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Product Description
Polycrete 1600 is an Elastomeric concrete specially engineered for use in nosing applications alongside expansion joint systems, or as a durable filler material for patching concrete substrates. The material is an epoxy blend that resists wear due to impact of vehicular loadings, and also resists cracking at low temperatures.
Polycrete outperforms traditional nosing materials such as concrete, epoxies and asphalt. These materials historically showed breakdowns due to cracking, and allowed moisture and salts to penetrate the concrete surrounding the expansion joint system. The moisture and salt traveled down through the joint opening to the structure’s support members and directly caused premature deterioration of those members.
Polycrete has a 12-year track record of excellent performance. It is one of two EMS materials that anchor its extensive line of expansion joint products. The list includes applications with the CR-Series, WM-Series and M-Series membranes, Steel Strip Seal System ,and TM, TMW, and TP Aluminum Strip Seal Systems.
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FEATURES AND BENEFITS
- Ideal for Rehabilitation Work – Polycrete, used with EMS membrane systems quickly replaces urethane T-joint products with little or no modification to the existing recess.
- Permanent Header System –Polycrete provides durability under vehicular loadings, unlike other cementitious and epoxy products. Its elastomeric properties resist cracking, particularly in colder temperatures.
- Performance Acknowledged by Prime Specifiers – Major specifiers throughout North America include Polycrete as a primary item for parking deck joint work. Its chemistry and performance have remained the same since the product’s inception.
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PHYSICAL PROPERTIES
The Polycrete system consists of three (3) items: two resin components and a pre-measured blended aggregate. The material is an ambient-cured epoxy mixture.
Limitations
To function as intended, the expansion joint system should be placed on sound concrete in the block out recess. It is important that the recess be clean and dry to ensure proper bond.
Due to the “thick” viscosity of the blended materials, a superior drum mixer type is required to properly blend the materials. EMS supplies a list of equipment that has been used successfully, and is therefore recommended for job-site activities. Failure to use the recommended equipment may jeopardize the installation of the materials and affect the warranty.
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Installation
- Prepare the block-out recess. It must be clean, dry, and level. Unsound concrete must be removed and the area repaired. Sandblast the recess to remove laitance and contaminants. Tape off the edges of the recess. Also, tape off the area adjacent to the joint using a roll of 36” wide brown paper. This will make for a clean appearance once the Polycrete has been poured and cured.
- Install the expansion joint assembly into the concrete recess.
- CR-Series Membranes: Install the cross-section into the joint opening, prior to application of the bedding mix.
Other Membranes and Systems: Apply the layer of bedding mix as described in Step C, prior to the installation of the system.
- Apply a 1/8” to ¼” thick layer of the Polycrete bedding mix to the recess base, to a width equal to that of the flap or flange of the expansion joint system used. Press the flaps/flanges down into the resins so that the Polycrete oozes up through the holes in the flaps.
- Using a Jiffy Mixer paddle and electric drill, thoroughly blend the two resin components together for one minute. No streaks should be visible. Pour the resins into the Kol Mixal drum mixer. Pour the sand mix into the mixer and blend with the resins. Mix until there are no signs of uncoated particles.
- Place the mortar mix over the flaps/flanges of the expansion joint system and fill the recess area. Compact the material so that no honeycombing can occur.
- Level off the Polycrete and trowel the finish smooth. For best results, use a trowel that is repeatedly cleaned with a rag and solvent. Upon completion, carefully remove the tape and brown protection paper.
- Cure the Polycrete overnight at 70 F. Warmer temperatures will accelerate the cure and cooler will retard the process.
- Clean up the work area.
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