For Industrial Warehouse Floors and Loading Docks Subject to Continual Vehicular and Foot

VELVET POUR

DESCRIPTION

VELVET POUR is a self-levelling, self-drying overlay, based on High-Hydrated Cement Technology, that is specially formulated for fast-track resurfacing and construction of interior horizontal wear surfaces.

AREAS FOR USE:

 For industrial warehouse floors and loading docks subject to continual vehicular and foot traffic.  Suitable for retail stores, mall corridors, showroom floors, restaurant floors, hotel lobbies and loft apartments;  For applications where a unique, easy to clean, smooth, living, coloured creative floor is desired;

LIMITATIONS

 Do not install over substrates containing asbestos or of substandard quality.  Do not install over particleboard, gypsum-based patching materials or any other dimensionally unstable materials.  VELVET POUR accepts a wide variety of acid-based, acrylic-based or colloidal-based stains and a wide variety of penetrating and topical sealers as well as epoxy or urethane coatings. Due to the wide variety of products available, mockups must be performed to verify optimal results and timing for staining, sealing or coating. ALWAYS perform mockup tests to verify compatibility between VELVET POUR, colorants and other materials.  Before application of VELVET POUR, always properly prepare the surface and prime with GALLANT FLOOR FIX broadcast method (see the respective Technical Data Sheets for details).  Always use the GALLANT FLOOR FIX broadcast method for applications where the highest quality decorative surface is required, and/or where high point load, heavy traffic and/or potential deflection of slab is anticipated.  Use 12mm minimum thickness of VELVET POUR when dealing with rolling dynamic loads such as palette trucks, forklifts or other rubber-wheeled vehicles.  VELVET POUR is for use only in dry, interior areas. For exterior use or for areas subject to prolonged exposure to moisture, use an exterior rated GALLANT STONE topping or screed.  Use only between the temperatures of 10°C and 35°C. In cooler conditions, use indirect auxiliary heaters to maintain ambient and substrate temperatures within the required range. For temperatures about 29°C, follow ACI hot-weather application guidelines to ensure a successful installation.  Always provide for expansion and control joints where specified. Do not bridge expansion or control joints. Failure to honour existing joints may lead to the formation of hairline or larger cracks in the underlayment, as well as disbanding of the topping. Where control or expansion joints do not exist in the substrate, provide for them in the system.  Always isolate any sharp corners that protrude into the room receiving the topping, as well as column bases, supports or equipment pedestals, etc, using caulking or foam tape to round them off. Consider the use of foam tape around the perimeter of the pour if the circumstances require it.  The colour of VELVET POUR Light Grey may be subject to subtle smoothing marks or colour differences caused by a product dripping from placing and smoothing equipment. This is a normal aspect of coloured materials and can be addressed with proper placement techniques.  VELVET POUR is intended for foot traffic, rubber-wheeled forklift traffic and similar uses. Steel-wheeled and small-wheeled (high point loading) as well as hard-wheeled traffic, or dragging sharp or heavy metal objects over the floor, will cause indentations, grudging or similar damage. VELVET POUR is not suitable for such excessive service conditions, heavy manufacturing, or chemical or industrial applications. In these cases, specify a topping designed for the specific environment.

**NOTE: To insure installation success, test a small area for compatibility, bond strength and performance.**

SUITABLE SUBSTRATES

 Substrate must be free from hydrostatic pressure, and moisture vapour transmission must not exceed 2,27kg per 92,9 SQM per 24 hours. Use a calcium chloride test (reference ASTM F1869) before application. Consult the sealer manufacturer’s recommendation regarding the maximum allowable moisture vapour emission rate (MVER) and retained moisture content in the substrate.  For substrates with an MVER exceeding 2,27kg and 92,9 SQM per 24 hours, using a calcium chloride test (reference ASTM F1869), install “Planiseal EMB” or “Planiseal VS” moisture-reduction barrier. **NOTE: The maximum allowable MVER is always determined by the complete system installed, including primers and sealers.**

 Ceramic tile and cement terrazzo : The surface must be properly prepared, roughened and then bonded free of dirt and dust, and primed with GALLANT FLOOR FIX before application.

Consult GALLANT STONE’s Technical Services Department for installation recommendations regarding substrates and conditions not listed. SURFACE PREPARATION

 All substrates must be structurally sound and stable.  Thoroughly clean the surface of any substance that could interfere with the bond of the installation material, including dirt, paint, tar, asphalt, wax, oil, grease, latex compounds, sealers, curing compounds, form release agents, laitance, loose toppings, foreign substances and adhesive residue.  Mechanically profile concrete surfaces and prepare by shotblasting, sandblasting, scarifying or other engineer-approved methods (reference ICRI CSP 2 to 4 standards for acceptable profile height).  Ensure that concrete substrate and ambient room temperatures between are between 10°C and 35°C before application. Temperatures must be maintained within this range for at least 72 hours after the installation of VELVET POUR.  Fill deep areas, holes or cracks with appropriate concrete restoration materials, especially when installing on a floor on the second story or higher where fluid could leak to the floor below (contact GALLANT STONE’s Technical Services Department for details).  Always prime the prepared surface with GALLANT STONE FLOOR FIX before the application of VELVET POUR.  Do not apply primer over standing water.  Use this preferred method for decorative toppings: When priming with GALLANT STONE FLOOR FIX, prime the properly prepared surface at a thickness of 8 to 10 wet milds (0.20 to 0.25mm). Follow immediately with a fill sand broadcast (to rejection) with sand 20 to 40 mesh in size – sorted sand with no fines. Remove the excess sand once the material has hardened (typically after 12 hours), and proceed with placing the VELVET POUR.  Install a suitable moisture-reduction barrier if moisture vapour transmission exceeds 2,27kg per 92,9 SQM) per 24 hours. Apply a small test area to ensure compatibility with the moisture-reduction barrier before general installation. Once the barrier is cured, a GALLANT STONE-approved priming method (such as GALLANT STONE FLOOR FIX) before the application of VELVET POUR (see TDSs of primers for details).

ADDING INTEGRAL COLOUR TO VELVET POUR:

 Note that the amount and colour of the oxides used can alter the performance characteristics of a topping material, and that not all oxides of same colour are equal. For this reason, conduct a test pour using a specific amount of coloured material. During this test, each material should be carefully watched for the following four points : flow time, healing time, set time and ease of finishing. Oxides can alter these characteristics. Any substantial change in the four criteria will result in decreased product performance. Also be aware that some oxides may create a skin on the surface of the leveller, trapping air bubbles that can lead to pinholes. When adding integral colour to VELVET POUR, it is critical to maintain a consistent water ratio for each mix in a continuous pour. Even slight variation in the water ratio will impact the colour.

**NOTE: The installer should determine acceptance of these properties before site installation. Always pour the water into the mixing drum and blend the oxides in the water before adding the dry powder of the topping material. In addition, always precisely follow the water-mix ratio to ensure consistent colouring from mix to mix.**

MIXING

**NOTE: Choose all appropriate safety equipment before use. Refer to Material Safety Data Sheet (MSDS) for more information.**

General Mixing:

Into a clean mixing container, pour the required amount of cool, clean, potable water. If available water is not cool, chill water to 21°C. Add VELVET POUR powder while slowly stirring. Mix water and VELVET POUR powder to a mixing ratio of 4,50 to 4,73L of water per 20kg bag of VELVET POUR. The mixing ratio must remain consistent, especially when using VELVET POUR Light Grey, or when integral colour materials are involved. Do not overwater material.

Barrel Mixing:

Using the appropriate mixing ratio above, mix with a high speed mixer (about 1 200 rpm) with an “egg beater” mixing paddle. Mix to a homogenous, lump-free consistency, for about 3 minutes. Do not overmix: Overmixing or moving the mixer up and down during the mixing process could cause air entrapment, which could shorten the pot life or cause pinholing during the application or curing.

Pump Mixing:

VELVET POUR can be mechanically mixed, using the appropriate mixing action above, with a continuous mixer or pump (with at least 15,2ml of hose. Mixer and pump must be in good working condition. Periodic cleaning of pumping equipment is required per the manufacturer’s instructions. Be sure to pressure-test rotor and stator for proper mixing. Use a mesh-screen “sock” at the end of the hose to catch any foreign material that could enter the hopper of the mixer. Apply to a small test area before general application to ensure a successful installation.

PRODUCT APPLICATION

 Read all the installation instructions thoroughly before installation.  Before installation, close all doors and windows and turn HVAC systems off to prevent draughts. Protect all areas from direct sunlight.  Make sure concrete substrate and ambient room temperature are between 10°C and 35°C before application. Temperatures must be maintained within this range for at least 72 hours after the installation of VELVET POUR. In cooler conditions, use indirect auxiliary heaters to maintain ambient and substrate temperatures within the required range. For temperatures above 29°C, follow ACI hotweather application guidelines to ensure a successful installation.  Application of VELVET POUR over large areas can be made easier and more efficient by using conventional piston, rotor-stator or underlayment-type pumps (contact GALLANT STONE’s Technical Services Department for recommendations).  For best results, work as a team to provide a continuous flow of wet material to maximise working and finishing time and achieve a uniform finish throughout.  Set the width of the pour at a distance that is ideal for maintaining a wet edge throughout placement. Quickly pour or pump VELVET POUR onto the properly prepared and primed surface in a ribbon pattern. It a wet edge cannot be maintained, reduce the width of the pour.  VELVET POUR has an approximate flow time of 15 minutes at 23°C, is self-levelling and can be applied from 6mm to 5cm in a single application. Please note that the temperature and humidity will affect working time, flowability and setting time. Apply enough material to adequately cover all high spots.  Immediately after placing the VELVET POUR, spread the material with a guage rake. After achieving the desired depth, smooth with a smoother to obtain an even surface. To avoid air entrapment, do not overwork the material. VELVET POUR Light Grey may be subject to subtle smoothing marks or colour differences cause by product dripping from placing and smoothing equipment. This is a normal aspect of coloured materials and can be overcome with proper placement techniques.  VELVET POUR quickly hardens within 2 – 3 hours and is ready to accept stains, water-based coatings or sealers in as little as 24 hours. Sealers and coatings protect surfaces from contaminants and soiling, optimising the surface integrity and aesthetics.  For installations extended with pea gravel from 5 – 12,5cm, contact GALLANT STONE’s Technical Services Department.

CURING AND PROTECTION

 VELVET POUR is self-curing, do not use a damp-curing method, or curing and sealing compounds.  Protect VELVET POUR from excessive heat and draught conditions during curing. Turn off all forced ventilation and radiant-heating systems. Protect for up to 24 hours after completion.  Avoid walking on the installed surface for at least 2 -3 hours after installation, depending upon temperature and humidity conditions.  Protect from traffic, dirt and dust from other trades until the final floor sealer or coating has been installed and completely cured. When using VELVET POUR to repair a concrete surface, do not leave the surface exposed. Cover with a final wear surface.  Do not expose VELVET POUR to rolling dynamic loads, such as forklifts and scissor lifts, for at least 48 hours after installation.  Always apply a protective coating or sealer over VELVET POUR. VELVET POUR can generally be stained, coated or sealed 24 hours after application. Deeper applications and cooler temperatures may require a longer waiting period before application of subsequent treatments. Follow the recommendations of the stain, sealer or coating manufacturer. Test all surface treatments on a representative sample area before application, to ensure adequate installation techniques as well as the desired results.

CLEANUP

 Wash hands and tools with water promptly before material hardens.  Cured material must be mechanically removed.

PRODUCT PERFORMANCE PROPERTIES LABORATORY TESTS RESULTS Flammability Flame Spread: 0 Fuel Contribution: 0 Smoke Development: 0 Compressive Strength: ASTM C109 (CAN / CSA – A5) 1 day > 2 500 psi (17,2 MPa) 7 days > 4 400 psi (30,3 MPa) 28 days > 6 100 psi (42,1 MPa) Flexural Strength: ASTM C348 (CAN / CSA – A23.2 – 8C) 1 day > 650 psi (4,48 MPa) 7 days > 1 280 psi (8,83 MPa) 28 days > 1 400 psi (9,66 MPa) **Note : Protect containers from freezing in transit and storage. Provide for heated storage on site and deliver all materials at least 24 hours before work begins.** SHELF LIFE AND APPLICATION PROPERTIES (BEFORE MIXING) Shelf Life 6 months in original bag, in dry, heated and covered place Physical State Powder Colours Enquire with Technical Assistance department for a wide range of colours SHELF LIFE AND APPLICATION PROPERTIES (MIXED) Mixing Ratio Water / VELVET POUR (powder) ratio: 4,50 to 4,73L per 22,7kg bag) Density 2,06kg per L pH 11 Application Temperature Range 10°C to 35°C Pot life 20 – 30 minutes Flowing time 15 minutes Final Set 2 -3 hours Time required before installation of stains or coatings Typically 4 – 24 hours depending on the coating, stain, temperature and humidity CSI DIVISION CLASSIFICATIONS Concrete Toping 03 53 00 Cast in Place Concrete 03 30 00 PACKAGING PRODUCT CODE SIZE AND COLOUR 19852000 Bag, natural grey, 22.7kg 19350000 Bag, white, 22,7kg APPROXIMATE PRODUCT COVERAGE **Coverages shown are for estimating purposes only. Actual jobsite coverages may vary according to substrate conditions and setting practices.** Yield 0,014m³ Coverage at 6mm thickness 2,23m² Coverage at 12mm thickness 1,11m²

TECHNICAL ADVICE CENTRE

Gallant Stone, Plot 4, Witkoppen Road, Northriding Tel: 011 026 8229 / Fax: 086 536 9510 Email: [email protected]