International Intercrete 4840

SKU id20844 Non Hazardous
Formerly Flexcrete Cemprotec E942. A 2 part, water-based (VOC-free), epoxy and polymer modified cementitious coating for the protection of concrete and ferrous metals.
Available in 3 x 30 Kg in Grey
£530.00 (£636.00 Inc VAT)

Product Description

Please note, this product has an expected lead time of 5 - 7 working days.

International Intercrete 4840 is a two component, water-based (VOC-free), epoxy and polymer modified cementitious coating for the protection of concrete and ferrous metals. London Underground Approval No. 2686.

Best Uses

International Intercrete 4840 exhibits a high degree of thixotropy for easy application by brush or spray to give a smooth surface finish without sagging. It cures to form a dense, highly alkaline coating offering low permeability to water and very high diffusion resistance to chloride ions and oxygen, ensuring long-term protection.

International Intercrete 4840 is specifically designed for the structural waterproofing and protection of concrete substrates where improved chemical and abrasion resistance is required. Intercrete 4840 can be reinforced with Intercrete 4872 tape to accommodate movement of cracks and joints.

Intercrete 4840 offers low permeability to water at 10 bar positive and negative pressure along with excellent resistance to carbon dioxide gas and chloride ion diffusion. It can also be used as a one or two coat, direct-to-metal corrosion protection system for suitably prepared steel substrates. Suitable for asbestos encapsulation - see BT Underground Tunnels case study.

CE-marked in accordance with BS EN 1504-2. Suitable for surface protection systems principles 1.3, 2.2, 5.1, 6.1, 8.2 as defined in BS EN 1504-2.

Application

Preparation of Concrete Substrates
Concrete should have a minimum strength of 20MPa. All surfaces should be clean and free from laitance, curing compounds, release agents, efflorescence, grease, oil, dirt, organic growth, old coatings and loose or disintegrating concrete. Smooth surfaces should be roughened, using high pressure water jetting or similar techniques. The prepared substrate should be thoroughly soaked with clean water until uniformly saturated without any standing water. All concrete floors, decks and highly porous substrates should be appropriately sealed using Intercrete 4850.

Preparation of Steel Substrates
Intercrete 4840 is self-priming and requires direct contact with the steel to afford maximum corrosion protection. For maximum durability, steel should be cleaned back to bright metal, ideally to ISO8501-1 Sa2½ (SSPC-SP10) using an angular grit to achieve a surface profile of 75-110 microns. For marine structures, ultra-high pressure jetting at circa 20,000psi is effective. Where environmental constraints preclude blast cleaning, lower forms of preparation are acceptable providing all loose oxides are removed. Handheld power tools capable of achieving the necessary preparation can be used. Metal prepared in this way should be to minimum standard of ISO8501-1 St3 (SSPC-SP3). Arrises and welds should be ground to remove sharp edges.

Intercrete 4840 is supplied in two parts; a liquid component (Part A) and a powder component (Part B). MIX FULL UNITS ONLY. Shake Part A thoroughly and pour into a suitable mixing container, then slowly add Part B whilst stirring with a mechanical agitator. Mixing should be carried out with a suitable slow-speed drill and paddle. Mix for 5 minutes with regular scraping of the container sides to prevent lumps from forming. For spray application, material should be filtered through a 4mm
sieve. Once the unit has been mixed it should be used within the working pot life specified.

Intercrete 4840 is ideally suited to brush application, although spray techniques should be used in large areas. Care should be taken to ensure that air is not entrapped onto the surface. Apply the first coat, approximately 1mm thick, onto the prepared substrate. To ensure total protection, a second coat should be applied in the same way, after waiting approximately 60 minutes (depending on temperature) when the first coat is stable but not fully cured (maximum 7 days).

Carefully check on completion for pinholes and misses and spot treat where necessary. The total finished coating must be at least 2mm thick to provide complete protection. When treating structures in a tidal zone, Intercrete 4840 should be applied in a single 2mm layer to avoid inter-coat contamination. Intercrete 4840 must be allowed to cure for a minimum of 2 hours before being immersed. On horizontal deck applications, apply a single 2mm layer with a skid leveller or notched trowel and immediately release entrapped air with a spiked roller.

Detail Work
On steel, apply a 1mm stripe coat of Intercrete 4840 by brush to all welds, cut edges and fixings, e.g. nuts and bolt heads. On welds and cut edges, embed a suitable edge scrim. Over joints, large cracks, etc. in concrete, apply a 1mm stripe coat of Intercrete 4840 by brush and immediately embed Intercrete 4872. Allow to stabilise before proceeding. Please consult separate Technical Data Sheet.
Curing
Normal concreting procedures should be strictly adhered to. It is important that the surface of the mortar
is protected from strong sunlight and drying winds with Intercrete 4870, polythene sheeting, damp
hessian or similar (see separate Data Sheet for full details).

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