Application Guide

for
Ucrete®

April 2018 Page 1

Ucrete Industrial Flooring
Application Manual CONTENTS

SECTION A INTRODUCTION

1 Introduction page 4
2 Product Overview page 4

SECTION B PREPARATION OF SUBSTRATES

3 General Application Guidelines page 5
3.4 Laying Rates page 6

4 Site Storage page 6

4.1 General page 6
4.2 Cold Temperatures page 7
4.3 Hot Temperatures page 7
4.4 Relative Humidity page 7
4.5 Safety Notes page 7

5 PREPARATION OF SUBSTRATES page 8

5.1 Substrates page 8
5.1.1 Suitable page 8
5.2 Unsuitable page 8
5.3 Design and Preparation of Concrete Substrates page 8
5.3.1 Floor Base/Slab page 8
5.4 Expansion Joints page 9
5.5 Damp-proofing Membranes page 9
5.6 Screeds page 9
5.7 Preparation/General Requirements page 10
5.8 Moisture page 10
5.9 Holes/Cracks page 11
5.10 Tolerances page 11
5.11 Falls page 11
5.12 Coves page 11
5.13 Areas around Ovens page 11
5.14 Cold Rooms page 12
5.15 Anchor Grooves page 12
5.16 Other Substrates page 21
5.17 Scratch coating page 21
5.18 Scratch Coats page 22
5.19 Typical Overcoat for Scratch coats page 22
5.20 Planning the Laying page 22
5.21 Working in Food factories page 22
5.22 Detail Illustrations page 24-35

SECTION C PRODUCTS
6 MIXING page 36
6.1 Equipment page 36
6.2 Notes Regarding Packaging and Units page 36
6.2.1 Ucrete Components page 36
6.3 Ucrete Units page 37
6.4 Liquid Pigment Sachets page 37
6.5 Mixing Procedure page 38

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Ucrete Industrial Flooring
Application Manual CONTENTS

7. Products and Systems

7 Ucrete DP page 41
8 Ucrete IF page 46
9 Ucrete MF page 48
10 Ucrete MFAS page 50
11 Ucrete UD200 page 53

SECTION D SPECIAL TECHNIQUES

12 SPECIAL TECHNIQUES page 55

12.1 Earthing Anti-Static Systems page 55
12.1.3 Earth Linkages page 55
12.1.10 Copper Tape Geometry page 56
12.2 Channels and Sumps page 59
12.3 Dairy Grids page 60
12.4 Recommended Grating page 60
12.5 Repairing Ucrete Flooring page 60
12.6 Ucrete Fast page 61

SECTION E HEALTH AND SAFETY

13 HEALTH AND SAFETY page 63

13.2 Protective Equipment page 63

13.3 Treatment of Spillages page 63
13.4 Disposal page 64
13.5 Solvents page 64

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Section A: Introduction

1. INTRODUCTION
1.1.1. This manual is a guide for applicators laying Ucrete flooring. Compliance with the
procedures described should ensure that end-users are provided with a floor having the
benefits that are associated with Ucrete floors.

1.1.2. It is assumed that applicators of Ucrete flooring are experienced installers of resinous
flooring. On-site operations, including the assessment of substrates, especially in
refurbishment situations, the use of proper and safe working practises, and estimating,
are in the applicators' area of expertise and remain their responsibility.

1.1.3. The manual contains recommendations based upon our knowledge of Ucrete flooring,
extensive laboratory testing and more than 40 years of successful application.

2. PRODUCT OVERVIEW

Unit weight Coverage Min site/slab

Ucrete Kg kg/m² application
temp °C

MF scratchcoat RG MTO 1.43 0.15 - 0.2 5

Basecoat MF 18.88 6 @ 3mm 12
Basecoat BC6 23.18 10 @ 5mm 8
Basecoat BC9 26.88 16 @ 8mm 8
Topcoat 3.72 0.4 – 1.2 8
IF MTO 35.53 28 at 9mm 5
MF 20.28 8 at 4mm
12 at 6mm 12
MFAS Imported (3 16.88 8-10 at 4mm
months lead 12-14 at 6mm 18
time)
RG MTO 11.80 8 - 10 at 4mm
12 - 14 at 6mm 5
18 - 20 at 9mm
UD200 30.68 15 at 6mm
5
21 at 9mm

Notes:
Wastage The figures quoted do not allow for wastage or an allowance for excessive
substrate texture.

Vertical/Coving The coverage figures quoted do not include an allowance for the radius of the
cove.

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Section B: Preparation of substrates

3. GENERAL APPLICATION GUIDELINES

3.1. Ucrete is a rapid curing material and the open time is only 10 minutes at 20°C, less at higher
temperatures. If the material is retouched after 10 minutes the appearance of the finished floor is
likely to be impaired. It follows that with all grades of Ucrete, including the topcoats, the floor is laid
in bays with the bay width narrow enough that a single mix will reach the full width of the bay in
order to maintain a wet edge throughout.

3.2. Guidance is given in Section 7 on the appropriate bay widths for each product. Consideration
should also be given to how long the front will become when it turns to exit the bay or to go out of
a door, for example.

3.3. The mix time for Ucrete is typically 4 - 5 minutes and there should be enough floor layers present
to apply the Ucrete within this time so that they are ready for the next charge from the mixer. A wet
front must be maintained at all times. The mixing should be continuous and is the rate determining
step for the installation. The same mixing bucket should not be used to mix and transport the
material unless a second is available to allow the next mix to be started straight away.

3.4. In principle the application is as follows:

• Mix 1 is spread across the full width of the bay and applied
• Mix 2 is spread across the full width of the bay and applied working into the previous mix
• Mix 3 is spread across the full width of the bay and applied working into the previous mix but
Mix 1 can no longer be touched.
• Mix 4 is spread across the full width of the bay and at this time Mix 2 can no longer be touched
• …and so on, until the end of the bay is reached.

3.5. It is important that the application is planned in advance so that the seams between the various
bays of a large floor can be placed in the optimum locations to give the best aesthetic result. The
seams can be hidden under plant or made to coincide with joints, for example. Try to avoid having
such seams in main traffic aisles where they will stand out. It is good practice to discuss these with
the client before starting to lay the floor.

3.6. Because the open time of Ucrete is so short, it is normally not possible to lay a floor in a corridor
and into side rooms seamlessly. Plan to lay the side rooms first, the corridor after, with a seam
between the two hidden under the door.

3.7. Use battens wrapped in brown parcel tape, or similar, to provide a straight edge to the bay.
3.8. There must be an anchor groove of the appropriate size around the edge of each bay as close to
the edge as possible (maximum 100mm from the edge), around all columns, the feet of plant and
equipment, to either side of any joints, around drainage and any other free edge.

3.9. Mask off all adjacent surfaces.

3.10. Where required the appropriate MF scratchcoat must be installed and properly cured within the
intercoat window. Check that the MF scratchcoat is hard and tack free. Ensure that any defects in
the MF scratchcoat layer have been addressed.

3.11. Think through the application before you start work, from where the first mix is to go, to the last.
Look out for any snagging points; for example, where the wet front might become too long, where
there are lots of details required around the legs of equipment, etc. Ensure there are sufficient
men available to do all the operations required in the time available, even at these snagging
points.

3.12. Masking tapes should be removed after ~1 hour.

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Section B: Preparation of substrates

3.13. If the mixer stops during the operation for more than 2 or 3 minutes, for example because of a
power failure, stop the application and finish to a neat straight line. Do not try and restart the front
later as this will always be visible in the finished floor. It is better to wait until it is cured and to
leave a tidy seam as between two bays in the finished floor.

3.14. LAYING RATES

1.1.1. Site conditions influence laying rates.

1.1.2. Trowel Application

In an 8 hour day, an experienced 3 man team with:-

• 1 man mixing
• 1 man labouring
• 1 man trowelling/laying,

Could be expected to cover, on a prepared substrate under normal conditions:

• Ucrete UD200 60-100m²

• Ucrete DP 150-200m²
• Ucrete MF 150-200m²
• Ucrete MFAS 150-200m²

1.1.3. Rake Application

In an 8 hour day, an experienced 5 man team with:-

• 1 man mixing
• 1 man labouring
• 1 man raking
• 1 man spike rollering
• 1 man scattering, trowelling edgework details, some rollering etc

And an appropriate sized mixer, could be expected to cover, on a prepared substrate

under normal conditions:

• Ucrete DP 200-800 m² depending upon thickness

• Ucrete MF 300-600 m²
• Ucrete MFAS 300-500 m²

4. SITE STORAGE
4.1. General
4.1.1. All of the components that are used to make Ucrete flooring - and the ancillary products
that are used in the substrate preparation and laying - must be stored under cover, above
5°C and below 30°C and out of direct sunlight. Materials must be raised off the floor
and kept dry, this is especially important for Part 3 components to prevent them becoming

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Section B: Preparation of substrates
hard and lumpy and unsuitable for use.

4.1.2. The ideal storage temperature lies in the range 16-22°C; this is also the preferred
temperature range for mixing, laying and curing. Parts 1 and 2 components must not
be allowed to freeze.

4.1.3. Provided these storage conditions are maintained, most components have a shelf life of 12
months. All Ucrete and ancillary products are clearly marked with a use-by date. Do not
exceed it without reference to BASF Construction Chemicals.

4.1.4. Short term exposure to direct sunlight or other intense heat sources will cause uneven
temperature gradients in the stored material; such product must not be used until the
temperature has become uniform, otherwise application inconsistencies may arise.

4.2. Cold Temperatures

4.2.1. When site temperatures fall below 15°C the following should be considered:-

4.2.2. All grades of Ucrete will become more difficult to apply, consequently laying rates are
reduced.

4.2.3. In each section minimum application temperatures are specified these should be
maintained to ensure the expected finish is achieved.

4.2.4. In practice it is often necessary to heat the material to aid application. When heating is
required, it is preferable to keep the material in a heated room to ensure even
temperatures are realised. If this is not practical, some form of portable heating is
recommended at the mixing area. On large contracts some form of "tent" will make raising
the temperature more efficient. All components should be heated, with care being taken to
keep temperatures uniform.

4.3. Hot Temperatures

4.3.1. When temperatures during application are expected to be above 30°C some form of air
conditioned storage is required. Keeping the materials at 20-25°C will reduce the
possibilities of flash setting and other defects.

4.3.2. Do not apply the Ucrete in direct sunlight or on very hot substrates.

4.4. Relative Humidity

4.4.1. If the relative humidity drops below 50%, this can increase the time to become tack free for
all grades of Ucrete, including MF scratchcoats. If the humidity is below 30%, this can
extend for several days.

4.4.2. If MF scratchcoats or basecoats are overlaid before they are dry/tack free this can lead to
blistering.

4.5. Safety Notes

4.5.1. If moisture enters containers of Part 2 components, it reacts chemically with the contents
producing carbon dioxide gas. If this occurs, do not replace the lids, otherwise a
dangerously excessive pressure can develop which may lead to rupture of the can.

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Section B: Preparation of substrates

5. PREPARATION OF SUBSTRATES

5.1. Substrates

5.1.1. Suitable

The following substrates are known to be suitable for receiving Ucrete flooring subject to
correct preparation procedures:

• Concrete
• SBR or Acrylic polymer-modified sand/cement fine aggregate screeds
• Granolithic concrete
• Cementitious terrazzo surfaces
• Previously laid Ucrete floors
• Mild steel in limited cases

5.1.2. Substrates should have a minimum tensile strength of 1.5MPa. Concretes should be
specified as 30MPa design strength or better. Substrates must be adequately designed to
accommodate the in service stresses to be encountered due to static and dynamic loads,
thermal movement and impact.

5.2. Unsuitable

5.2.1. Known to be unsuitable are:

• Unmodified sand/cement screeds

• Asphalt/bitumen
• Bricks or block pavers
• Magnesite
• Galvanised steel
• Stainless steel
• Copper
• Aluminium
• Wood
• Aerated concrete blocks
• Tiled floors
• Natural Stone

5.2.2. NOTE: Steel fibre reinforced substrates can cause problems where there is thermal shock
due to differential thermal movements. Where steel fibre reinforced concrete is used as a
substrate in areas subject to thermal shock a suitable fully bonded screed of minimum 20
mm thickness should be installed prior to the application of the Ucrete floor.

5.3. Design and Preparation of Concrete Substrates

5.3.1. Floor Base/Slab

In general, concrete bases and screed should be constructed in accordance good industry
practise and have a minimum direct tensile strength of 1.5MPa, and established engineering
practices, including provisions for movement joints and membranes, where necessary.

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Section B: Preparation of substrates
5.4. Expansion Joints (see Figures 5 and 6)

5.4.1. All expansion and crack propagation joints formed in the floor base must be carried through
the Ucrete flooring and it is advisable, when forming expansion joints around columns and
equipment set in the floor, to include radial corners to avoid stress-creating angles. A
minimum 5cm radius is advised.

5.4.2. Experience has shown that it is normally advantageous to form expansion joints in the base
floor around areas which may be subjected to thermal or vibrational movement in service.

5.4.3. Typical situations include:

• Boundaries between different floors or flooring materials

• Load supporting columns set in the floor
• Vessel sealing rings
• Areas around ovens, freezers and other process equipment

5.4.4. All joints must be filled with a suitable joint sealant. The best joint sealant for any particular
application will depend upon the width of the joint and the amount of anticipated movement
as well as the chemical nature and temperature of any spillages likely to impact upon the
floor. In the food industry a deteriorating sealant may allow water ingress and a build-up of
microbial contamination so it is critical that joints are properly designed, detailed and installed.
They should also be visible / accessible for inspection and maintenance as required.

5.5. Damp-proofing Membranes

5.5.1. A damp-proof membrane is essential where rising moisture may cause the concrete to
become saturated and negative pressures to adversely affect the bond to the Ucrete
flooring.

5.5.2. Ucrete flooring, although effectively impermeable to liquids, must not be used as a
substitute for a membrane or vapour barrier.

5.5.3. Damp-proof membranes must be incorporated beneath the floor slab and not laid directly
beneath the Ucrete flooring.

5.6. Screeds

5.6.1. Topping screeds for concrete bases are often used as substrates for Ucrete flooring, where
additional falls, etc, are required. The following have been found to be suitable:

5.6.2. Fine concrete must be minimum 75 mm thick and have a direct tensile strength of 1.5MPa
with appropriate reinforcement.

5.6.3. Polymer modified fine aggregate/sand/cement bonded screeds with a minimum of 40mm
thick with a direct tensile strength of 1.5MPa In thicker sections these should contain a
significant proportion of 6-10mm aggregate.

5.6.4. MasterEmaco T 920 CI or MasterEmaco T 545

5.6.5. Bonded screeds greater than 70 mm thick should be reinforced with appropriate steel mesh
reinforcement.

5.6.6. All screeds must be properly designed to accommodate in service stresses, this may require
the inclusion of steel reinforcement. Waterproofing additives should not be included in

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Section B: Preparation of substrates
screeds.
5.6.7. Steel mesh reinforcement must be a minimum of 25 mm below the surface, especially in
extreme thermal shock environments.

5.7. Preparation/General Requirements

5.7.1. Floor bases and screeds which are to receive Ucrete flooring should be of sufficient
strength. This can be checked using a pull-off test. A tensile strength of 1.5MPa is
required. Ucrete floors may be applied to substrates of lower strength but the long term
performance may be affected. This is particularly relevant in areas subject to heavy
thermal or mechanical stress in service.

5.7.2. Good curing under polythene is recommended. Liquid or spray applied curing membranes
should not be used.

5.7.3. Any laitance present on the concrete surface must be removed by mechanical methods
(see below) before Ucrete flooring is applied, otherwise delamination will occur. Existing
screeds may be contaminated with mould-release oils, chemical spillage or previously
applied coatings. Contaminated concrete must be removed before the application of
Ucrete flooring if a good bond is to be obtained.

5.7.4. All substrates will require preparation. Cementitious substrates must be mechanically
prepared so that the large aggregate of the concrete/ screed is exposed. A surface profile
of CSP 3 or 4 is recommended Preferred methods of preparation are:

• Vacuum shot blasting (Blastrac or similar equipment)

• Concrete surface planer
• Grit blasting
• Surface grinder - care should be taken to avoid polishing the substrate
• Drum sander
• Ultra-high pressure water blasting followed by captive shot blasting

5.7.5. Acid etching is not reliable and should not be used.

5.7.6. High impact preparation methods (scabbling) may cause internal fracture of the concrete
matrix and a subsequent reduction in strength and should not be used.

5.7.7. While ultra-high pressure water blasting is very effective at removing old finishes and
laitance and exposing the aggregate in a concrete, it can leave the aggregate smooth and
polished and this can have a negative effect upon adhesion. For this reason it must be
followed by captive shot blasting

5.7.8. After treatment, all dust and loose particles should be removed from the whole surface,
including grooves and cracks. Cleaning by Vacuum is the most effective method.

5.8. Moisture

5.8.1. Standing water must be removed completely by using an industrial vacuum cleaner
followed by drying with a hot-air blower, infra-red heater or flame gun.

5.8.2. Ucrete is tolerant of residual moisture in the substrate concrete/screed, however, the
surface must be visibly dry.

5.8.3. The substrate temperature should be at least 3°C above the dew point during application.

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Section B: Preparation of substrates
5.8.4. Do not apply when atmospheric condensation is occurring or likely to occur before full cure
is obtained.
5.8.5. Care should be taken when using propane heaters in cold conditions. The water produced
by these heaters can often cause condensation.

5.9. Holes/Cracks

5.9.1. Cracks in the substrate must be investigated and the appropriate remedial action taken.
Smaller irregularities will be filled or sealed during the application of the Ucrete flooring.
Larger holes or irregularities may be filled with MasterEmaco S 5400 or T 920. Ensure
sufficient material has been allowed for. With Ucrete MF any irregularities should be filled
with the scratch coat MFscratchcoat, to ensure an even final finish.

5.9.2. All repairs to the substrate must be completed in good time prior to the application of the
Ucrete floor

5.10. Tolerances

5.10.1. Ucrete flooring should not be relied upon to improve the tolerances or flatness levels in the
substrate. The substrate should be applied to the appropriate tolerances prior to the
application of Ucrete floor finish.

3.10.2 Tolerances can be corrected but this is a separate operation which must be completed
before installing the Ucrete floor.

3.10.3 The Ucrete floor finish will generally follow the contours of the substrate and have the
same tolerances as the substrate to which it is applied. Applicators are advised to check
the tolerances of the substrate before they begin with the preparation.

5.11. Falls

5.11.1. These should be formed in the screed in accordance with good building practice or, in the
case of polymer-modified screeds, to the manufacturer's instructions with special attention
being paid to minimum and maximum thickness.

5.11.2. The steepest falls to which Ucrete can be laid at 20°C are as follows. These will be
reduced at higher temperatures.

• Ucrete DP can be laid to falls not exceeding 1:25

• Ucrete IF can be laid to falls as steep as 1:25
• Ucrete MF & MFAS can be laid to falls not exceeding 1:100
• Ucrete UD200 can be laid to falls as steep as 1:20

5.12. Coves (See Section 5.5 Detailed Illustrations )

5.12.1. These will usually be formed in the Ucrete RG coving material. Large radius coves should
be formed in fine concrete to the same standard as the screed before application of the
coving mortar. Where the cove is not subject to the same temperatures and stresses as
the floor such as in process rooms or corridors the use of a filled epoxy (such as
MasterEmaco 2525 and sand) followed by Ucrete DP topcoat is a convenient option.

5.13. Areas around Ovens

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Section B: Preparation of substrates
5.13.1. Floor areas subject to high temperatures and thermal cycling need special attention. The
oven area should be isolated from the surrounding floor by an expansion joint. It is good
practice to lay clay tiles in this oven area with a heat shield immediately under the ovens.

5.13.2. Where hot steel-wheeled trolleys are removed from ovens onto Ucrete flooring, it is
recommended that dairy grids are used in conjunction with Ucrete MF: see section 8.3.
Ucrete IF may also be an option in some cases.

5.14. Cold Rooms and Freezers

5.14.1. A cold room should be isolated from the surrounding floor by an expansion joint. Within a
cold room the Concrete Society recommends that bays have an aspect ratio as close to
one as possible. The bay joints must be carried through the Ucrete flooring. In cases
where the concrete floor is not laid onto an insulating layer additional movement joints may
be necessary. Care should be taken with the junction between floor, cove and insulation
panel to prevent moisture ingress, this is particularly important when the area will cycle
above and below freezing.

5.14.2. Edge Details (See Section 5.5 Detailed Illustrations.)

5.14.3. Wherever we come to the edge of a floor there is a decision to be made as to how we
detail this edge. The floor might finish at a metal stop edge, be rebated into the substrate,
there may be a cove. These edge details should be discussed and agreed with the client
as they affect the aesthetics and the technical performance of the floor.

5.15. Anchor Grooves (see figures over the next few pages)

5.15.1. Wherever a free edge of Ucrete flooring will occur, for example, around the perimeter of a
bay, along channels, drains or expansion joints, at doorways and around the feet of
machinery, plinths and columns, anchorage must be provided to help distribute
mechanical and thermal stresses arising from curing, heavy traffic and temperature
changes.

5.15.2. This is achieved by cutting an anchor groove in the concrete, with a depth and width about
twice the thickness at which the Ucrete flooring will be applied, using a diamond cutting
wheel. Suggestions for various situations are shown below and set outs at various
junctions in the Section 5.5 Detailed Illustrations.

5.15.3. Drains: two lines of anchor grooves around drains should be created. The first as close as
possible to the drain and forming part of the cut out to accommodate a sealant if one is
required. The second approximately 50mm away should serve as a secondary restraint
and to prevent liquids getting under the Ucrete in the event of the sealant or drain edges
failing. Small drains such as floor wastes especially round ones by squaring off the anchor
groove about 25-40 mm from the edge of the drain.

5.15.4. Doorways: Ucrete should not be carried through a door without anchor grooves across the
doorway. The external corners of the doorways especially when the wall is cast into the
floor should have an extra 45 degree groove cut coming out from the external corner. This
will relieve the stress at this change of direction and should continue into the floor twice the
width of the wall structure (if the wall is 100mm wide the anchor groove should extend out
into the floor for 200mm).

5.15.5. Day joints: when the room is too large to complete in a day then the Ucrete should end in
an anchor groove. The next days’ work should start in an anchor groove. This can be
decided in advance and cut once the days’ work is understood.

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Section B: Preparation of substrates

5.15.6. Complex shaped rooms: small complex shapes like bars, kitchens etc present a challenge
as although the size is small the changes in direction creates extra stress. In these cases
dividing the area into 2:1 segments and adding stress relief grooves at external corners
will eliminate potential for cracking. The larger number of anchor grooves does not mean
that the application should take longer or create a need for day joints but just to relieve the
stress at the various changes of direction of the floor.

5.15.7. The maximum distance between anchor grooves in either direction is 16 m. if a bay is
larger than 16 m then extra anchor grooves will need to be cut.

5.15.8. Extra anchor grooves can be used around areas of extreme thermal shock or heavy
impact for example to help manage stress, especially on poorer substrates.

Figure 1 plan view of anchor grooves at door

Figure 2 3D view of anchor grooves at door

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Section B: Preparation of substrates

Figure 3 3D view with scratchcoat applied

Figure 4 3D View with final body coat applied

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Section B: Preparation of substrates

Figure 5 Plan view of small room with anchor groove layout for strip drain and day joints

Figure 6 3D view of anchor grooves for drains and day joints

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Section B: Preparation of substrates

Figure 7 scratchcoats applied

Figure 8 Plan view of large room with drains and day joints

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Section B: Preparation of substrates

Figure 9 3D view of large room with drains and day joints

Figure 10 All anchor grooves scratchcoated

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Section B: Preparation of substrates

Figure 11 Plan view of complex shaped installation

Figure 12 3D view of complex installation notice relief grooves at direction changes

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Section B: Preparation of substrates

Figure 13 Scratch coated and notice each section is a 2:1 ratio of length to width

Figure 14 Anchor groove set out for drain

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Section B: Preparation of substrates

Figure 15 Set out showing anchor groove along edge of drain and secondary groove

Figure 16 finished floor showing the filled anchor grooves.

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Section B: Preparation of substrates

5.16 Other Substrates

5.16.1 Where appropriate, the foregoing recommendations for concrete substrates also apply to
other suitable substrate materials.

5.16.2 Additional special points are:

5.16.3 Mild steel, for example, chequer plate - Metal strips should be welded onto the edges of
steel plates to protect the edges of the Ucrete flooring. All paint, grease, rust or scale must
be removed by grit blasting, abrasion or thorough wire brushing to ensure an adequate
bond when Ucrete flooring is applied. Application should take place within hours of
preparation to prevent an oxide layer forming that might impair adhesion.

5.16.4 Previously laid Ucrete flooring - the substrate must be sound and the previously laid
Ucrete floor well bonded to it and free from chemical attack or contamination. The surface
should be prepared by abrasion, grinding or scarification and all dust removed. Care
should be taken to ensure that the anchor grooves are adequate, especially where there
has been a change in specification and in thermal shock environments. New Ucrete
flooring can then be laid in the normal way.

Figure 17 How to overlap day joints without an extra Anchor groove

5.17 Scratch coating

5.17.1 Prepared concrete substrates are to varying degrees porous. If Ucrete flooring is applied
directly to prepared concrete, air displaced from the concrete can rise and cause defects in
the finished floor. It is thus recommended that when the surface quality of the finished
Ucrete floor is important for hygiene or aesthetic reasons the prepared concrete substrate
be scratch coated prior to the application of Ucrete flooring. Scratch coating also has the
effect of making the subsequent application easier by reducing the "drag" caused by the
porous concrete drawing the resin out of the still fluid Ucrete.

5.17.2 Detailed information on scratch coating requirements can be found for each grade in the
application section of this manual.

5.17.3 Note: A poor quality or contaminated substrate cannot be made satisfactory by scratch
coating.

5.17.4 Normal scratch coating requirements are as follows however it will depend upon the
porosity of the substrate concrete and the profile left after preparation.
• Ucrete DP Scratch coating not normally required
• Ucrete IF Scratch coating not normally required.
• Ucrete MF & MFAS Scratch coat required
• Ucrete UD200 Scratch coating must be used if appearance/hygiene is
important

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Section B: Preparation of substrates

5.18 Scratch Coats

5.18.1 Ucrete MF ~ 2.25kg/m2 or more Applied by trowel

5.19 Typical overcoat time for scratchcoats

Ucrete MF scratchcoat
@10 oC @20 oC Maximum
24 hour 16 hour 48 hour

5.20 Planning the Laying

5.20.1 It is necessary to plan and mark out bay lines noting the following:

5.20.2 Day joints and sometimes other bay lines will show in the finished floor. Wherever
possible, these should be positioned so that they will be hidden by plant to be installed on
the floor. The position of bay lines and day joints should be agreed with the client before
commencing the laying of the Ucrete floor.

5.20.3 Bay widths should be such that each mix can cover the width of the bay in a band ~ 0.5m
wide. Bigger mixers will allow a wider bay to be undertaken. Insufficient labour for the
amount of material per mix or insufficient material per mix for the width of the bay will,
almost inevitably, result in an inferior surface appearance and possible client rejection.
Guidance on bay widths is given for each product in Section 7.

5.20.4 Bay lengths are determined by the area to be applied between breaks. This depends on
the grade, the size of the laying team, mixing equipment and the temperatures of the
atmosphere and the substrate.

5.20.5 To ensure a neat appearance, bay lines should be straight and formed with polyethylene-
film-coated timber strips slightly thicker than the required thickness of the Ucrete floor.

5.20.6 As a visual aid to achieving the correct thickness and a level floor, the area to be covered
by individual mixes can be marked by chalk lines on the substrate.

5.21 Working in Food factories

5.21.1 When installing Ucrete flooring within working food factories, specific attention must be
given to working in a clean and orderly manner and minimising the impact on adjacent
areas. The applicator must ensure adequate protection of floor and wall finishes along the
access routes, around the work area and in the mixing station. In particular ensure that
drainage elements are closed/masked and protected from mechanical damage along the
access routes.

5.21.2 The customer must be informed of the risk of contamination from dust during installation of
this product. It is important that there is no food in the area during installation. If the

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Section B: Preparation of substrates
customer cannot remove food then enclosures and extraction systems will be required.
The applicator and the customer must agree on the best solution.

5.21.3 Applicators should discuss the application in detail with the customer to minimise any risk
to food quality. In particular the following areas should be addressed and agreed

5.21.4 The route of access from outside to the work area and to facilities needs to be agreed.
Where necessary openings off this route should be temporarily screened.
5.21.5 The location of the mixing station so that any dust generated or cleaning solvent vapours
are localised/controlled. This may be external or within an enclosed or tented area with
forced ventilation/extraction, for example.
5.21.6 The protection of adjacent plant and equipment from resin splash and dust.

5.21.7 Applicators should recommend the use of resin anchors (such as the Hilti H1T) when
drilling through the floor to anchor plant, especially in wet areas. The use of mechanical
anchors allows liquid contaminants to penetrate the floor which will compromise hygiene
and can lead to degradation of the substrate and subsequent floor failure. Properly used
the resin anchors will re-establish the continuity of the Ucrete flooring.

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Section B: Preparation of substrates

5..22 DETAILED ILLUSTRATIONS

See ‘Design Details for Ucrete’’
Full size cad drawings available on request

Figure 18 Termination at free edge

Figure 19 Termination at stop bead or edge strip

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Section B: Preparation of substrates
5.22 Detailed Illustrations: Continued

Figure 20 Termination at wall

Figure 21 Termination new to old Ucrete

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Section B: Preparation of substrates

5.22 Detailed Illustrations: Continued

Figure 22 Cove flush with Ucrete floor

Figure 23 Cove sitting on Ucrete floor

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Section B: Preparation of substrates
5.22 Detailed Illustrations: Continued

Figure 24 Cove to Curb

Figure 25 Cove to insulated panel

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Section B: Preparation of substrates
5.22 Detailed Illustrations: Continued

Figure 26 Cove to cladding

Figure 27 Joint movement reflected through floor

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Section B: Preparation of substrates
5.22 Detailed Illustrations: Continued

Figure 28 Joint induced/control reflected through Ucrete floor

Figure 29 Drain stainless steel channel A

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Section B: Preparation of substrates
5.22 Detailed Illustrations: Continued

Figure 30 Drain stainless steel channel B

Figure 31 Drain Ucrete lined

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Section B: Preparation of substrates
5.22 Detailed Illustrations: Continued

Figure 32 Channel greater than 400MM lined with Ucrete

Figure 33 Channel less than 400MM lined with Ucrete

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Section B: Preparation of substrates
5.22 Detailed Illustrations: Continued

Figure 34 Plinth less than 300mm with coving

Figure 35 Plinth less than 300mm with expansion joint detail

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Section B: Preparation of substrates
5.22 Detailed Illustrations: Continued

Figure 36 Plinth greater than 300mm with coving

Figure 37 Bund wall rendered in Ucrete

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Section C: Products
5.22 Detailed Illustrations: Continued

Figure 38 Bund lining Ucrete render and floor

Figure 39 Blind sump rendered in Ucrete

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Section C: Products
5.22 Detailed Illustrations: Continued

Figure 40 mild steel mezzanine

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Section C: Products
6. MIXING
6.1. Ucrete flooring products are 4 or 5 component systems with all components being reactive. There
are reactions that must take place in the mixer, and not on the floor, so it is important that the
mixing regimes are strictly adhered to. In general all the liquid components are mixed together
until homogenous, the powders added and mixing continued for a further 3 - 4 minutes. Please
refer to specific mixing instructions for each product in Section 7.

6.2. Equipment

6.2.1. The small units of Ucrete DP Topcoat should always be mixed in an appropriately sized
bucket with a slow speed drill fitted with an appropriate mixing head. Otherwise, the
following mixing plant has been found suitable for the various Ucrete grades as indicated:

Mixer Grade of Ucrete

(bodycoat)
Creteangle All grades except MFAS
Mixal MR40 All grades except MFAS
Imer mixer All grades except MFAS
Pennine Casco G5/G8: triple blade B6, MF
single blade All grades except B6, MF,
MFAS,
Collomatic XM2 650 or similar All grades
Slow speed drills, < 350 RPM B6, DP Topcoats, MF, MFAS

Slow speed planetary mixer like a Soroto UD 200, B9, IF

Twin headed mixing drills, < 350 RPM , B6, B9, MF
Twin headed mixing drills, < 150 RPM All grades except B6, MF,
All grades MFAS,

6.2.2. Other mixers should be checked for efficiency before use. Do not mix by hand.
6.2.3. It should be noted that some larger mixers cannot mix single units of Ucrete, and 2 or 3 units
may have to be mixed each time to achieve proper dispersion.

6.2.4. When using mixing drills use an appropriately sized bucket to ensure the mixing head is
fully submerged to avoid entrapping too much air. If the bucket is too big for the volume of
material then mixing efficiency will be poor.

6.2.5. Mortar grades, Ucrete IF and UD200 should not be mixed with a normal drill and paddle,

6.3. Notes Regarding Packaging and Units

6.3.1. Ucrete components

6.3.2. Ucrete Part 1 is a white liquid which can separate into a clear and oily mixture over time.
The bottle should be lightly shaken before use. Ucrete Part 1 is packed in a white plastic
bottle, 4 to a box.

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Section C: Products
6.3.3. Ucrete Part 1 with a YELLOW cap is for PIGMENTED products

6.3.4. Ucrete Part 1 with a Yellow label is for normal PIGMENTED products (which have
YELLOW caps)

6.3.5. Ucrete Part 2 is a brown liquid in a white plastic bottle, 4 to a box

6.3.6. Ucrete Part 2 bottles have a BLUE cap and a WHITE label

6.3.7. Ucrete Part 3 is an off white powder

6.3.8. Ucrete Part 3 is in printed white paper valve sacks.

6.3.9. Ucrete Part 4 is a sachet containing 0.5 kg of a coloured paste and is packed 25 to a box.

6.3.10. Ucrete Part 4 Sachets:- for pigmented grades.

6.3.11. Ucrete Part 5

6.3.12. A few products have a 5th component

6.3.13. Basecoat BC9 has an optional thickening agent 5th component

6.3.14. Ucrete IF has a metallic 5th component

6.4. Ucrete UNITS

6.4.1. A Ucrete unit consists of:

• Ucrete Part 1
• Ucrete Part 2
• Ucrete Part 3
• Ucrete Part 4

6.4.2. A few products also have a Part 5 as noted above and detailed in Section 7, below.

6.5. Ucrete Part 4 LIQUID PIGMENT sachets

6.5.1. The pigment in the sachet is dispersed in part of the resin, a Part 4 pigment pack must be
used as otherwise the resin content is too low and the material will lose its chemical and
physical properties.

6.5.2. Do NOT use more than one pigment sachet per unit of Ucrete. To do so would lead to loss
of both chemical and temperature resistance properties and possible failure during
application.

6.5.3. Ucrete Part 4 sachets are supplied with a “tear top” for ease of opening. To open cleanly,
hold the sachet firmly between your thumb and forefinger below the pre-formed nick, then
using the other hand tear open the top in a horizontal motion to the sachet.

6.5.4. If a clean and even tear is not achieved change the direction of opening, for example, change
hands or instead of tearing towards the body tear away from the body. This should solve
any problems experienced.

6.5.5. The Ucrete Part 4 sachets should be added together with the Part 1 and Part 2 during mixing
(see section 6.3). It is important to empty as much of the Ucrete Part 4 from the sachet as
possible as it is a reactive component of the Ucrete.

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Section C: Products
6.5.6. The recommended method of emptying the sachet once the top has been removed is
detailed below:

6.5.7. Hold the sachet loosely in the palm between the thumb and fingers vertically.
6.5.8. Tip the sachet directly into the Part 1 and 2 avoiding contamination of the sides of the
mixing vessel.
6.5.9. Fold the sachet in two down its length and using the other hand squeeze the sachet out in
a fluid motion using the thumb and forefinger. Done properly this will removed almost all of
the Ucrete Part 4.
6.5.10. It is not normally necessary to repeat the above step to remove more material.

6.6. Mixing Procedure

6.6.1. Please refer to specific mixing instructions for each product in Section 7.

6.6.2. Position the mixer as near to the working area as possible. It is important to keep the
mixing station clean and to avoid spilled materials being trafficked onto the substrate as
this may lead to blistering.

6.6.3. Ensure that the components are at the correct temperature, preferably 16-22°C. Open
packaging while the previous mix is mixing, with the exclusion of the Ucrete Part 4
sachets, to facilitate rapid turn-around of the mixer. When using fast systems material
temperatures should be lower, if above 15 °C use a double mix with one Fast and one
Normal part 1, if above 20 °C do not use Fast systems (see below).

6.6.4. Add the liquid components to the mixer and blend for 20-60 seconds until uniform
depending upon mixer efficiency. Normally maximum 30 seconds when mixed with a drill
and paddle, and up to 1 minute when mixed in a large mortar mixer.

6.6.5. When using Part 1 in a bottle with a YELLOW label and a YELLOW cap, a Ucrete Part 4
sachet must be used.

6.6.6. Therefore the liquid components are: Part 1, Part 2 and Ucrete Part 4 sachet.

6.6.7. Some large mixers do not mix the small amount of liquids effectively, in which case it may
be necessary to pre-blend the liquid components in a separate container prior to addition
to the mixer. This can be effectively done with a slow speed drill and paint stirrer head.
Avoid overmixing and spillage of the mixed liquids onto the substrate as this can lead to
blistering. Do not pre-mix liquid components in advance. As soon as they have been mixed
they must be added to the mortar mixer and the Part 3 added directly.

6.6.8. Gradually add the Part 3 whilst mixing continues; mix until the aggregate is thoroughly
dispersed and the mix is uniform, typically 3 – 4 minutes. Ucrete is a balanced system, it is
important that all of each of the components is added to the mixer, failure to do so is likely
to result in blistering of the floor.

6.6.9. During mixing the components will generate heat; this is advantageous when the
components are cold as this will help raise the material temperature on mixing, so
improving workability.

6.6.10. However, when the stored components are already warm, over mixing must be avoided as
the chemical curing reaction will proceed at too fast a rate, leading to decreased working
time.

6.6.11. The required mixing time may be judged with experience and will depend on the individual

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Section C: Products
grade, the efficacy of the mixer and the number of units mixed. The table below should be
used as a guide (note this excludes MFscratchcoats and anti-static system, please see
separate product information).

Component Typical Mixing time after

temperature (oC) Part 3
addition

<10 6
10 to 14 5
15 to 19 4
20 to 24 3
>25 2

6.6.12. Once the mix time is determined keep constant throughout the application.
6.6.13. Large variations in mix time can produce variations in colour shade and surface texture.
6.6.14. It is important to disperse the Part 3 component effectively during mixing as it is an integral
part of the chemistry. See note 2 below.

6.6.15. When finally mixed, immediately discharge the product onto the substrate to be coated.

6.6.16. Given a suitably sized mixer double and triple mixes can be used. Careful planning and
enough labour are required to ensure large mixes are applied quickly and uniformly.

6.6.17. Mixes larger than 3 units should not be undertaken.

[Link]. Notes:

[Link]. It is important that the mixed Ucrete is placed on the floor quickly and that
mixing of the subsequent batch starts straight away. This ensures good
uniformity between mixes.

[Link]. To ensure the time between mixes is kept to a minimum the mixer should either:

[Link]. have two mixing vessels/containers which are rotated;

OR
[Link]. have the facility to tip the mix contents into a separate container for
transportation to the application area, i.e. wheelbarrow.

[Link]. Incorrect mixing, i.e. either too short or too long a mixing time may cause:

[Link]. poor aggregate dispersion

.1. poor flow
.2. excessive trowel marking
.3. pimples or blisters in the cured floor
.4. surface unevenness

6.6.18. Spillages of components onto the substrate to be coated must be avoided as

this may cause blisters when the area is coated later.

6.6.19. As far as possible, drain all liquid from the Part 1, Part 2 and Ucrete Part 4 sachet to
ensure that the correct formulation ratios are used.

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Section C: Products

6.6.20. Scrape out the mixing vessel and paddles between each mix and thoroughly clean them
whenever mixing ceased for 5 minutes or more. Solvents such as propylene carbonate,
white spirit and xylene may be used for cleaning. Care must be taken to ensure solvents
do not spill into components, mixes or onto coated floors. Solvents must be used strictly
according to the manufacturer's instructions. The use of solvents when applying Ucrete
flooring in situations where a taint could develop must be minimal and, in any case, great
care must be exercised.

6.6.21. To minimise the risk of shade variations:

• The components should be used in numerical sequence of the batch numbers on the
containers.
• Adjacent areas should be laid with product from the same batch.
• Use a constant mixing time (except where significant temperature variations occur).
• Have sufficient labour on site to install the product properly within the ~ 5 minutes
between mixes.
• Work consistently throughout.
• Keep the mix size constant, i.e., single or double.
• Ensure adequate mixing time, especially at low temperatures.

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Section C: Products
7. Ucrete DP

7.1.1. Heavy duty polyurethane defined profile flooring

7.1.2. Ucrete DP is a series of broadcast systems that provides three surface textures defined as Ucrete
DP10, Ucrete DP20 and Ucrete DP30. Each can be installed onto a basecoat to produce a floor 4,
6 or 9mm thick.

[Link]. Ucrete DP10 is produced by broadcasting Filler F10

[Link]. Ucrete DP20 is produced by broadcasting Filler F20
[Link]. Ucrete DP30 is produced by broadcasting Filler F25
[Link]. For a 4mm floor use Ucrete MF
[Link]. For a 6mm floor use Ucrete Basecoat BC6
[Link]. For a 9mm floor use Ucrete Basecoat BC9

7.1.3. Packaging

Pigmented Basecoats Part 1 Part 2 Part 3 Part 4 Part 5

Ucrete MF: 20.28kg unit 2.52 kg 2.86 kg 14.40 kg 0.5 kg None
Ucrete Basecoat BC6: 23.18kg unit 2.52 kg 2.86 kg 17.30 kg 0.5 kg None
Ucrete Basecoat BC9: 26.88/30.88* kg unit 2.52 kg 2.86 kg 21.00 kg 0.5 kg 4.0 kg*

* Basecoat BC9 Part 5 is only added when applied at high temperatures and steep falls

[Link]. Filler F10* 25kg per bag

[Link]. Filler F20* 25kg per bag
[Link]. Filler F25* 25kg per bag
[Link]. Calcined bauxite filler

Part 1 Part 2 Part 3 Part 4

Ucrete Topcoat 3.72 kg unit 0.77 kg 1.09 kg 1.36 kg 0.5 kg

7.1.4. Coverage

Ucrete MF 6 kg/m²
Ucrete Basecoat BC6 10 kg/m²
Ucrete Basecoat BC9 16 kg/m²
FILLER F10 4 - 5kg/m²
FILLER F20 4 - 5kg/m²
FILLER F25 4 - 5kg/m²
Ucrete Topcoat on FILLER F10 for Ucrete DP10 R11 floor 0.4-0.6kg/m²
Ucrete Topcoat on FILLER F20 for Ucrete DP20 R13 floor 0.7-0.9kg/m²
Ucrete Topcoat on FILLER F25 for Ucrete DP30 R13 Floor 1.0-1.2kg/m²

NOTE: The broadcast filler will penetrate the bodycoats and will add at least 1mm in thickness to
the floor. Thus a 4mm DP 10 floor is made up of 3mm of MF bodycoat, aggregate broadcast and
topcoat to give a minimum of 4mm thickness. DP 20 and DP 30 floors will have a higher
thickness as the aggregate creates a greater profile but the body of the floor will be a minimum
eg 4mm, 6mm or 9mm. For a 4mm DP10 floor, If a scratch coat is used then the build-up would
be 1mm for the MF applied at 2.25kg/m2 as a scratch coat, 2mm of MF, the broadcast aggregate
and topcoat for a 4mm floor.

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Section C: Products

7.1.5. Planning

[Link]. The width of the bay should be such as to produce a strip of material minimum 40cm
across along the whole width of the bay to allow for efficient use of the pin rake. The
maximum bay widths are therefore:

For MF/(used 7.5m for a single 15m for a double mix

as B4) mix
For Basecoat 5.7m for a single 11m for a double mix 17m for a treble mix
BC6 mix
For Basecoat 4m for a single mix 8m for a double mix 12m for a treble mix
BC9

[Link].On larger floors plan how the area is to be divided to produce the most practical and
aesthetically acceptable floor.

7.1.6. Scratch coating

[Link]. The use of a scratchcoat is not normally necessary but has been shown to be beneficial
in cold conditions or on porous concrete as it reduces resin absorption into the substrate
and aids application.

[Link]. On rough substrates, and on substrates with large bleed run pores, it is recommended
that a scratchcoat of Ucrete MF is used to produce a smooth and sealed substrate for
the application of the Basecoat so ensuring the best aesthetic results.

[Link]. Ensure the MF scratchcoat is properly cured and dry to the touch before application of
the Basecoat. If the time between coats exceeds 48 hours, or if condensation or water
impacts the surface, fully abrade the surface prior to overlaying.

7.1.7. Mixing

[Link]. Temperature requirements: site temperatures 8 or 12 - 30°C, material temperatures 18

- 22°C.

[Link]. Temperature is critical to the correct application of the Ucrete basecoats. Particular
attention should be paid to Section C and the table of mixing times.

[Link]. Temperatures below 180C will make application more prone to problems. Careful
consideration should be given to storage of materials in cold conditions. The air and
substrate temperature during application should be above 120C for Ucrete MF, 80C for
Basecoat BC6 & BC9.

[Link]. When discharged from the mixer the Basecoat should be at least 180C.

[Link]. Mix the Basecoat as per Section C.

[Link]. Basecoat BC9 has been designed with an optional 5th component. Basecoat BC9 Part
5 is a thickening agent which is added together with the Part 3 powders during mixing.
Basecoat BC9 Part 5 is not normally required when temperatures are below 20°C. The
use of BC9 Part 5 becomes essential in situations where there is the combination of
high temperature and steep falls.

[Link]. Under most conditions falls of 1 in 25 can be accommodated.

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7.1.8. Application

[Link].Spread the mix evenly over the substrate using a pin rake, with pins set to the appropriate
depth. Using a steel trowel for edgework.

[Link]. Use a spiked roller to produce a smooth even finish. The whole floor should be spiked
rollered twice.

[Link]. On the first pass the spiked roller should be pushed right through the material to the
substrate to assist the flow, remove pin rake marks and to flatten the floor.

[Link]. Subsequent passes with the roller held lightly just upon the surface to bring the resin up
to the surface and so improve aesthetics.

[Link]. To ensure an even finish all trowelling and spiked rollering should be completed before
the mix is more than 10 minutes old at 230C. At higher temperatures this time reduces
so organisation of the application of the materials is crucial to a good job.

[Link]. Be careful to guard against throwing resin onto the already scattered floor by too
aggressive use of the spiked roller as this will create surface defects.

Notes:
[Link]. If the Basecoat does not flow sufficiently and pin rake marks, etc. remain in the surface,
even after spike rollering, try the following remedies.

 Scratchcoat the substrate

 Raise material temperature
 Increase mix time
 Increase thickness
 Remove Part 5 from Basecoat B9 if used
 Raise substrate and or site temperature

[Link]. Failure to address the problem will result in poor aesthetics, variable surface texture a
sub-standard finish and possible client rejection.

7.1.9. Broadcast

[Link]. The Basecoat must be flat and smooth prior to broadcasting. Imperfections in the
surface of the Basecoat will be seen in the finished floor.

[Link]. The time at which the Basecoat is scattered is critical.

[Link]. Too early and the surface will become uneven.

[Link]. Too late and the aggregate will not penetrate sufficiently.

[Link]. To ensure long term performance it is essential that the scatter is applied early enough
to allow absorption into the surface.

[Link]. At 20°C the scatter should be started after 10 - 15 minutes, so typically after a further
two to three mixes of Basecoat have been applied and the same gap kept as the
application proceeds. This will be reduced at higher temperatures, one to two mixes,
and extended at lower temperatures, three to four mixes.

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Section C: Products

[Link]. The FILLER F10, F20 or F25 is broadcast onto the curing Basecoat. If hand scattering
is undertaken care must be taken to ensure an even scatter is achieved. Ensure that
the aggregate falls vertically onto the surface of the Basecoat, never throw the
aggregate at the floor.

[Link]. As the scatter is applied, the resin from below should be seen to rise to the surface. The
aggregate scatter is then continued until an excess is applied. It is important to scatter to
excess otherwise bald patches will be created which will detract from the aesthetic
appearance and slip resistance of the floor. The broadcast floor should look like just the
aggregate (like a beach) with no resin showing. The application rate of 4-5kg/m² is much
higher than that usually used for scatter systems as the aggregate is absorbed into the
resin matrix and the final aggregate loading is almost the same as UD 200. It has been
found that this level of scatter is required to produce a consistent, durable and uniform
finish.

[Link]. After overnight cure (typically 16 hours) remove excess FILLER by brush and vacuum.
Provided the recovered FILLER is clean and dry, it can be re-used for subsequent areas.

[Link]. Lightly abrade the floor using a rotary sanding machine (Polyvac machine) to remove the
partially adhered aggregate, so producing a much more uniform surface and reducing
coverage rates for the Ucrete Topcoat. After sanding clean the whole floor by vacuum.

7.1.10. Topcoat

[Link]. Planning the application

[Link]. It is important to remember that you are not painting the floor, but applying a Ucrete
topcoat. The width of the bay should be such as to produce a strip of material minimum
50 cm across along the whole width of the bay to allow for efficient use of the squeegee
and roller. The maximum bay widths are therefore:

For Ucrete DP10 R11 floor 15 m for a single mix 30 m for a double mix
For Ucrete DP20 R13 floor 7 m for a single mix 13.5 m for a double mix
For Ucrete DP30 R13 floor 7 m for a single mix 13.5 m for a double mix

[Link]. On larger floors plan how the area is to be divided to produce the most practical and
aesthetically acceptable floor.

[Link]. Ucrete Topcoat is a four component topcoat.

[Link]. Temperature requirements: site temperatures 8 - 30°C, material temperatures 18 - 22°C.

[Link]. Temperature is critical to the correct application of the Ucrete Topcoat. Particular
attention should be paid to Section C and the table of mixing times.

[Link]. Temperatures below 180C will make application more prone to problems. Careful
consideration should be given to storage of materials in cold conditions. The air and
substrate temperature during application should be above 80C.

[Link]. Mix Part 1, Part 2 and Part 4 liquid pigment together for 30 seconds using a paint stirrer
in a slow speed electric drill until homogenous and then add part 3 and mix for a further
1 – 3 minutes depending upon temperature and mixer efficiency.

[Link]. Do not apply when atmospheric condensation is occurring or likely to occur before full
cure is attained, i.e., when the dew point is reached or when the ambient or substrate

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Section C: Products
temperature is within 30C of the dew point.

[Link]. For large open floor areas double mixes may be appropriate, but generally single mixes,
mixed and applied quickly will produce the most uniform appearance. On larger floors
plan how the area is to be divided to produce the most practical and aesthetically
acceptable floor.

[Link]. Make sure there are sufficient operatives on site to apply the whole of the mix within
the 3-4 minutes before the next mix arrives. Operatives can wear spiked shoes but
these must have flat spikes to prevent damage to the floor. As with all grades of Ucrete
the mixing and the application of the material must occur at the same rate.

[Link]. Pour all of the mixed Ucrete topcoat across the width of the bay immediately after mixing
and spread with a soft foam squeegee and back roll with medium (8 - 12 mm) pile
rollers.

[Link]. It is important to achieve the correct coverage rate with the squeegee so that the roller
only needs to even up the application to give a uniform texture and appearance and the
rollers do not pick up too much material. Experience shows that the squeegee should
be approximately 35 cm wide so that sufficient pressure can be applied to achieve the
correct coverage. If the squeegee is too wide, slight unevenness in the floor will result
in too much material being left behind. Squeegee in both directions across the floor to
fill the texture properly and to avoid pinholes forming in the 'shadow' of the aggregate
peaks

[Link]. Initially roll up and down the bay, across the strip of Topcoat currently being applied.
Do not roll beyond the previous mix of Topcoat in order to reduce any variations in
colour or gloss. If the roller picks up too much of the Topcoat it will spill off the ends of
the roller and leave deposits at the end of each stroke. To avoid this remove the excess
Topcoat by rolling out onto the Basecoat or a piece of cardboard, for example.

[Link]. A uniform surface is best achieved by lightly rolling across the bay, at right angles to
the initial rolling, with a wide (50 - 60 cm) roller to remove roller marks.

[Link]. If too much Topcoat is delivered to the floor then there will be insufficient time to do the
rolling operations properly. If this is the case, reduce to single mixes, slow up the mixing
or get more operatives.

[Link]. Use a brush and small hand roller to coat the coving together with the floor, this
produces a seamless transition and improves aesthetics. Some coves may require a
number of coats to give an even appearance.

[Link]. Full cure is normally reached after 24 hours, but under very cold or very dry conditions
this may be extended to 48 hours.

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Section C: Products
8. Ucrete IF

8.1 Iron Filled heavy duty polyurethane trowel applied floor finish

Packaging
Part 1 2.52 kg
Part 2 2.86 kg
Part 3 15.60 kg
Part 4 0.50 kg
Part 5 12.50 kg
 33.98 kg net per unit

8.1 Coverage

Typically - 9mm 28 kg/m²

8.2 Planning

8.2.1 The width of the bay should be such as to produce a strip of material 30 – 40cm across along
the whole width of the bay to allow for efficient trowelling. The optimum bay widths are
therefore:

8.2.2 For a 9mm floor 3-4m for a single mix 6-8m for a double mix 9-12m for a triple mix

8.2.3 On larger floors plan how the area is to be divided to produce the most practical and
aesthetically acceptable floor.

8.3 Scratch coating

8.3.1 Ensure that a good profile of minimum 3mm is achieved in the substrate to ensure good
transmission of stress in high impact environments

8.3.2 A scratch coat is not normally required.

8.3.3 On very porous substrates and where hygiene, ease of cleaning and appearance are important
the use of an MF scratch coat is beneficial.

8.4 Mixing

8.4.1 Temperature requirements: site temperatures 5 - 30°C, material temperatures 15 - 20°C.

8.4.2 Mix in a forced action mixer. It is not possible to mix effectively with a drill and paddle.

8.4.3 Mix the liquid components (parts 1, 2 and 4) and add the Ucrete IF Part 3 as per section C.
After 2 - 3 minutes add the Ucrete IF Part 5 component and mix for a further 1 - 2 minutes. All
mix times dependent on temperature and mixer efficiency.

8.4.4 Temperatures below 15°C will make application more difficult and careful consideration
should be given to storage of materials in cold conditions.

8.4.5 Maintain consistent mix times throughout or the colour of the floor will be affected.

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Section C: Products
8.5 Application

8.5.1 Spread the mix evenly over the substrate and close using a steel trowel.

8.5.2 Avoid over-trowelling as this may result in gloss variations and impaired slip resistance.

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Section C: Products
9 Ucrete MF

Heavy duty polyurethane flow applied floor finish

9.1 Packaging

Part 1 2.52 kg
Part 2 2.86 kg
Part 3 14.40 kg
Part 4 9.1.1 0.50 kg
20.28 kg net per unit

9.2 Coverage

Nominal 1mm scratchcoat 2.25kg/m2

4 mm 6 kg/m²
6 mm 10 kg/m²

9.2.1 A 4mm MF floor consists of a 1mm scratcoat and 3mm of MF body coat. Direct application of
4mm of MF to a prepared floor may result in poor aesthetics and pin holes and thus as a rule
a scratch coat should be used.

9.3 Planning

9.3.1 The width of the bay should be such as to produce a strip of material minimum 40cm across
along the whole width of the bay to allow for efficient use of the pin rake. The maximum bay
widths are therefore:

For a 4mm floor 6m for a single mix 12m for a double mix
For a 6mm floor 4m for a single mix 8.5m for a double mix

9.3.2 On larger floors plan how the area is to be divided to produce the most practical and
aesthetically acceptable floor.

9.4 Scratch coating

9.4.1 Ensure that Ucrete MF scratch coat has been correctly applied and cured. All anchor
grooves should be filled with the MF scratch coat to ensure they do not ‘grin through’ the
finished floor.

9.4.2 The use of Ucrete MF as a scratch coat MF scratchcoat, is recommended to ensure that the
substrate is completely sealed. Defects in the primed surface, such as blow holes in the
surface as a result of air rising out of bleed run pores in the substrate, should be remedied
prior to overlaying. Failure to do so may lead to surface defects in the finished floor and
possible client rejection.

9.4.3 If the time between coats exceeds 48 hours, or if condensation or water impacts the surface,
fully abrade the surface prior to overlaying.

9.5 Mixing

9.5.1 Temperature requirements: site temperatures 12 - 30°C, material temperatures 18 - 22°C.

9.5.1 Temperature is critical to the correct application of the Ucrete MF. Particular attention should

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Section C: Products
be paid to Section C and the table of mixing times. Temperatures below 18°C will make
application more prone to problems. Careful consideration should be given to storage of
materials in cold conditions. The air and substrate temperature during application should be
above 12°C.

9.5.2 When discharged from the mixer the Ucrete MF should be at least 18°C.

9.5.3 Mix the material as per section C.

9.6 Application

9.6.1 Spread the mix evenly over the substrate using a pin rake, with pins set to the appropriate
depth. Using a steel trowel for edgework.

9.6.2 Use a spiked roller to produce a smooth even finish. The whole floor should be spiked rollered
twice.

9.6.3 On the first pass the spiked roller should be pushed right through the material to the substrate
to assist the flow, remove pin rake marks and to flatten the floor.

9.6.4 Subsequent passes with the roller held lightly just upon the surface to bring the resin up to the
surface and so improve aesthetics.

9.6.5 The roller should be carried no more than 10cm into the previous mix. To ensure an even
finish, all trowelling and spiked rollering should be completed before the mix is 10 minutes
old. This time reduces at higher temperatures and at 300C trowelling and rollering should be
completed by 6 minutes of finishing the mixing.

Notes:

9.6.6 Expansion joints in Ucrete MF are best produced by saw cutting the material after application.
This will produce a more uniform joint when compared to one made by placing a piece of wood
in the concrete and applying the Ucrete to either side.

9.6.7 Care should be taken at doorways. Hot/cold draughts will affect the cure/flow of the material.
This can cause the spike roller marks to not "settle" out.

9.6.8 Late trowelling will sweep the pigment rich surface layer aside exposing the fillers below
resulting in variations in texture and colour shading.

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Section C: Products

10 Ucrete MFAS

Heavy duty polyurethane flow applied anti-static floor finish.

10.1 Packaging

Part 1 2.52 kg
Part 2 2.86 kg
Part 3 11.00 kg
Part 4 0.50 kg
16.88 kg net per unit

10.2 Coverage

4mm 8 kg/m²
6mm 12 kg/m²
10.2.1 This is in addition to the scratch coat which is only to seal the surface as a place to put the
earthing tape.

10.3 Planning

10.3.1 The width of the bay should be such as to produce a strip of material minimum 40cm
across along the whole width of the bay to allow for efficient use of the pin rake. The
maximum bay widths are therefore:

For a 4mm floor 5m for a single mix 10m for a double mix
For a 6mm floor 4m for a single mix 8m for a double mix

10.3.2 On larger floors plan how the area is to be divided to produce the most practical and
aesthetically acceptable floor.

10.4 Scratch coating

10.4.1 Ensure that the Ucrete MF has been correctly applied and cured. All anchor grooves
should be filled with the MF scratchcoat to ensure they do not ‘grin through’ the finished
floor.

10.4.2 The use of Ucrete MF scratch coat, is recommended to ensure that the substrate is
completely sealed. Defects in the primed surface, such as blow holes in the surface as a
result of air rising out of bleed run pores in the substrate, should be remedied prior to
overlaying. Failure to do so may lead to surface defects in the finished floor and possible
client rejection.

10.4.3 If the time between coats exceeds 48 hours, or if condensation or water impacts the
surface, fully abrade the surface prior to overlaying.

10.4.4 Earthing: See section 8.1 for details of earth connections.

10.4.5 Install copper tapes with conductive adhesive and linkages, abrading the MF scratchcoat
with emery paper and removing dust by vacuum to ensure good adhesion of the copper
tape.

10.4.6 Wipe the tape carefully with a dry cloth or paper towelling to ensure there is no oil or
contamination upon the surface. Sufficient copper tape must be left uncovered to allow for

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Section C: Products
connection to the next bay of material.

10.5 Mixing

10.5.1 Temperature requirements: site temperatures 18 - 30°C, material temperatures 18 - 22°C

10.5.2 Temperature is critical to the correct application of the Ucrete MFAS. Particular attention
should be paid to Section C and the table of mixing times. Temperatures below 18°C will
make application more prone to problems. Careful consideration should be given to storage
of materials in cold conditions. The air and substrate temperature during application should
be above 18°C.

10.5.3 When discharged from the mixer the Ucrete MFAS should be at least 18°C.

10.5.4 Mixing is critical for Ucrete MFAS floors as incorrect mixing will adversely affect the
antistatic properties of the finished floor.

10.5.5 Suitable mixing equipment: Collomatic XM2 650 or similar

Slow speed drill & corkscrew paddle (max 350rpm)
BEBA (twin screw hand held mixer max 350 rpm)

10.5.6 Unsuitable mixing equipment: High speed drill & paddle

Cretangle
Mixal
Pennine

10.5.7 When the correct type of mixer has been selected, follow the mixing instructions in section
C.

10.5.8 Mixing must be sufficient to disperse the fibre but not so aggressive as to damage the
fibre. Care must be taken to ensure lumps of undispersed fibre do not fall into the material
as it is discharged from the mixer.

10.5.9 Too little mixing leads to clumps of fibres left in the mix which inhibit flow and leave a poor
surface appearance. Excessive mixing breaks up the fibres and leaves the colours looking
dark and dirty. Correctly mixed material will have very few lumps of fibre, a good colour
and individual fibres should just be visible in the surface of the finished floor.

10.5.10Typically at 20°C mixing time of one unit in a 300mm diameter pail, using a 350rpm drill
and paddle with a corkscrew blade, after the addition of the Part 3 component, would be
between 2 minutes (min) and 3 minutes (max).

10.6 Application

10.6.1 Spread the mix evenly over the substrate using a pin rake, with pins set to the appropriate
depth. Using a steel trowel for edgework.

10.6.2 Use a spiked roller to produce a smooth even finish. The whole floor should be spiked
rollered twice:

[Link] On the first pass the spiked roller should be pushed right through the material to
the substrate to assist the flow, remove pin rake marks and to flatten the floor.

[Link] Subsequent passes with the roller held lightly just upon the surface to bring the
resin up to the surface and so improve aesthetics.

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Section C: Products

[Link] The roller should be carried no more than 10cm into the previous mix. To ensure
an even finish, all trowelling and spiked rollering should be completed before the
mix is more than 10 minutes old.

[Link] It is essential that all areas of the floor are passed over with the spiked roller.
Areas missed by the roller will have poor electrical properties. Within the 10
minute time period continuous spike rolling will improve both the electrical
properties and appearance of the finished floor.

Notes:

[Link] Expansion joints in Ucrete MFAS are best produced by saw cutting the material
after application. This will produce a more uniform joint when compared to one
made by placing a piece of wood in the concrete and applying the Ucrete to either
side.

[Link] Care should be taken when installing joints not to damage the copper tapes
within the floor

[Link] Care should be taken at doorways. Hot/cold draughts will affect the cure/flow of
the material. This can cause the spike roller marks to not "settle" out.

[Link] Late trowelling will sweep the pigment rich surface layer aside exposing the fillers
below resulting in variations in texture and colour shading.

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Section C: Products

11 Ucrete UD200

Heavy duty polyurethane trowel applied floor finish

11.1 Packaging

Part 1 2.52 kg
Part 2 2.86 kg
Part 3 24.80 kg
Part 4 0.50 kg
 30.68 kg net per unit

11.2 Coverage

Nominal 1 mm MF scratch coat 2.25Kg/m2

6 mm Floor 10 kg/m² (1mm scratchcoat plus 5mm of UD 200 to give 6mm thickness)
9 mm Floor 16 kg/m² (1mm scratchcoat plus 8mm of UD 200 to give 9mm thickness)
12 mm Floor 22 kg/m² (1mm scratchcoat plus 11mm of UD 200 to give 12mm thickness)

11.3 Planning

11.3.1 The width of the bay should be such as to produce a strip of material 30 - 50cm across
along the whole width of the bay to allow for efficient trowelling. The optimum bay widths
are therefore:

For a 6mm floor 4-6m for a single mix 8-12m for a double mix
For a 9mm floor 3-4.5m for a single mix 6-9m for a double mix
For a 12mm floor 2.5-4m for a single mix 5-8m for a double mix
11.3.2 On larger floors plan how the area is to be divided to produce the most practical and
aesthetically acceptable floor.

11.4 Scratch coating

11.4.1 Ensure that Ucrete MF scratch coat has been correctly applied and cured. The use of
the Ucrete MF scratch coat MF scratchcoat is recommended to ensure the best surface
finish and to aid application by reducing resin absorption into the concrete. It is
particularly important in food industry applications where hygiene, ease of cleaning and
aesthetics are key requirements.

11.5 Mixing

11.5.1 Temperature requirements: site temperatures 5 - 30°C, material temperatures 15 - 20°C.

11.5.2 Mix the material as per section C. Ucrete UD200 is best mixed in a mortar mixer.

11.5.3 Too aggressive mixing with a drill and paddle can lead to the inclusion of air that may
cause surface defects in the finished floor.

11.5.4 Temperatures below 15°C will make application more difficult and careful consideration
should be given to storage of materials in cold conditions.

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Section C: Products
11.6 Application

11.6.1 Spread the mix evenly over the substrate and close using a steel trowel.

11.6.2 Avoid over-trowelling as this can result in gloss variations and impaired slip resistance.

11.6.3 The use of a short pile roller, in gentle sweeps over the surface, will provide a more even
finish. Rolling is best conducted immediately after trowelling. The roller should be passed
over the surface a maximum of twice. The roller should be kept “dry” by rolling excess
material onto a piece of cardboard.

11.6.4 You cannot use the roller to flatten the surface of a poorly trowelled floor.

11.6.5 Care should be taken not to roll back into material that is partially cured as this will be
clearly visible in the finished floor. Avoid an excessive build-up of resin on the roller by
rolling out immediately in front of the wet front, or on a piece of cardboard.

11.6.6 The use of a short pile roller will reduce the slip resistance and care should be taken that
the correct degree of slip resistance versus ease of cleaning is produced in line with the
end users requirements. Excessive use of the roller can lead to the inclusion of air into the
surface of the floor resulting in pinholes.

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Section D: Special Techniques

12 SPECIAL TECHNIQUES

12.1 EARTHING ANTI-STATIC SYSTEMS

12.1.1 Earth connections are required to ensure that antistatic floors are properly connected to
the correct earth.

12.1.2 The earthing cable and copper tapes have to be applied with all the Ucrete antistatic
flooring systems. Copper tape and earth connections are applied to the surface of the
cured scratch coat or MF scratchcoat before the application of the antistatic
bodycoat/layer. Please see the individual system guidelines.

12.1.3 Earth Linkages

12.1.4 Every floor should have at least one earth linkage connection as shown in Fig 1. It is
however good practice to install more than one connection even in small areas, this is
insurance should one be damaged.

12.1.5 As the area of floor increases the number of connections should also be increased.
Individual rooms should be connected to earth along with corridors etc. On a large open
area connections at each corner should be considered. In addition careful thought should
be given to areas divided by expansion joints, these have to either be bridged by copper
tape or treated as isolated areas with individual earth connections.

12.1.6 An earth Linkage should be installed as follows

Figure 41: Earth Linkage.

12.1.7 A multi strand piece of copper wire is connected to the earth at one end and opened out to
a fan shape at the other. The earthing cable should be provided by the site electrical
contractor as some sites have very specific specifications as to what is acceptable.

12.1.8 Self-adhesive copper tape with conductive adhesive is then used to fix the fan of copper
wire to the floor. The scratchcoat, should be abraded where copper tape is to be applied to
ensure good adhesion.

12.1.9 The strips of copper tape that will extend in to the main floor are then placed over this

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Section D: Special Techniques
area. Ensure good contact is made between the copper tape and the multi strand wire.

12.1.10 Copper Tape Geometry

[Link] Connected to the earth linkage points are strips of self-adhesive copper
tape applied to the cured MF scratchcoat. The purpose of the tape is to ensure
that each mix within each bay of material is connected to the earth linkage.

[Link] To achieve this there must be one tape running the length of each bay
and another running across each bay of Ucrete. Normally these are placed
at the edges of the bay to reduce the risk of damage during application of the
floor, resulting in an “L” of copper tape for each bay of material applied;
these are then linked together as work progresses and are connected to the
earthing points.

[Link] With Ucrete anti-static systems no part of the floor should be more
than 6 m from a copper tape. Normally the tapes running the length of the
bays should be no more than 10m apart. The length is determined by the
area that can be applied in one day. In the event that it is essential to apply a
single bay more than 10m across, then extra copper tapes may be required.
Consult BASF Construction Chemicals for guidance.

[Link] The following drawings show possible working sequences and copper
tape geometries for a number of situations. The copper tape shown is the
MINIMUM required. The use of more tape for added security or for areas
where it is felt movement / cracking may occur thus isolating that area is
advised.

[Link] All copper tape should be connected in both directions (at both ends)
to an earth linkage. This ensures that the antistatic properties are maintained
even if the copper tape is damaged or severed, for example during the
installation of plant.

Figure 42 90m2 room (6m by 15 m)

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Section D: Special Techniques

Figures 43-45. 1200m² room 20m x 60m

[Link] This will be applied in four bays. First the MF scratchcoat is applied on
the initial area to be coated. The MF scratchcoat is applied to a larger area
than required 10-15cm to each side. This allows for easier connection of
adjacent pieces of copper tape. When the MF scratchcoat is cured the
copper tape is applied in the same “L” shape as figure 2. Ensure sufficient
tape is applied to allow for connection to the next bay. Ucrete anti-static
systems are then applied to this area.

Figure 43 Day one laying 1200M2 room

[Link] The MF scratchcoat to the next area is then applied. When cured
another “L” of copper tape is applied.

[Link] Connected at the top to the previous bay of material. This area is then
coated.

Figure 44 Day two laying 1200m2 room

[Link] Work then continues in the same way with the last two bays.

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Section D: Special Techniques

Figure 45 final bays done

[Link] Earth linkages are required at the free ends of the copper tapes. Every
copper tape is connected at both ends. The number of earth linkages could
be reduced if the free ends were connected to one another by extra tapes.

[Link] The earth linkages can be positioned as required by adjusting the copper
tape geometry. Discuss the locations with the client and the site
engineering contractor.

[Link].1 Using the same principles this is a plan for a more complicated
area.
Figure 46 earthing of complex room grid

[Link] The exact location of the tapes can be varied to suit the various

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Section D: Special Techniques
requirements of the project. So for example the tapes can be moved away
for the sides of the bay to allow for services and fixings to be installed
along the wall without damaging to the earth.

[Link] The adhesion of Ucrete to the copper tape is not as good as it is to

concrete, so the tapes should be positioned to avoid areas of heavy traffic
or heavy impact etc.

12.1.11 Recommended Copper Tape:

[Link] 3M 1181 Tape. Copper foil with conductive adhesive 15mm wide
[Link] From 3M Electrical Products Division
[Link] [Link]
12.2 Channels and Sumps

12.2.1 Rendered Channel see section 5.6 above.

12.2.2 Ucrete UD 200 grade (primed with MF scratchcoat ) may be used for lining channels and
sumps; apply 6 - 9 mm in one application by using formwork.

12.2.3 Fully lined Channel see section 5.6 above

12.2.4 Drainage channels and sumps may be subject to continuous exposure and contact with
aggressive chemicals; in addition, metal implements may be used for cleaning them.

12.2.5 In such circumstances, where greater chemical resistance and ability to withstand
mechanical abuse is required, Ucrete UD200 grade is preferred. This is applied to vertical
surfaces behind temporary shuttering; an 18 mm thickness of Ucrete UD200 is suggested
for such applications. Brown parcel tape produces excellent results as a release agent on
shuttering.

12.2.6 Do not attempt to cast too great an area at one time, a wet front must be maintained and
rodding or vibration may be required to ensure there are no voids in the finished lining.
Anchor grooves are required around each lift as if around the bay on a flooring application.

12.2.7 Do not use Fast Part 1 for this application as the bulk of material is likely to cause a very
large exotherm which could lead to defects in the Ucrete lining.

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Section D: Special Techniques

Figure 47 Build up of lining for drain

12.2.8 Contact BASF Construction Chemicals for specific advice.

[Link] Note: Corrosion resistance data for Ucrete flooring products has been derived
from relatively short-term immersion tests and may not be relevant to
continuous contact. Contact BASF Construction Chemicals for specific
advice.

12.3 Dairy Grids

12.3.1 The use of cast iron dairy grids has been found to provide excellent results when used in
conjunction with Ucrete flooring outside ovens and other process equipment when steel
wheeled trolleys are removed at elevated temperatures and passed over the floor. The
diary grids should extend over a sufficient area to hold the contents of the oven for a few
minutes while the tray racks cool.

12.3.2 The dairy grids are 13mm in depth and, therefore, either require:-

12.3.3 The concrete being removed to accommodate the extra depth of the grid

or

12.3.4 The adjacent area of Ucrete ramped up to the grid to provide an even transition.

12.3.5 Ensure the grids are free from contamination and set into a Ucrete MF scratch coat, 1-
2mm in thickness.

12.3.6 Care should be taken to ensure a good level finish. Closed section border grids are
available for the perimeter; this prevents the infill of Ucrete MF from slumping.

12.3.7 If a thickness of up to 5mm is required under the grids Ucrete UD200 can be used as a

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Section D: Special Techniques
bedding material. A thickness greater than 5mm must be made up with a separate
additional layer of Ucrete or, in extreme cases, polymer modified sand cement/fine
aggregate concrete. Correct curing of the infill is essential, refer to Section C.

12.3.8 With the grids set and cured in a Ucrete bed, fill flush to the surface with Ucrete MF simply
scraping the surface level.

12.4 Recommended Grating

12.4.1 Thomas Dudley Ltd.: Grating F04750-200-AFC, Pattern D356, 305mm x 305mm x 13mm.

12.4.2 [Link]

12.5 Repairing Previously Laid Ucrete Flooring

12.5.1 Refer to Section B paragraph 5.2.14 and the detailed illustration “Termination, to Old
Ucrete,” in section 5.5.

12.5.2 Cut around the perimeter of the area to be repaired with a diamond blade. Cut with angled
cuts so that the new material slightly overrides the old.

12.5.3 Remove the damaged Ucrete flooring using by hammer and chisel, taking care not to
damage the surrounding areas.

12.5.4 Thoroughly prepare the substrate to ensure the substrate is clean, sound and free from
any contamination. Ensure any repairs or making good is done in good time before
overlaying.

12.5.5 Cut anchor grooves in the substrate around the perimeter of the cut. Remove all dust and
debris by vacuum.

12.5.6 Prime the substrate as required with the appropriate Ucrete MFscratchcoat and allow to
cure.

12.5.7 Mask off the surrounding floor leaving the masking tape ~2mm from the edge of the repair.

12.5.8 Lay the new Ucrete flooring of the required grade, using standard techniques. Work well
into the edges of the repair and strike off from the surface of the surrounding floor not from
the masking tape.

12.5.9 Remove the masking tape after 1 hour.

12.6 Guide to Ucrete Fast Systems

12.6.1 There are two grades of Ucrete Part 1 available, Normal and Fast, for the trowel grades of
Ucrete and for pigmented Ucrete DP Basecoats This allows us to produce Ucrete with
three curing speeds.

12.6.2 Using the Normal Part 1 gives the maximum open time at all temperatures and normal
curing times.

12.6.3 Using the Fast Part 1 gives the fastest curing times especially for use at low temperature.

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Section D: Special Techniques
12.6.4 Mixing two units with one Fast Part 1 and one Normal Part 1 gives intermediate curing
rates.

12.6.5 The following table gives guidance on the curing times with temperature. Time To Traffic
is the time at which it will receive forklift traffic.

Fast F+N Normal

a double mix
with one
Normal and
one Fast Part = Normal Part
Site Temperature oC

= Fast Part 1 1 1

25 Do Not Use Do Not Use 12

20 Do Not Use 4 16

15 4 6 20

10 5 8 24

5 7 12 30

Time To Traffic, Hours

N+F = a double mix with one Normal Part 1 and one Fast Part 1
N = a mix with Normal Part 1
F = a mix with Fast Part 1

12.6.6 Do Not Use indicates that there is no longer sufficient open time for correct installation to
a good standard. In extreme cases blistering may occur. If materials are above 15oC
use the N+F mix.

12.6.7 Do NOT use the Fast Part 1 material as a substitute for the Ucrete DP Topcoat part 1, or
use with MF as this will affect the ability to finish the material.

12.6.8 The Fast Part 1 does not improve the flow characteristics of the products at low
temperatures, so the minimum application temperatures for products still apply.

12.6.9 For Fast Basecoats, the time at which excess aggregate may be removed and the floor
sanded ready to receive the Topcoat is 2 – 3 hours after the time to traffic.

12.6.10 The time at which a diamond saw can be used to cut joints etc, is 2 – 3 hours after the
time to traffic.

© BASF Australia Ltd, Page 62

Section E: Health and Safety

13 HEALTH AND SAFETY

13.1 Reference is made to the material safety data sheets for each individual component.
13.1.1 The following specific measures must be observed.

13.2 Protective Equipment

13.2.1 Eye protection, protective clothing and gloves should be worn by all personnel
handling Ucrete flooring products. In addition, personnel handling Part 3
components (aggregate blends) should wear dust masks.

13.2.2 Personnel engaged in grinding, polishing and grouting procedures should observe
strict use of proper protective measures.

13.3 Treatment of Spillages

13.3.1 Part 1 and Part 4 for all Ucrete scratch coating, flooring and vertical grades.

13.3.2 Ensure suitable personal protection during the removal of spillages. Absorb
spillages onto sand, earth or any similar absorbent material. Transfer to a container
for disposal. Wash the spillage area clean with water and detergent.

13.3.3 Part 2 for all Ucrete scratch coating, flooring and vertical grades and Topcoat
PU CLEAR.

13.3.4 Personnel dealing with major spillages should wear full protective clothing, including
respiratory protection. Evacuate the area. Prevent further leakage, spillage and
entry into sumps or drains. Contain and absorb large spillages onto an inert, non-
flammable absorbent material. Transfer to a container for disposal.

13.3.5 Wash the spillage area clean with a liquid decontaminant. (2)(3) Test the
atmosphere for isocyanate vapour. Neutralise small spillages with a liquid
decontaminant. Remove and dispose of residues.

13.3.6 Absorbent carrier - clean, dry sand or earth.

13.3.7 Liquid decontaminant - 5% solution of soda ash (sodium carbonate) in water.

13.3.8 Absorbent carrier and liquid decontaminant must both be readily accessible on
site.

13.3.9 Part 3 for all Ucrete scratch coating, flooring and vertical grades, Part 5 and
all FILLER grades

13.3.10Ensure suitable personal protection during the removal of spillages. Contain

spillages. Protect against dust. Clean up spillages. Transfer to a container for
disposal. Wash the spillage area clean.

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Section E: Health and Safety
Disposal

13.3.11Part 1 and Part 4 for all Ucrete scratch coating, flooring and vertical grades

13.3.12Disposal should be in accordance with local, state or national legislation. Bury on

an authorised landfill site or incinerate under approved controlled conditions, using
incinerators suitable for the disposal of noxious chemical waste.

13.3.13Part 2 for all Ucrete scratch coating, flooring and vertical grades

13.3.14Disposal should be in accordance with local, state or national legislation. Untreated

material is not suitable for disposal. Waste, even small quantities, should never be
poured down drains, sewers or water courses.

13.3.15Small quantities and empty drums (cans) - pre-treat with liquid decontaminant (5%
sodium carbonate solution in water) or waste polyol (ie, Part 1 components prior to
disposal).

13.3.16Large quantities - destruction by controlled pyrolysis with scrubbing and

neutralisation of the vapours, using incinerators specifically designed for the
destruction of noxious chemical waste.

13.3.17Part 3 for all Ucrete scratch coating, flooring and vertical grades, Part 5 and
all FILLER grades

13.3.18Disposal should be in accordance with local, state or national legislation. Bury on

an authorised landfill site or incinerate under approved controlled conditions.

13.4 Solvents

13.4.1 Solvents used are liable to present toxic and flammability hazards. Information on
these hazards and instructions relating to safe storage, handling, use and disposal
of any solvents used must be obtained from the relevant suppliers.

Application Guide Ucrete V4 0518

The technical information and application advice given in this BASF publication are based on the present state of
STATEMENT OF our best scientific and practical knowledge. As the information herein is of a general nature, no assumption can be
RESPONSIBILITY made as to a product's suitability for a particular use or application and no warranty as to its accuracy, reliability or
completeness either expressed or implied is given other than those required by law. The user is responsible for
checking the suitability of products for their intended use.

Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF either
NOTE orally or in writing may be followed, modified or rejected by the owner, engineer or contractor since they, and not
BASF, are responsible for carrying out procedures appropriate to a specific application.

BASF Australia Ltd BASF New Zealand Ltd BASF Emergency Advice:
ABN 62008437867 Level 4, 4 Leonard Isitt Drive 1800 803 440 within Australia (24hr)
Level 12 Auckland Airport 2022 0800 944 955 within New Zealand
28 Freshwater Place Auckland, New Zealand
Southbank VIC 3006
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