Chemcrete HD
High-strength, self-smoothing, electrostatic dissipative, hybrid polyurethane flooring system
Product Description
Chemcrete HD 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 processing plants.
- Chemical plants, laboratories, and 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 manufacturing date if stored properly in undamaged seal packaging, at 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 HD [R] Resin: | Cream colour liquid |
| Chemcrete HD [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 -40°C to130°C @ 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.
Chemical Resistance
Outstanding chemical resistance is observed against a wide range of materials like;
- Strong inorganic acids like sulphuric acid (<35%), Hydrochloric acid (<35%), and phosphoric acid (<50%).
- Strong organic acids commonly encountered in food processing industries, Acetic acid (<30%), citric acid, Formic acid, Uric acid, oleic acid, and Lactic acid
- Strong alkali solutions like Potassium hydroxide (<50%), sodium hydroxide (<50%), etc.
- Diesel, Petrol (gasoline), Mineral oils, etc.
- Vegetable oils, Hydrogenated vegetable oils, Fats, Glucose, Sucrose, etc.
- Sanitization chemicals like sodium hypochlorite solution, detergent solutions, etc.
- Commonly used solvents like ethyl alcohol, IPA, xylene, and various Amines.
- A detailed but non-exhaustive list of chemicals to which Chemcrete is resistant is available upon request.
Technical Profile
| Property | Test Method | Value and Unit |
|---|---|---|
| Mixing Ratio | NA | Pre weighed kit to cover:1) 2.35 sq.m area @ 6mm2) 1.55 sq.m area @ 9mm3) 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
| 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 | CPI1984 | -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, masks, goggles, etc.
Substrate Quality
Ensure that the concrete substrate has a minimum compressive strength of 250 kg/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, 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-day-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 3 °C above the prevalent dew point temperature to reduce chances of condensation on the floor.
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, surface treatments etc. Consider applying a test area if necessary.
Substrate Preparation
Concrete substrates must be prepared mechanically using abrasive blast cleaning, scarifying, or grinding equipment to remove cement laitance and achieve an open-textured surface. Remove weak concrete and expose surface defects such as blowholes and voids. Repairs to the substrate, filling of blowholes/voids, and surface levelling must be carried out using appropriate products. Ensure that the dust, loose and friable material is completely removed from all surfaces by brush and vacuum before application of the product.
The concrete substrate has to be primed or levelled with Chemprime/Chembase 150 in order to achieve an even surface. Allow the primer to cure for 5-6 hours.. After this, Mix Chembase-150 Resin and Hardener in a ratio of 2:1 and add Aggregate AG80/AG257 in a prescribed ratio and mix for 2 minutes with a helical paint mixer. Visually ensure that the mixture has become homogeneous.
Immediately lay the mixture on the floor and spread it with a trowel to the desired thickness. Use a spike roller to deareate the coating.
Mixing and Application
Pour Chemcrete HD[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 HD [H] and continue stirring for 1 more minute. After this, add chemcrete aggregates and thoroughly mix for 2min 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 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:
Curing Schedule
Clean all tools and application equipment with thinner PT 36 immediately after use. Hardened and/or cured material can only be removed mechanically.
| Temp. (°C) | Foot traffic | Full cure |
|---|---|---|
| 10°C | 24 hours | 7 Days |
| 20°C | 24 hours | 5 Days |
| 35°C | 16 hours | 4 Days |
Packing
Chemcrete HD is available in pre 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 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 sorts.
*All CPI test methods are our scientifically designed internal test methods which can be shared upon request.
