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zypex

xypex

CONCENTRATE

07160 | CEMENTITIOUS CRYSTALLINE

Concrete Waterproofing

Xypex is a unique chemical treatment for the waterproof-ing, protection and repair of concrete. XYPEX CONCEN-TRATE is the most chemically active product within the Xypex Crystalline Waterproofing System. When mixed with water, this light grey powder is applied as a cemen-titious slurry coat to above-grade or below-grade con-crete, 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 pre-vents 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.

Recommended for:

• Reservoirs
• Sewage and Water Treatment Plants
• Underground Vaults
• Secondary Containment Structures
• Foundations
• Tunnels and Subway Systems
• Swimming Pools
• Parking Structures

Advantages

• Resists extreme hydrostatic pressure
• Becomes an integral part of the substrate
• Can seal hairline cracks up to 0.4 mm
• Allows concrete to breathe
• Highly resistant to aggressive chemicals
• Non-toxic
• Does not require a dry surface
• Cannot puncture, tear or come apart at the seams
• No costly surface priming or leveling prior to application
• Does not require sealing, lapping and finishing of seams at corners, edges or between membranes
• Can be applied to the positive or the negative side of the concrete surface
• Does not require protection during backfilling or during placement of steel, wire mesh or other materials
• Less costly to apply than most other methods
• Not subject to deterioration
• Permanent

Packaging

• Xypex Concentrate is packaged in various sizes. Contact your local Xypex representative for details.

Storage

• Xypex products must be stored dry at a minimum tem-perature of 7ºC. Shelf life is one year when stored under proper conditions.

Coverage

• For normal surface conditions, the coverage rate for each Xypex coat is 0.65 – 1.0 kg/m2.

Test Data

• PERMEABILITY
• U.S. Army Corps of Engineers (USACE) CRD C48-73, “Permeability of Concrete”, Pacific Testing Labs, Seattle, USA
• Two inch (51 mm) thick, 2000 psi (13.8 MPa) Xypex-treated concrete samples were pressure tested up to a 405 ft. (124 m) water head (175 psi/1.2 MPa), the limit of the testing apparatus. While untreated samples showed marked leakage, the Xypex-treated samples (as a result of the crystallization process) became totally sealed and exhibited no measurable leakage.
• DIN 1048, “Water Impermeability of Concrete”, Bautest – Corporation for Research & Testing of Building Materials, Augsburg, Germany
• Twenty cm thick Xypex-treated concrete samples were pressure tested up to 7 bars (230 ft./70 m water head) for 24 hours to determine water impermeability. While the reference specimens measured water penetration up to a depth of 92 mm, Xypex-treated samples measured water penetration of zero to an average of 4 mm.
• ÖNORM B 3303, “Water Impermeability of Concrete”, Technologisches Gerwerbemuseum, Federal Higher Technical Education & Research Institute, Vienna, Austria
• Xypex-treated concrete samples were pressure tested to a maximum 7 bars (230 ft./70 m water head) for 10 days. Test revealed that while 25 ml of water had penetrated the untreated concrete samples, zero ml had penetrated the Xypex-treated samples. Test specimens were then broken and showed water penetration to a depth of 15 mm on untreated samples but no measurable water penetration on the Xypex-treated samples.
• CSN 1209/1321, “Impermeability and Resistance to Pressurized Water”, Institute of Civil Engineering, Technology and Testing, Bratislava, Slovak Republic
• Xypex-treated and untreated concrete samples were exposed to 1.2 MPa of pressure to determine water permeability. Results showed the Xypex-treated samples provided effective protection against hydrostatic water pressure. Treated and untreated samples were also sub-jected to contact with silage juices and various petroleum products (e.g. diesel oil, transformer oil, gasoline) at 14 kPa for 28 days. The Xypex-treated samples significantly reduced the penetration of these solutions.

CHEMICAL RESISTANCE

• ASTM C 267-77, “Chemical Resistance to Mortars”, Pacific Testing Labs, Seattle, USA
• Xypex-treated cylinders and untreated cylinders were ex-posed to hydrochloric acid, caustic soda, toluene, mineral oil, ethelyne glycol, pool chlorine and brake fluid and other chemicals. Results indicated that chemical expo-sure did not have any detrimental effects on the Xypex coating. Tests following chemical exposure measured an average 17% higher compressive strength in the Xypex-treated specimens over the untreated control samples.
• IWATE University Technical Report, “Resistance to Acid Attack”, Tokyo, Japan
• Xypex-treated mortar and untreated mortar were mea-sured for acid resistance after exposure to a 5% H2SO4 solution for 100 days. Xypex suppressed concrete erosion to 1/8 of the reference samples.
• FREEZE/THAW DURABILITY
• ASTM C 672, “Standard Test Method for Scaling Resistance of Concrete Surfaces Exposed to De-Icing Chemicals”, Twin City Testing Lab, St. Paul, USA
• Xypex-treated samples restricted chloride ion concen-tration to below the level necessary to promote electro-lytic corrosion of reinforcing steel. Visual examination of untreated panels after 50 freeze/thaw cycles showed a marked increase in surface deterioration compared to Xypex-treated samples.
• JIS A 6204, “Concrete Freeze/Thaw”, Japan Testing Center for Construction Materials, Tokyo, Japan
• The resonating frequency of both untreated and Xypex-treated concrete samples were measured throughout 435 freeze/thaw cycles. At 204 cycles, the Xypex-treated samples showed 96% relative durability compared to 90% in the untreated samples. At 435 cycles, the Xypex-treated samples measured 91% relative durability com-pared to 78% in the untreated reference samples.

POTABLE WATER EXPOSURE

  • NSF 61, “Drinking Water System Component-Health Effects”, NSF International, Ann Arbor, USA
  • Exposure testing of potable water in contact with Xypex-treated samples indicated no harmful effects.

RADIATION RESISTANCE

  • U.S.A. Standard No. N69, “Protective Coatings for the Nuclear Industry”, Pacific Testing Labs, Seattle, USA After exposure to 5.76 x 104 rads of gamma radiation, the Xypex treatment revealed no ill effects or damages.

Application Procedures

  1. SURFACE PREPARATION Concrete surfaces to be treated must be clean and free of laitance, dirt, film, paint, coating or other foreign matter. Surfaces must also have an open capillary system to provide “tooth and suction” for the Xypex treatment. If surface is too smooth (e.g. where steel forms are used) or covered with excess form oil or other foreign matter, the concrete should be lightly sand-blasted, waterblasted, or etched with muriatic (HCL) acid.
  2. STRUCTURAL REPAIR Rout out cracks, faulty con-struction joints and other structural defects to a depth of 37 mm and a width of 25 mm. Apply a brush coat of Xypex Concentrate as described in steps 5 & 6 and allow to dry for 10 minutes. Fill cavity by tightly compressing Dry-Pac into the groove with pneumatic packing tool or with hammer and wood block. Dry-Pac is prepared by mixing six parts Xypex Concentrate powder with one part water to a dry, lumpy consistency.
    1. NOTE:  Against a direct flow of water (leakage) or where there is excess moisture due to seepage, use Xypex Patch’n Plug then Xypex Dry-Pac followed by a brush coat of Xypex Concentrate. (Refer to Xypex Specification and Application Manual for full details.)
    2. For expansion joints or chronic moving cracks, flexible materials such as expansion joint sealants should be used.
  3. WETTING CONCRETE Xypex requires a saturated substrate and a damp surface. Concrete surfaces 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.
  4. MIXING FOR SLURRY COAT Mix Xypex powder with clean water to a creamy consistency in the following proportions:
    • For Brush Application
    • 0.65 – 0.8 kg/m2
    • 5 parts powder to 2 parts water
    • kg/m2
    • 3 parts powder to 1 part water
    • For Spray Application
    • 0.65 – 0.8 kg/m2
    • 5 parts powder to 3 parts water (ratio may vary with equipment type)
    • Do not mix more Xypex material than can be applied in 20 minutes. Do not add water once mix starts to harden. Protect hands with rubber gloves.
  5. APPLYING XYPEX Apply Xypex with a semi-stiff nylon bristle brush, push broom (for large horizontal surfaces) or specialized spray equipment. The coating must be uniformly applied and should be just under 1.25 mm.
    • 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. The Xypex treatment must not be applied under rainy conditions or when ambient temperature is below 4ºC. For recommended equipment, contact Xypex Chemical Corporation or your local Xypex representative.
  6. CURING 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. 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. During the curing period, the coating must be protected from rainfall, frost, wind, the puddling of water and tem-peratures below 2ºC for a period of not less than 48 hours after application. If plastic sheeting is used as protec-tion, it must be raised off the Xypex to allow the coating to breathe. Xypex Gamma Cure may be used in lieu of water curing for certain applications (consult with Xypex

Chemical Corporation or your local Xypex representative).

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

Technical Services

For more instructions, alternative installation methods, or information concerning the compatibility of the Xypex treatment with other products or technologies, contact the Technical Services Department of Xypex Chemical Corporation or your local Xypex representative.

Safe Handling Information

Xypex is alkaline. As a cementitious powder or mixture, Xypex may cause significant skin and eye irritation. Direc-tions for treating these problems are clearly detailed on all Xypex pails and packaging. The Manufacturer also maintains comprehensive and up-to-date Material Safety Data Sheets on all its products. Each sheet contains health and safety information for the protection of work-ers and customers. The Manufacturer recommends you contact Xypex Chemical Corporation or your local Xypex representative to obtain copies of Material Safety Data Sheets prior to product storage or use.

Warranty

The Manufacturer warrants that the products manufac-tured by it shall be free from material defects and will be consistent with its normal high quality. Should any of the products be proven defective, the liability to the Manu-facturer shall be limited to replacement of the product ex factory. The Manufacturer makes no warranty as to merchantability or fitness for a particular purpose and this warranty is in lieu of all other warranties expressed or implied. The user shall determine the suitability of the product for his intended use and assume all risks and liability in connection therewith

Application Procedures

1. SURFACE PREPARATION Concrete surfaces to be treated must be clean and free of laitance, dirt, film, paint, coating or other foreign matter. Surfaces must also have an open capillary system to provide “tooth and suction” for the Xypex treatment. If surface is too smooth (e.g. where steel forms are used) or covered with excess form oil or other foreign matter, the concrete should be lightly sand-blasted, waterblasted, or etched with muriatic (HCL) acid.

2. STRUCTURAL REPAIR Rout out cracks, faulty con-struction joints and other structural defects to a depth of 37 mm and a width of 25 mm. Apply a brush coat of Xypex Concentrate as described in steps 5 & 6 and allow to dry for 10 minutes. Fill cavity by tightly compressing Dry-Pac into the groove with pneumatic packing tool or with hammer and wood block. Dry-Pac is prepared by mixing six parts Xypex Concentrate powder with one part water to a dry, lumpy consistency.

NOTE:
• Against a direct flow of water (leakage) or where there is excess moisture due to seepage, use Xypex Patch’n Plug then Xypex Dry-Pac followed by a brush coat of Xypex Concentrate. (Refer to Xypex Specification and Application Manual for full details.)
• For expansion joints or chronic moving cracks, flexible materials such as expansion joint sealants should be used.

3. WETTING CONCRETE Xypex requires a saturated substrate and a damp surface. Concrete surfaces 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.
4. MIXING FOR SLURRY COAT Mix Xypex powder with clean water to a creamy consistency in the following proportions:
• For Brush Application
• 0.65 – 0.8 kg/m2
• 5 parts powder to 2 parts water
• kg/m2
• 3 parts powder to 1 part water
• For Spray Application
• 0.65 – 0.8 kg/m2
• 5 parts powder to 3 parts water (ratio may vary with equipment type)
• Do not mix more Xypex material than can be applied in 20 minutes. Do not add water once mix starts to harden. Protect hands with rubber gloves.
5. APPLYING XYPEX Apply Xypex with a semi-stiff nylon bristle brush, push broom (for large horizontal surfaces) or specialized spray equipment. The coating must be uniformly applied and should be just under 1.25 mm.

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. The Xypex treatment must not be applied under rainy conditions or when ambient temperature is below 4ºC. For recommended equipment, contact Xypex Chemical Corporation or your local Xypex representative.

6. CURING 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. 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. During the curing period, the coating must be protected from rainfall, frost, wind, the puddling of water and tem-peratures below 2ºC for a period of not less than 48 hours after application. If plastic sheeting is used as protec-tion, it must be raised off the Xypex to allow the coating to breathe. Xypex Gamma Cure may be used in lieu of water curing for certain applications (consult with Xypex

Chemical Corporation or your local Xypex representative).
NOTE: For concrete structures that hold liquids (e.g. reservoirs, swimming pools, tanks, etc.), Xypex should be cured for three days and allowed to set for 12 days before filling the structure with liquid.