Chemcrete AS
High-strength, heavy-duty, anti-skid, hybrid polyurethane flooring system
Product Description
Chemcrete AS is a 4-part, hybrid polyurethane concrete Resinous flooring system with a textured, seamless matt surface finish. It offers an aesthetically pleasing floor, providing good slip resistance, and can be installed at 6 to 12 mm thickness in a single application.
Chemcrete floors are known for their high thermal, chemical, abrasion, and impact resistance. They are formulated to withstand harsh temperature extremes and are tolerant to steam contact.
Uses
- Generally used in dry/wet areas such as food or pharmaceutical processingplants.
- Chemical plants, laboratories, clean rooms
- Heavy engineering and automobile workshops, warehouses.
- Slaughter houses
- Dairy and dairy products processing plants.
- Restaurant kitchens, cold storage facilities
- Beverages bottling plants
Storage Conditions/Shelf Life
12 months from date of mfg. if stored properly in shelf life, undamaged seal packaging, at a temperature between 5°C-30°C. It should be kept in a cool, well-ventilated area, away from heat, direct sunlight, sparks, and children.
Product Data
| Appearance / colour: | Chemcrete AS [R] Resin | Cream Colour Liquid |
| Chemcrete AS [H] Hardener | Dark Amber Liquid | |
| Chemcrete Aggregates | White Powder | |
| Chemcrete Pigment | Coloured Slurry |
Salient Features
- Excellent chemical resistance to a wide range of organic and inorganic acids, alkalis, amines, salts, and solvents.
- Excellent bond strength
- Low odour, VOC-free.
- High mechanical impact resistance. It has a plastic nature due to which it will deform but will not crack or debond even under heavy impact.
- Good slip resistance.
- High abrasion resistance due to scientifically selected aggregates.
- Easy to clean and sterilise. It can resist steam cleaning when laid at a thickness of more than 9 mm. Withstands temperature from -400C to 1300C @ 12 mm
- Fast one-step application. Suitable for weekend maintenance.
- Can be applied to substrates with high moisture content (5-day-old concrete)
- Hygienic. Resists growth of a wide array of pathogens, bacteria, and fungi.
Technical Profile
| Property | Test Method | Value and Unit |
|---|---|---|
| Mixing Ratio | NA | Pre-weighed kit to cover: 1) 2.35 sq.m area @ 6mm 2) 1.55 sq.m area @ 9mm 3) 1.18 sq.m area @ 12mm Coverage is approximate and depends on surface profile and quality. |
| Finish | CPI* 1001 | Textured, Matt |
| Pot Life | ||
| @ 10°C | CPI 1002 | ~35 min |
| @ 20°C | CPI 1002 | ~24 min |
| @ 35°C | CPI 1002 | ~12 min |
| Curing Time | ||
| Surface Dry @ 35°C | CPI 1002 | ~12 hours |
| Hard Dry [Open for foot traffic] @ 35°C | CPI 1002 | ~18 hours |
| Full Cure [Vehicular Movement] @ 35°C | CPI 1002 | ~3–4 days |
| Coverage | CPI 1010 | 2.2 Kg/m²/mm |
Mechanical Properties of CHEMCRETE AS
| Property | Test Method | Value and Unit |
|---|---|---|
| Compressive Strength | ASTM C 579 | >500 Kg/cm² |
| Flexural Strength | ASTM C 580 | >140 Kg/cm² |
| Tensile Strength | ASTM C 307 | >60 Kg/cm² |
| Pull off Adhesion Test | ASTM D 4541 | Concrete Failure @ 18 Kg/cm² |
| Abrasion Resistance [Taber] | ADTM D 4060 | 45 mg loss |
| Shore Hardness | ASTM D 2240 | D 80 – 85 |
| Shelf Life | – | 12 months in original unopened container when stored between 5 – 40°C |
| Surface spread of flame | BS476 Part 7 | Class 2 |
| Coefficient of thermal expansion | ASTM C531 | 2.5×10⁻⁵ / °C |
| Service temperature | CPI 1984 | -15 to 80°C @ 6mm -40 to 120°C @ 9mm -40 to 130°C @ 12mm |
Method of Application
All Chemsol Products are recommended to be applied only by Approved Applicators and should be handled after using proper PPEs like Gloves, mask, goggles, etc.
Substrate Quality
Ensure that the concrete substrate has a minimum compressive strength of 250kg/cm2. The CDS (clean, dry, sound) test must be conducted before application
of primer/scratch coat to the concrete substrate. The substrate must be free of all contaminants such as dirt, oil, grease, coatings, and surface treatments etc. Consider applying a test area if necessary.
Application conditions
Substrate temperature: 10-40°C
Substrate moisture content: - Chemcrete can even be applied on substrates with high moisture content like 6 days old concrete but ensure that the water is not ponded on the surface.
Relative humidity: 8o%max
Note: The substrate temperature must be at least 30°C above the prevalent dew point temperature to reduce
chances of condensation on the floor.
Substrate Preparation
Mechanically prepare the concrete substrate to achieve a concrete surface profile between 4-6. This will also aid in removing weak concrete and cement laitance. Suitably established methods like scarification, grinding, abrasive shotblasting, etc., should be employed to achieve the same. Fully expose the blowholes and voids and repair them using appropriate products like Chemprime, Chemseal, etc. Remove oils, grease, wax, etc. by using detergent, low-pressure water, steam, or suitable chemicals, as they create a hindrance in developing a strong bond between the concrete and Chemcrete.
Prime the surface with a 1mm scratch coat of Chemcrete MD or a 200 micron primer coat of Chemcrete LV primer. Your Chemsol solutions expert will choose the suitable primer depending on the substrate condition. Identify and treat the expansion
joints properly. Refer the method statement for doing the same.
Mixing
Pour Chemcrete AS[R] into a 30-liter bucket/ pail and add Chemcrete pigment paste to it. Stir with a helical paint mixer for 1 minute, now add chemcrete AS [H] and continue stirring for 1 more minute. After this, add Chemcrete aggregates and thoroughly mix for 2 minutes with a heavy-duty mixer. Always mix complete packs, never split packs. Note that Chemcrete aggregates are specially formulated reactive materials, and their quantity should not be altered to adjust the viscosity for workability. Visually ensure that the mixture has become homogeneous. Immediately lay the mixture on the floor and spread it with a gauge rake or screed box to the desired thickness. Use a steel trowel with rounded edges to make the surface even. Now using a short pile roller, gently roll the surface for two times in the same direction. Avoid excessive rolling as it will adversely impact the slip resistance by smoothening the surface and reducing the textured profile of the surface. Adhere to the following curing schedule before bringing the floor to service:
Note that the mixture has a stipulated pot life hence the application should immediately commence after mixing the contents.
| Temp. (°C) | Foot traffic | Full cure |
|---|---|---|
| 10°C | 24 hours | 7 Days |
| 20°C | 24 hours | 5 Days |
| 35°C | 16 hours | 4 Days |
Cleaning of Tools
Clean all tools and application equipment with thinner PT 36 immediately after use. Hardened and/or cured material can only be removed mechanically.
Packing
Chemcrete AS is available in a pre-weighed kit of 31kg consisting of Resin, Hardener, Aggregates, and pigment paste.
Handling & Safety
Keep the containers tightly sealed when not in use. Avoid skin contact and inhalation of fumes (if any). While spraying, it is advised to wear a mask. If it comes in contact with the body, wash affected parts with plenty of soap and water. In case of persistent irritation, contact a physician.
*Disclaimer: The Information provided is based on our experience, thorough investigations & sophisticated testing methods, but due to the vast number of applications and usage methods, Chemsol Polymer Industries cannot accept responsibility of any kind for any particular result. It is the responsibility of the user to verify the suitability of the product for their end use and in accordance with the rules and regulations of that country /territory. All information provided pertaining to our products should be treated only as a guidance tool without any guarantee or warranty of any sort.
* All CPI test methods are our scientifically designed internal test methods which can be shared upon request.
