement should be sandblasted to remove all traces of contamination. Preblended and premeasured aggregate is poured from the aggregate bags into the turning mixers to acquire the desired batch size. For example, a unit (200 pounds) requires two bags of aggregate. Immediately after placing aggregate into the turning mixer, add the premeasured appropriate amount of catalyst and allow to mix well for at least two minutes.

Next, the appropriate premeasured amount of resin (two gallons per unit) is added to the aggregate/catalyst mix. Allow this mixture to blend for another two minutes.

This entire mixture is then poured into a clean, sandblasted wheelbarrow and placed into the forms to be filled. This procedure is followed in a continuous manner until an expan­sion joint is reached or until the pour is completed.

After being placed into the slab or trench form, screed and hand trowel in the same man­ner as standard Portland cement concrete until desired surface finish is achieved. Mechanical vibrating or hand-tamping can be used as desired for ease of placement.

Surface bleeding or “puddling” may occur with the use of Hortoncrete. This “puddl­ing” is the formation of resin/catalyst liquid on the surface, resulting in an exother­mic reaction. If such “puddling” and exothermic reaction occurs, it can be dissipated by (a) adding additional, fresh-mixed Hortoncrete to the “puddled” area and re-troweling, or (b) sprinkling clean, dry sand onto the “puddled” area.

This surface bleeding or “puddling” can easily be avoided by proper workmanship. For example, (a) do not allow “low spots” on horizontal surfaces, (b) do not over-trowel, and thereby bring excessive resin/catalyst to the surface, or (C) do not entrap surface liquids inside forms. Construct forms to exact elevation desired, over-fill with Hortoncrete, compact, and trowel down to form level. When this is not prac­tical, drill one inch “weep holes” into forms at desired elevation to allow any excess surface liquids to drain, during the troweling process.

When the chemical reaction curing begins, about one-half hour after placement, some reaction heat is generated (about 122 F.) for about one hour. After that time, the forms can be removed and the slab or trench can be placed into service. Mixers and hand tools can be cleaned with water.

PREPARATION OF SLABS OVER EXISTING OR DAMAGED CONCRETE SURFACES

All loose or damaged concrete must be removed to expose a solid, undamaged concrete. This concrete surface must then be sandblasted, air-blasted, or cleaned by other approved means. Steel anchor bolts of approved design must then be placed at 24-inch to 36-inch centers (depending upon slab design, live or dead loading, etc.). When these drilled-into-place bolts are placed, all powdered concrete in bolt heads and around bolts must be air-blasted off the surface. (See Hortoncrete Detail Drawing 512-04 and 512.04A.)

After necessary forms are lined with plastic, placed and sealed with silicone, Hor­toncrete Primer is then rolled, brushed or sprayed on all concrete surfaces in accor­dance with the Primer data sheet. The polymer ready-mix concrete is then placed, screeded and finished according to recommended practices.

FOR TRENCHES AND WALLS

For relining existing damaged trenches, or constructing new ones, the above procedures are followed, where applicable, along with accepted construction procedures for the forming and placement of standard Portland cement ready-mix concrete. Wall steel reinforcing or the use of anchor bolts should be used as stated above, in accordance with wall and trench floor thickness and load-carrying design as calculated by the project engineer. An electric or air-operated, pencil-type internal vibrator is to be used to ensure proper Hortoncrete placement and consolidation on all vertical wall pours.

Refer to Hortoncrete Guide Specification for additional, details.

EXPANSION JOINTS

Expansion joints of ¼-inch to ½-inch width and 2-inch depth should be constructed during pouring by using removable expansion joint stripping or by saw-cutting after pouring. These expansion joints should be placed 10 feet apart on outside slabs and 13 to 15 feet apart on interior slabs. Trench wall or trench bottom expansion joints should be designed to conform with the above criteria.

According to the Hortoncrete Guide Specification, the Hortoncrete Joint Compound is placed into expansion joints by pouring. It is important to note that materials with tensile elasticity do not always yield the same wide range of chemical resistance as Hortoncrete. This is true of Hortoncrete Joint Compound when subjected to some high concentration acids. Therefore, it is recommended that all installed expansion joints be checked for possible required replacement maintenance every four to six months, minimum. (See Hortoncrete Detail Drawing 512-05 and 512-06.)

Replacement can be done by hand-routing or saw-cutting. Then remove any damag­ed expansion joint material and repour as in initial construction.

Contact EMI, INTERNATIONAL for any particular detail information on trench, wall construction or expansion joints.

SURFACE TEMPERATURE

Minimum 50 F.          Maximum 120 F.

The surface should be dry and at least 5 F. above the dew point.

NUMBER OF COMPONENTS

Three - aggregate, resin and catalyst.

PACKAGED IN

1.5 cubic-foot units (200 pounds), up to 20 units, or in bulk as might be needed.

NET WEIGHT PER UNIT

220 lbs.

STORAGE TEMPERATURE

Minimum 50 F           Maximum 110 F.

SHELF LIFE

12 months at recommended storage temperature in unopened containers. Keep dry.

SAFETY INFORMATION

This product (and any recommended thinners) contains solvents and/or other chemical ingredients. Adequate health and safety precautions should be observed during storage, handling, app­lication and curing. For information regarding the potential hazards associated with this product, please refer to the con­tainer label or request a Material Safety Data Sheet from EMI, INTERNATIONAL at the address noted in this data sheet. Please direct your inquiries to the attention of our Safety Director.

DESCRIPTION

Specialized two-component, high-build primer tor application to properly prepared concrete surfaces prior to the application of Hortoncrete.

SURFACE PREPARATION

Sandblast, air-blast or clean by other approved means. All surfaces must be dry and clean prior to coating.

COLOR

Black

FINISH

Semi-gloss

SOLIDS BY VOLUME

75.0±2.0% (Mixed)

THEORETICAL COVERAGE

1,203 mil sq. ft. per gallon.

DRY FILM THICKNESS

15.0         to 24.0 mils

CURING TIME—AT 75 F.

To touch: 6 hours    To recoat: 4 hours minimum, 24 hours maximum

TEMPERATURE RESISTANCE

(Dry) Continuous 200 F.          Intermittent 250 F.

MIXING RATIO

By volume - One (Part A) to one (Part B)

NUMBER OF

COMPONENTS

Two - Part A and Part B

PACKAGED IN

5-gallon pails and 1-gallon cans. All sizes must be ordered in multiples of 2.

NET WEIGHT PER GALLON

Mixed:      11.60± 0.25 lbs.

STORAGE TEMPERATURE

Minimum 50 F.          Maximum 110 F.

SHELF LIFE

12 months at recommended storage temperature

FLASH POINT-SETA

Part A and Part B: 81 F.

MIXING

Stir contents of each container separately, making sure no pigment remains on the bottom of the can. Pour a measured amount of Part B into a clean container large enough to hold both components. Add an equal volume of Part A to Part B while under agitation. Continue agitation until the two components are thoroughly mixed. Do not use mixed material beyond pot life limits.

SPREADING RATE

Application of coating below minimum or above maximum dry mil thickness recommended may adversely affect coating performance.

SURFACE TEMPERATURE

Minimum 50 F.  Maximum 120 F.

The surface should be dry and at least 5 F. above the dew point. Coating will not cure below minimum surface temperature.

POT LIFE

6 hours at 60 F. 2 hours at 77 F. 1 hour at 100 F.

APPLICATION EQUIPMENT

Brush or roller. Spray optional.

Air Spray

Suggested equipment, or equal:

*(Thiokol Solvent Resistant Type). Low temperatures or longer hoses require higher pot pressure.

Airless Spray

Use appropriate tip and atomizing pressure for equipment, applicator technique and weather conditions.