Poly-Crete PC-1500 Novolac Resin

A 100% solids, two component Epoxy Novolac resin designed for concrete restoration and protection in extremely chemical corrosive environments. PC-1500 resin and curing mechanism is based on advanced polymer chemistry, providing the highest chemical resistance of epoxies available today. PC-1500 has excellent chemical resistance to acids, caustics, salts, aromatic and aliphatic solvents.

Features
1. Excellent resistance to acids, alkalis, salts, most industrial chemicals and many solvents
2. Extremely tough with high wearing properties
3. Excellent abrasion and impact resistance
4. Thin film – self leveling.
5. Meets USDA requirements
6. V.O.C. Compliant
7. No solvent odor when applying

Color Brick Red
Clear
Dark Gray
Finish High Gloss
Volume Solids 100 percentage
Recommended Dry Film Thickness Thin Film 16 – 40 mils
40 – 100 sq. ft/gal.
Mixing Ratio 2:1 by volume
Pot Life 15 – 20 minutes at 75 F
Compressive Strength 12000 psi – 14000 psi per ASTM-C109-49
Flexural Strength (per ASTM D-790) 4000 psi
Bond Strength 350 psi fails per ACI test 59-43
Shore D Hardness 85 per ASTM D2240
Tensile Strength 8000 psi per ASTM D638-60
Tensile Elongation 2.3 per ASTM D-638-60
Thinning Do not thin
Application Roller, squeegee, seed in, or trowel
Application Temperature 55 to 100 F
Dry Service Temperature 250 F
Recoat Time 4 – 24 hours at 75 F
Packaging 1.5 gal. units
15 gal. units
V.O.C 7 GMS/Liter
Shelf Life 1 year from date of manufacture
Uses
Recommended as a resin for restoration of concrete floors, sumps, drainage ditches, loading docks, tanks, ramps, storage silos, pump pads, and other concrete structures subjected to extreme chemical attack. PC-1500 is used frequently in secondary containment areas as a coating as well as a trowel down system. PC-1500 is also used as a resin with fiber glass reinforced systems. PC-1500 is used as a coating in “seed-in” systems. PC-1500 is also used as a “neat” coating.

Ideal for most type services in chemical processing plants, pulp and paper mills, sewage and waste water treatment facilities, fertilizer plants, petroleum refineries, electric generating stations, coal handling operations, food processing, etc.

Surface Preparation
Gulf Coast Paint Mfg., Inc. recommends four types of surface preparation. Any one of the four sur face preparations may be sufficient or a combination of the four may be required depending on the condition of the concrete surface.

1. High Pressure Wet Abrasive Blast Cleaning
All loose and unsound concrete must be mechanically removed down to sound concrete by means of power tool equipment, such as chipping/scaling hammers, rotary scalers, etc.

High pressure water blast with sand injection on all surfaces to remove all concrete laitance, contaminants, and other foreign deposits to provide a sound, clean surface. Use clean, dry air to blow down these areas to remove excessive moisture.

2. Acid Etch
Apply Gulf Coast Paint’s Clean & Etch Concrete Acid Solution at a spread rate of approximately 75-150 square feet per gallon. Work the solution into the concrete with a stiff broom or fiber brush. Allow solution to remain on the concrete surface for approximately 10 minutes, or until the effervescing and bubbling ceases. Then flush floor thoroughly with clean, fresh water to remove all laitance, dirt, and other foreign materials.

Random pH readings using distilled water should be made to insure all contaminants have been removed. A final pH between 7.0 and 8.5 is acceptable.

NOTE: Do not allow the Clean & Etch solution to dry on the floor before flushing off because dirt, etc., can be redeposited in the pores of the concrete.

3. Vacuum Blast
All areas of the existing concrete shall be Vacuum Abrasive Blast cleaned using a Wheelabrator Blastrac Shot Blast Machine with Dust Collector. A proper anchor profile pattern shall be achieved to provide maximum adhesion of the recommended system. A thorough washing may be necessary prior to blasting to remove all foreign matter. Check with Blastrac Mfg. for proper shot and application procedures.

4. Dry Abrasive Blast
Abrasive blast concrete surface to remove all laitance, loose concrete, coating, sealers, etc. It is necessary to achieve a rough anchor pattern and get to sound concrete. All blast material and foreign matter must be removed before application.

In all cases of surface preparation, the pH should be checked. A pH reading of 7.0 to 8.5 is acceptable. Also, a “Water Dissipation Test” should be made on random areas of the floor to determine that the proper degree of porosity has been achieved. A “Vapor Barrier Test” should also be run on the concrete. Consult Gulf Coast Paint Mfg. for specifics on testing. New concrete must be cured at least a minimum of 28 days before applying a coating. All laitance, efflorescence, chemical contaminants, grease, oil, and other foreign material must be removed. The prepared surface must be clean, dry and structurally sound.

Do not mix PC-1500 until surface has been primed with PC-155 or PC-1702 PC-1500 Base and Hardener should be stored at or above 75 F for 24 hours prior to mixing to insure normal viscosity. Poly-Crete PC-1500 is prepared by mixing 2 parts Base (Part A) to 1 part Hardener (Part B) by volume with an explosion proof variable speed drill with a Jiffy mixer for approximately 2-3 minutes. Immediately after mixing pour material out of container and spread out on primed substrate. The pot life is 15-20 minutes at 75 F.

Application Procedure & Cure Time
Application Procedure
PC-1500 must be applied over the PC-155 or PC-1702 while they have a slight tack. PC-1500 can be applied as an aggregate filled epoxy mortar by hand trowel. Apply pressure to “compact” material to a dense, monolithic topping. PC-1500 can be squeegeed for self-leveling, thin film coating and reinforced floors. PC-1500 is also used as a 16-40 mil coating. A porcupine roller is recommended to break any air bubbles in the PC-1500 when rolling. For exterior use or higher film build, seed dry PC- 1500 with fine aggregate. For use as a vertical coating, contact Gulf Coast Paint for recommendations.

Cure Time
The aggregate filled epoxy mortar has an “open” time of approximately 15-20 minutes at 75 F. Immediately after mixing a batch it should be placed and spread onto the surface to be protected. Highly filled “mortar” will be ready for foot traffic in 4-5 hours. Self-leveling slurries will be ready for foot traffic in 6-8 hours and fork lift traffic in 24-48 hours. In aggressive areas, a 16-40 mil dry sealer coat of PC-1500 is recommended to top coat mortars and self leveling slurries. A 16-40 mil coat will be ready for foot traffic in 8-12 hours.

Cautions
Poly-Crete PC-1500 is not a fire hazard; the flash point is 300 F. However, under conditions of fire it will burn and release potentially toxic fumes. The Base portion is relatively inert physiologically. The Hardener portion is corrosive and contains amines and related materials. These can cause irritation and possibly chemical burns to the skin and eyes. This is also true for mixtures of Base and Hardener. Wear safety glasses, gloves, and protective clothing when using Poly-Crete PC-1500. This product is sold without warranty as to performance expressed or implied. Users are urged to make their own tests to determine the suitability for their particular conditions.

For Professional and Industrial use only.
Keep away from children.

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