LS 486 / GLASS MAT REINFORCED SYSTEM A LAVALINE - SERIES 48 SYSTEM / Vinyl Ester CONCRETE & MASONRY SURFACES

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1 LS 486 / GLASS MAT REINFORCED SYSTEM / Vinyl Ester CONCRETE & MASONRY SURFACES

2 The LS-486 system may be installed on various substrates, including carbon and stainless steel and concrete and other masonry surfaces. The following Guideline covers applications over Concrete & Masonry Substrates. Please note these are not to be construed as engineered specifications or project specific unless so noted by the specifying authority. These are only guidelines to allow for a good understanding of surface preparation, mixing, installation and environmental conditions typically required to affect a successful project. 1. Scope CONCRETE & MASONRY SURFACES 1.1 This recommendation covers the requirements for the surface preparation, application of primers and finish coats to affect appropriate corrosion protection on concrete and/or secondary containment structures and vessels using vinyl ester products. 1.2 The lining materials covered in this installation guide are components that make up a LavaLine System. This installation guide covers PROPOLYMER Coatings vinyl ester materials LavaLock 4860 and LavaLock 4847 used in LS-486 Glass Mat Reinforced System. Typical installations achieve a nominal 90- mdft on horizontal surfaces and 30-mdft on vertical surfaces. 1.3 LS-486 consists of surface preparation, prime coating, void filling, a mortar bed with 1.5-ounce chopped strand glass mat embedded and saturated with un-pigmented resin and a final resin rich color coat on all horizontal surfaces and coved areas. Walls receive two coats of pigmented coating. See drawing detail for sequencing and individual material thicknesses and coverage rates. 1.4 This installation guide is not intended to supersede any specification. It is intended as assistance to the specifying source, the installation contractor and the field inspector. 1.5 This is only a guide and field conditions may warrant the alterations of some procedures. Check with the owner, or the owner s representative, or the material supplier when in doubt. LAVALINE SERIES / LS-486 Concrete Page 1

3 2. Surface Preparation-Concrete 2.1 New concrete must cure a minimum of 28-days or have been poured with an approved non-chloride curing accelerant additive such as Gill # All prepared concrete must be free of curing compounds, release agents and/or other contaminants. Prepared concrete shall have a nominal tensile strength of 250-psi as per ASTM-D-4541 Standard Test Method for Pull-Off Strength. 2.3 Concrete must be cleaned as per ASTM-4258 Standard Practice for Cleaning Concrete and prepared as per ASTM-4259 Standard Practice for Abrading Concrete or using other appropriate standards accepted by the owner and PROPOLYMER Coatings prior to project start. Abrade surface to create sufficient texture to hold and support the full LavaLine System, LS-486. Abrasive blasted, mechanical scarification or ultra-high water jetting are preferred methods. Surface texture shall be a minimum visual standard of CSP-3 as set by the International Concrete Institute. 3. Materials 3.1 For this project the lining materials selected are to be solely sourced from the PROPOLYMER Coatings Company (St. Louis, MO). All primers, thinners, additives shall be from the manufacturer in new and unopened containers. 3.2 The following materials are required on site in order to install LAVALINE System, LS-486, and should be used as directed in the installation sequence. Primer: ProPrime 4806 Vinyl Ester Primer Concrete Basecoat: Reinforcement: Aggregate: Mortar Additive: Finish Coat: Smoothing Liquid 4. Application Parameter & Details LavaLock 4860M (with Color Packs or CP/factory tinted) LavaMat 9011 Glass Mat / 1.5-ounced Chopped Strand LavaCast 9240 Broadcast Aggregate (Optional for non-slip finish) LavaThix 9111 Bulking Additive LavaLock 4860CP (with Color Packs or CP/factory tinted) ProSlick 4809 Smoothing Liquid 4.1 All manufacturers mixing application, finishing and safety instructions must be strictly followed through all phases of the lining application. Consult PROPOLYMER Coatings product data sheet for more details including environmental conditions for storing, mixing, applying and curing LavaLine Systems. 4.2 It is highly recommended that when applying LavaLine Systems over concrete that application of materials begins when ambient temperatures or falling as opposed to rising as this condition is helpful in minimizing out-gassing. LAVALINE SERIES / LS-486 Concrete Page 2

4 4.3 Only PROPOLYMER Coatings thinners, finishing liquids or other additives shall be employed into the LavaLine System. A written waiver of alternately acceptable materials must be accepted in advance by both the owner and PROPOLYMER Coatings. 4.4 When any of the following conditions exist, no blasting, priming or any other part of the lining system application shall be attempted without written waiver from the lining manufacturer. A. The relative humidity in the work area is greater than 90 percent. B. The surface temperature is less than 5 F above the dew point of the air in the work area. C. The temperature of the steel surface, lining materials or the air in the work area is higher than 110 F or less than 50 F. 5. ProPrime 4806 Application and Scratch Coat/Void Filling 5.1 Apply ProPrime 4806 by spray, brush or roller. Apply at 6-8 mdft or at a spread rate not to exceed 200- square feet per gallon on concrete and masonry substrates. If ancillary metal substrates are encountered, 4806 may be used as a primer on these surfaces. Do not allow primer to puddle. Follow mixing and application instructions for ProPrime ProPrime 4806 must be allowed to dry tack free before proceeding with additional steps in System LS Mix ProPrime 4806 with PROPOLYMER Coatings LavaThix 9111 Bulking Additive to make a dry-wall mud consistent mixture. Scratch this material onto the surface using trowels to push material into pits and voids. Remove excess from surface. If on concrete additional LavaThix 9111 and/or aggregate additives may be required, consult PROPOLYMER Coatings. LAVALINE SERIES / LS-486 Concrete Page 3

5 6. LavaLock 4860M Basecoat with Glass Mat & Saturant Application 6.1 The primer and scratch coat must be sufficiently cured prior to the basecoat application. If the primer remains uncoated more than 48 hours at 75 F or as directed by the manufacturer, the primed surfaces must be completely styrene wiped prior to the application of the basecoat. 6.2 If the primed surface remains uncoated for more than 5 days at 75 F, the primer must be tested for styrene sensitivity in several locations. Styrene sensitivity indicates the capability of the primer to soften and chemically bond to the basecoat. If the primer is not styrene sensitive, the areas of insensitivity must be lightly abraded by abrasive blasting and re-primed. 6.3 All horizontal to vertical transitions, such as floor to wall and floor to pump pad shall receive an installed cove. Coving material shall be made by mixing 1-gallon of catalyzed LavaLock 4860 with 25- pounds of LavaCast 9240 and 50-pounds of clean, dry and smooth -3/8-inch pea gravel. Place and form to relieve the 90-degree angle by creating a form or employing a tool to extend the cove a minimum of 3-inches on the horizontal and vertical surfaces. Basecoat application shall include LavaLock mortar bed and LavaMat 9011 up and over this coved area, a minimum of one-inch vertically past the top of the cove. 6.4 Remove any dirt, dust or other contamination prior to the application of the basecoat. 6.5 Plan the basecoat application carefully as multiple steps occur in a short period of time. Sufficient empty pails for splitting catalyzed material prior to addition of bulking additive, color packs (if appropriate), bags of LavaThix 9111 and pre-cut sheets of LavaMat 9011 should be ready on site for installation. 6.6 Work in sections whereby, steps can be achieved through easy access to the work surfaces. 6.7 LavaLock 4860M consists of the basecoat material Part A, either factory tinted or sent with color packs (CP). Mix the Part A until a uniform color is achieved. Next add ProLine Catalyst Part B and power mix for additional 1 to 2 minutes. Commonly, one half of the catalyzed material is poured off into a second clean five gallon container, making both containers now ready for incorporation of thickening additive to create the mortar. Immediately begin adding pounds of LavaThix 9111 per gallon and aggressively power mix into the 4860M to create a fluid mortar. LavaThix 9111 loading may be increased as necessary for obtaining better application conditions on vertical and overhead surfaces. LAVALINE SERIES / LS-486 Concrete Page 4

6 6.8 Immediately begin using the LavaLock 4860M mixture moving it on to the primed surfaces and coved areas. Spread out using an appropriate tool such as a tight or notched squeegee, trowel or other appropriate placing tool. Apply as evenly as possible to remove the irregularities in the prepared concrete surface and set up a mortar bed for accepting glass mat reinforcement. 6.9 A typical basecoat thickness for LS-486 system is nominal 50-mils, with a spread rate of square feet per gallon While the LavaLock 4860M mortar mixture is still in a fluid condition, place the LavaMat 9011 onto the surface and impress into the 4860M using a dry or steel-ribbed roller. When placing sheets of LavaMat 9011, overlap each pass or lift of glass mat a minimum of 2-inches While LavaLock 4860M with LavaMat 9011 is still has not fully cured, apply a saturant coat over the exposed chopped strand glass mat. This saturant coat is made by mixing LavaLock 4860 / 010 Translucent Part A with ProLine catalyst. Working from a roller bucket, wet a 3/8-inch solvent resistant roller with the LavaLock 4860 and lightly roll over the LavaMat 9011 to orient the glass fibers and satisfy the porosity of the surface A typical spread rate for LS-486 system in the saturant stage is square feet per gallon which will yield about 40-mils over the LavaMat At this stage all materials should be allowed to cure before proceeding to next step in LavaLine System LS-486. LAVALINE SERIES / LS-486 Concrete Page 5

7 7. LavaLock 4860CP Vertical Applications & Adjustments 7.1 Prior to the application of the final coat in LS-486, the entire basecoat application shall be roughened to knock-down the saturant glaze and to grind off any protrusions and stray glass strands. 7.2 After roughening the surface, it shall be vacuumed free of debris and lightly wiped with ProSlick LavaLock 4860CP is either a factory tinted color, or if Color Packs (CP) have been provided, the LavaLock 4860 / 010 Translucent is used as the base and the appropriate number of CP units are added to the Part A and mixed prior to catalyzing material. 7.4 Add Color Packs or proceed to power mixer agitation of the factory tinted LavaLock 4860 Part A. Once color is uniform, add ProLine Catalyst Part B and mix for an additional 1-2 minutes. 7.5 Wall and vertical applications in LS-486 is one coat of LavaLock 4860CP adjusted with LavaThix 9111 to assist in application build over the substrate that has been coated with ProPrime The application coat should be a nominal 10-mdft. 7.6 A typical application sequence will have the vertical or wall topcoat applied as part of the horizontal surfaces finish coat. Note: material for vertical applications will require thickening with LavaThix 9111 in order to achieve specified film thickness. Additional thickening of the LavaLock 4860 is not advised when top coating on horizontal surfaces as this material is self-leveling. 7.7 Adjustments can be made to LS-486 if desired see Alternately, review LS-481 / 60-mil Broadcast System including Non-Slip Option, as this system may be more appropriate for specific project conditions Non-Slip: To create this surface, within 24-hours of the cure of the self-leveling application, the surface shall be wiped clean with a mild soap water solution, rinsed and dried. Once dry, scuff and de-gloss the surface and wipe with clean water again. Allow to dry. Apply an additional coat of LavaLock 4860CP sprinkling in appropriate sized aggregate and back-roll to lock into the coating Vertical Applications: When applying LavaLock 4860CP to walls, curbs or other non-horizontal surfaces, increase LavaThix 9111 as necessary to thicken material to hang on the surface and achieve specified thickness. Typical application is two coats at mils per coat for no less than 30-mdft, pinhole free. 7.8 Depending on chemical service, allow a minimum of 24-hours cure for light traffic, 48-hours cure for heavy equipment and maximum chemical resistance is usually achieved within 72-hours. END SPECIFICATION LAVALINE SERIES / LS-486 Concrete Page 6

8 SOME or ALL OF THE SUPPORTIVE DOCUMENTS THAT MAY BE ENCLOSED HEREIN ProPrime 4805 ProPrime 4806 LavaLock 4860 LavaLock 4847 LavaMat 9011 LavaCast 9240 LavaCast 9216 LavaThix 9111 Bulking Additive ProSlick 4809 Smoothing Liquid CP-Color Packs LAVALINE SERIES / LS-486 Concrete Page 7