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XYPEX Concrete Waterproofing - Coating Application

Xypex Concentrate

Xypex Concentrate is the most chemically active product within the Xypex Crystalline Waterproofing System. When mixed with water, this light grey powder is applied as a cementitious slurry coat to above-grade or below-grade concrete, either as a single coat or as the first of a two-coat application. It is also mixed in Dry-Pac form for sealing strips at construction joints, or for the repairing of cracks, faulty construction joints and honeycombs. Xypex prevents the penetration of water and other liquids from any direction by causing a catalytic reaction that produces a non-soluble crystalline formation within the pores and capillary tracts of concrete and cement-based materials.

Xypex Modified

OVERVIEW

Xypex Modified can be applied as a second coat to reinforce Xypex Concentrate, or applied by itself to dampproof the exterior of foundation walls. Applied as a second coat, Xypex Modified chemically reinforces Xypex Concentrate where two coats are required and produces a harder finish. Where dampproofing is required, a single coat of Modified may be used as an alternative to a spray/tar emulsion. Xypex prevents the penetration of water and other liquids from any direction by causing a catalytic reaction that produces a non-soluble crystalline formation within the pores and capillary tracts of concrete and cement-based materials.

1. The Xypex treatment must not be applied under rainy conditions or when ambient temperature is below 40°F (4°C).

2. Because Xypex requires moisture to initiate the crystalline waterproofing process, all concrete, whether fresh or old, must be saturated with water. (Refer to "Wetting Concrete" under Preparation section.)

3. The concrete surface must be a minimum of 20 hours old before application of the Xypex coating treatment.

4. For fresh concrete, the period between 24 hours and 72 hours is the optimum time within which to apply Xypex, as the new concrete is still 'green' and requires very little pre-watering.

For normal surface conditions, the coverage rate for each Xypex coat is 1.25 - 1.5 lb./sq. yd. (0.65 - 0.8 kg/m2).

1. The concrete surface to be treated must be clean and free of laitance, dirt, film, paint, coatings or other foreign matter. The surface must also have an open capillary system to provide "tooth and suction" for the Xypex treatment.

2. If surface is too smooth (e.g. where steel forms are used) or if surface is covered with excess form oil or other foreign matter, the concrete should be lightly sand-blasted, water-blasted, or etched with muriatic (HCL) acid.

3. Horizontal surfaces should have a rough wood float or broom finish. Concrete laitance must be removed from surface by light sand-blasting, water-blasting or etching with muriatic (HCL) acid.

4. Surfaces to be etched with muriatic acid should be dampened with water before application of the acid. After acid etching flush concrete thoroughly with clean water.

1. Rout out cracks, faulty construction joints and other structural defects to a depth of 1.5 inches (37 mm) and a width of one inch (25 mm).

2. Apply a brush coat of Xypex Concentrate in cavity and allow to dry for 10 minutes.

3. Fill cavity by tightly compressing Dry-Pac into the groove with pneumatic packing tool or with hammer and wood block. (Refer to Dry-Pac mixing instructions.)

4. Against a direct flow of water (leakage) or where there is excess moisture due to seepage, use Xypex Patch'n Plug in lieu of Dry-Pac followed by a brush coat of Xypex Concentrate. For expansion joints or chronic moving cracks, flexible materials such as expansion joint sealants should be used.

Refer to Xypex Repair Procedures for more detailed instructions.

Xypex requires a saturated substrate and a damp surface. Concrete surfaces, therefore, must be thoroughly saturated with clean water prior to the application so as to aid the proper curing of the treatment and to ensure the growth of the crystalline formation deep within the pores of the concrete. Remove excess surface water before the application. If concrete surface dries out before application, it must be re-wetted.

1. Mix Xypex with clean water only (water that is free of salt and other deleterious materials).

2. Mix clean water into the Xypex powder with a paddle on a slow speed electric drill (250 RPM) or with other equipment that ensures adequate mixing. For small jobs, Xypex may be mixed by gloved hand or by trowel.

3. Be sure that the quantity mixed can be applied within 20 minutes. As the mixture thickens, stir frequently but do not add water.

Mix Xypex powder with clean water to a creamy consistency in the following volume proportions:

For Brush Application
1.25 - 1.5 lb./ sq. yd.
(0.65 - 0.8 kg/m2)
5 parts powder to 2 parts water

2.0 lb./sq. yd.
(1.0 kg/m2)
3 parts powder to 1 part water

For Spray Application
1.25 - 1.5 lb./sq. yd.
(0.65 - 0.8 kg/m2)
5 parts powder to 3 parts water
(Ratio may vary with equipment type)

Using a trowel, mix 1 part clean water with 6 parts Xypex Concentrate powder by volume for 10 to 15 seconds. Lumps should be present in this mixture. Do not mix more than can be applied in 20 minutes.

1. Apply Xypex with a semi-stiff nylon bristle brush, push broom (for large horizontal surfaces), or specialized spray equipment. Do not apply Xypex with a trowel, roller, paintbrush or paint sprayer. Contact your Xypex representative for further information.

2. The Xypex coating must be uniformly applied and should be just under 0.0625 inches (1.25 mm) thick. A thicker coating can cause curing difficulties, especially in warm weather.

3. When a second coat (Xypex Concentrate or Xypex Modified) is required, it should be applied after the first coat has reached an initial set but while it is still "green" (less than 48 hours). Light pre-watering between coats may be required due to drying.

4. For slab (horizontal) applications, care should be taken to spread the Xypex evenly, pulling a heavy broom over the fresh Xypex. This should be done in long strips and will serve to eliminate settlement of the Xypex in low spots on the slab and also to remove excess material which may have been applied.

5. In hot weather it is advisable to apply Xypex either early in the morning or late in the day. This will prevent the Xypex coating from drying out too quickly.

Note:Where a smooth, steel-trowelled finish is required for horizontal slab or where slab will be exposed to traffic (e.g. parking deck), apply Xypex Concentrate DS-1 or DS-2 by dry shake method. Consult Xypex Technical Data or your Xypex representative for further information.

1. A misty fog spray of clean water must be used for curing the Xypex treatment. Curing should begin as soon as the Xypex has set to the point where it will not be damaged by a fine spray of water.

2. Under normal conditions, it is sufficient to spray Xypex treated surfaces three times per day for two to three days. In hot or arid climates, spraying may be required more frequently to prevent premature drying of the coating.

3. During the curing period, the coating must be protected from rainfall, frost, wind, the puddling of water and temperatures below 36°F (2°C) for a period of not less than 48 hours after application. If plastic sheeting is used as protection, it must be raised off the Xypex to allow the coating to breathe.

4. For concrete structures that hold liquids (e.g. swimming pools, reservoirs, wet wells, tanks, etc.), Xypex should be cured for three days and then allowed to set for 12 days before filling the structure with liquid.

5. For structures holding particularly hot and/or corrosive liquids, Xypex should be cured for three days and allowed to set for 18 days before filling.

6. In situations where there is poor air circulation (e.g. small, enclosed reservoirs or wet wells), fans or blown air may be necessary to aid the curing of Xypex.

7. Xypex Gamma Cure may be used in lieu of water curing for certain applications (consult with Xypex Chemical Corporation or your nearest Xypex distributor). Gamma Cure should be applied using a garden type sprayer and must be diluted as per directions before use. Do not apply more Gamma Cure than is specified.

8. For Xypex coated slabs that will be a wearing surface, water curing is recommended.

Backfilling can take place 36 hours after the Xypex application. If backfilling takes place within seven days after the application, the backfilling material should be moist so as not to draw moisture from the Xypex coating.

Xypex requires 21 days of curing and crystal generation before the application of any paint or epoxy. Washing the Xypex surface with a 3 - 5% muriatic acid solution is recommended before applying the coating. Be sure to flush all acid off the wall.

It is important that any other cementitious system be applied over the Xypex coating before the Xypex crystals have had time to plug the pores of the concrete. Therefore, grouts, cement parge coats, etc. should be applied after the Xypex has completely set but while it is still "green" (8 to 48 hours). Use of a bonding agent is recommended.

Note:Xypex Chemical Corporation makes no representations or warranties regarding the compatibility of Xypex products with plasters, stuccos, tiles and other surface-applied materials. It is the responsibility of the installer of these surface-applied materials to take whatever measures are necessary, including testing, to ensure acceptance by or adhesion to the Xypex treated surface. For more instructions, alternative application methods, or information concerning the compatibility of the Xypex treatment with other products or technologies, contact the technical department of Xypex Chemical Corporation.

Xypex is highly alkaline.

1. Avoid contact with skin or eyes.

2. Protect hands with rubber gloves when handling dry powder or wet mixture.

3. If skin comes into contact with Xypex material, wash immediately and thoroughly with water for 15 minutes. If discomfort continues, seek prompt medical attention.

4. Wear eye protection. If dry powder or wet mixture gets into eyes, flush immediately and thoroughly with water and seek medical aid.

5. Wear a suitable mask where there is potential for generating dust. If Xypex is ingested, do not induce vomiting; have affected person drink two glasses of water and obtain immediate medical attention.

6. For material safety data sheets, contact Xypex Chemical Corporation at 604.273.5265 or toll free 800.961.4477.

Xypex Chemical Corporation
13731 Mayfield Place
Richmond, BC V6V 2G9
Tel: (604) 273-5265
Fax: (604) 270-0451
Tollfree: (800) 961-4477
E-mail: info@xypex.com
Web site: http://www.xypex.com